Design of Segmented Boost Constant Voltage Battery Charger Based on Leakage Transformer

High-power lead-acid batteries are widely used in traction motors, where electric forklifts are active in stationary factories with convenient charging, thus lead-acid storage for forklift motors is widely used. The article uses the characteristic that the output voltage of the leakage transformer increases as the current decreases to discuss the characteristics of lead-acid batteries for forklift motors. It employs the low-voltage constant-voltage charging method in the initial stage to develop an intelligent charging device for traction batteries. This method ensures that the charging current curve closely resembles Mas’s optimal charging curve and addresses the issue of high current at the start of charging, which is caused by the deep discharge of the batteries in the intermittent charging method. Additionally, a capacity estimation method is proposed to complement battery aging and cycle count, reducing the capacity error caused by inaccurate measurement of individual current. The experimental results demonstrate that the designed charger adheres to Mas’s optimal charging curve change pattern when charging the battery’s current and the capacity estimation is a close approximation to the actual battery capacity.