Circuit panel

A close call on the road can really focus your mind on the importance of having a battery monitor in a car. I had been enjoying a pleasant week of travelling around the countryside at a leisurely pace and taking in the beautiful scenery each day. It wasnt until the final day, with the big rush to return home, that I had to drive at night.My home is deep in the country and on the road I was travelling the closest petrol station may be 80km away. I was travelling through an area that is full of open-cut coal mines and large heavily loaded semi-trailers constantly pound the roads, travelling at quite high speeds. It was around 8pm at night and everything was very dark no street lights or house lights anywhere.

After the initial shock wore off, I put on my thinking cap to come up with a PIC-based solution to the problem. What was really needed was a display and a buzzer, to get my attention should the voltage fall outside a specified range. So my design criteria was set, a series of LEDs could indicate the voltage and a buzzer would also be used to warn of problems.

Circuit details:

The circuit is based on PIC16F819 18-pin microcontroller which has an analog-to-digital (A/D) input to monitor the battery voltage and outputs capable of driving LEDs directly, to keep the component count down. There are seven LEDs in all, giving a good range of voltage indication. The topmost LED, LED1, comes on for voltages above 14V which will occur when the battery is fully charged. LED2 indicates for voltages between 13.5V and 14V while LED3 indicates between 13V and 13.5V. Normally, one of these LEDs will be on. LED4 covers 12.5V to 13V while LED5 covers 12V to 12.5V. LED6 covers from 11.5V to 12V while LED7 comes on for voltages below 11.5V. These two LEDs are backed up by the piezo chime which beeps for voltages between 11.5V and 12V and becomes more insistent for voltages below 11.5V.

That might seem fairly conservative. After all, most cars will start with no troubles, even though the battery voltage might be a touch below 12V, wont they? Well, no. Some modern cars will happily crank the motor at voltages below 11V but their engine management will not let the motor start unless the voltage is above 11V. So dont think that a modern car will always start reliably. This little battery monitor could easily prevent a very inconvenient failure to start! So lets describe the rest of the circuit. The incoming supply is connected via diode D1 which provides protection against reverse polarity while zener diode ZD1 provides protection from spike voltages.

A standard 7805 3-terminal regulator is then used to provide a stable 5V to the microcontroller. The battery voltage is sensed via a voltage divider using 33kΩ and 100kΩ resistors. This brings the voltage down to within the 0-5V range for the A/D input of the PIC16F819. Port B (RB0 to RB7) of the microcontroller is then used to drive the various LEDs, with current limiting provided via the 330Ω resistor network. RB7, pin 13, drives a switching transistor for the piezo buzzer.

Software:

Building it:

All the parts are mounted on a small PC board measuring 46 x 46mm (available from Futurlec). The starting point should be the IC socket for the PIC16F819, as this is easiest to mount while the board is bare. The next item can be the PC terminal block. The resistors and capacitors can then follow. Make sure the electrolytics are inserted with correct polarity.

Make sure that you do not confuse the zener (ZD1) with the diode when you are installing them; the diode is the larger package of the two.

There are a couple ways you could modify the circuit to work with a 5-cell 6-volt receiver battery pack. The two 1k resistors are a divider network, so one way would be to change the resistors to change the sampling voltage at the comparator. The formula for a divider network is Vout=Vin(R2/(R1+R2)) or R1=R2*((Vin/Vout)-1). Here, R1 is the resistor connected to the positive lead and pin 7 of the comparator, Vin is 5.25 volts (1.05 volts per cell discharge shutoff threshold), and Vout is the reference 2.1 volts (the voltage produced by the LM317T and the 180 and 270 ohm resistors). You can use R2 as the same 1k value that was there before. So R1=1000*((5.25/2.1)-1)=1500=1.5k. So swap the top 1k resistor in the schematic for a 1.5k, and the new shutoff voltage for your device will be 5.25 volts.

To increase the discharge rate, decrease the resistance of the load resistors. You could use four 100 ohm resistors in parallel instead of two, for example, and it would discharge twice as fast. Resistance of a number of resistors in parallel is the value of the resistor devided by the number of the resistors. Here, 100 ohms/ four resistors is 25 ohms. At five volts, current is (5 volts)/(25 ohms)=0.2 ampere or 200mA. Be careful not to decrease resistance too much however--the small signal transistor used in this particular circuit is probably only rated for maximum 500 mA.

Circuit diagram :

Parts:
273-074 Miniature Piezo Buzzer, 12v, PC board mount
271-312 1/4 watt 5% carbon film resistors, 500 pieces (Just do it!)
276-1778 LM317T adjustable voltage regulator
276-1712 Quad comparator LM339
276-1622 LED assortment (20 count)
276-2009 NPN Silicon transistor MPS2222A (2N2222)

Custom electronics:
 
I post this design not because I think this is a brilliant piece of circuit design but because the design works, and it can give you a start on your own experimentation. The idea is to use the power available from the discharging battery to monitor the voltage of the battery, shut off discharging at a preset voltage (here 1.05 volts/cell), and sound an alarm when discharging is complete. To do so means a voltage reference powered by the changing voltage of the battery, here the LM317T and the 180 with 270 ohm resistors. You could just as easily use a LM336 (see the low voltage warning buzzer page) or a zener with resistor, or something else as a reference. Since the reference voltage must be below the ambient battery voltage, a pair of 1k resistors provides the divided test voltage. The LM339 is a four way comparator.
 
This design uses really three comparators: in addition to the one driving the transistor, a comparator drives the LED and another drives the buzzer. But you could use a single comparator (like the LM311) with the buzzer across the emitter and collector of the transistor, and the LED in series with a 270 ohm resistor across (parallel with) the 100 ohm load resistors. With the transistor conducting, the voltage drop across base and emitter is low, and the buzzer is quiet. The tiny current in a piezo buzzer (7 mA), when the transistor is not conducting, would be divided between the load resistors and the LED, and the LED is dark.
A word about the comparator.