In this post we learn about a car voltage stabilizer circuit which could be made and installed in all cars for ensuring a perfectly controlled and stabilized supply for the associated sensitive electronics and gadgets.
Contents
Understanding Car Electrical
A car electrical is probably more volatile than our house electrical, simply because it is generated from a source called alternator whose output considerably varies with the speed of the vehicle.
It means if you are driving your car with sudden changes in its speed or if you are often applying brakes, would consequently generate varying voltages from the alternator outputs.
Since nowadays our car and other vehicle interiors heavily involve sophisticated electronic gadgets, an unstable voltage conditions can cause serious effects on their performance and life.
The circuit idea was requested by Mr.Haziq, let's know more about the making of the proposed circuit (designed by me for the application).
Today we have some wonderful ICs at our disposal which are specifically designed for voltage regulation applications.
The LM317 and the LM338 are a couple of them which are versatile with their voltage regulation functions, I have discussed them elaborately in some my earlier posts.
The LM317 can handle up to 1.5 Amps while its big brother the LM338 can hold not more than 5 Amps.
However these values are quite meager when compared to the huge asks in automobiles.
By suitably modifying the configurations, the IC can be made to regulate any desired levels of currents though.
In the proposed car voltage stabilizer circuit we incorporate the IC LM317 and modify its standard design such that it enables the car electrical with sufficient power and yet restricts it from all possible dangers like overloads, over current, fluctuating voltages and short circuits, providing an ideal voltage conditions for the vehicle interiors.
Circuit Description
The circuit diagram shows a rather simple configuration where the IC 317 has been wired in its standard voltage regulator mode.
R1 limits the surge current, while R2 decides the triggering voltage to T1, if the current consumption crosses the 1.5 amp mark, T1 conducts and assists the IC by sharing the excess current through it.
P1 is set for achieving around 13 volts across C3.
R5 monitors over load conditions and short circuits, if the current crosses beyond 12 amps, sufficient current develops across R5 to trigger T2, which instantly switches OFF the IC so that the output voltage drops and restricts the current below 12 amps.
Ideal Specifications:
- Constant voltage = 13 volts
- Current Limit = 12 Amp
- Overload protection = above 12 amp cut OFF
- Thermal protection (if the transistor and IC are mounted on the same heatsink with mica isolation)
- Short circuit protection (fire hazard protection)
Parts List
R1 = 0.1 Ohms, 100 watts, made from 1mm iron wire.
R2 = 2 Ohms, 1 watt,
R3 = 120 Ohms, 1/4watts,
R4 = 0.1 Ohms, 20 watts, as explained for R1 (this resistor is actually not required, may be replaced with a wire short.)
R5 = 0.05Ohms, 20 watts, make as R1
T1 = MJ2955 mounted on big finned type heatsink
T2 = BC547,
C1 = 10,000uF, 35V
C2 = 1uF/50V
C3 = 100uF/25V
P1 = 4k7 preset,
IC1 = LM317
D1, D2 = 20 amp diode (3nos. 6 amp diodes in parallel)
Simplified Version
Using the IC LM196, the above configuration becomes extremely simple, you may refer to the following diagram which illustrates a simplified version of the proposed car alternator voltage stabilizer circuit using bare minimum components.
R3 = 240 ohms
D1, D2 = 15 amp diodes
P1 = 10k preset
C1,C2,C3 as specified above
IC1 = LM196
Anonymous says
Hi Sir, Thank you very much for this great circuit. I know it can easily being build only thing is I need to survey for the components R1, R2 and R5 in the market here, as for the diode I presumed it is 1N5408 in parallel. Other component is the Power Transistor MJ2955 which is PNP rated at 15Amps 60V.., is there any suitable substitution recommendation..? I know 2N3055 is among the same rated power but it's an NPN, please advise Sir..
Regarding the R1, R2 and R5,if so it's not in the market..how can diy it or where can I scavenged it from..lol..! As for the rest of those components, I guess it shouldn't be a problem.,as for heat sink and mica isolation.. I have all lying around as I used to scavenged waste parts and components..lol..
Thanks again Sir for all the efforts given.
Haziq.
Anonymous says
Hi Sir Swagatam,
I need help.
For project on my colledge I need to make AVR using microcontroller and relays.
Do you have any idea how I can do that?
I need some sheme or anything for this.
Thank you!
Anonymous says
Hi Sir,
Oh..ok got it..but onto what shall i wound it to..? The digital multimeter is to measure the ohm, what about the wattage..? how do I measure that.. or is it the 1mm iron wire can stand the extreme heat (wattage)produce..? I really like to learn more on how to wound or diy it.. I really hope you can show me the way or at leased point me to the right link about how to do this hand made thingy.
My appreciation in advance for all future advise and assistance from you.
Thank you Sir.
Haziq.
Anonymous says
Thank you Sir, I'll build it once I get all the components in hands and would present it to you and of course to the link given earlier.
Haziq.
Anonymous says
Hi sir swagatam,
Do you have circuit for AC over current protection?
Thanks
Anonymous says
sir kindly help me make a R1, R2, R4 and R5. formula of finding right way of Resistance make at home.
Thanks
Swagatam says
There's no formula for making resistors….you will have to use special digital meters for measuring the resistances while making them, or you can use many resistors in parallel, for example you can connect 10 nos. of 1 ohm 10 watt resistors in parallel for getting 0.1 ohms/100 watt
Bibin Edmond says
hi swagatam,
in this circuit how we can limit the current to .2amps(200milliamps).
and voltage to 4.7 volt.
Regards,
Bibin Edmond
Swagatam says
Hi Bibin,
Remove R4, it's not required, short the connections.
R5 alone will fix the current….R5 = 0.7/0.2 = 3.5 Ohms.
Swagatam says
P1 can be used for adjusting the voltage.
Bibin Edmond says
Hi swagatam,
i made that circuit on a breadboard yaar… its working… Thanks for your gr8 support…
Regards,
Bibin Emdond
Swagatam says
You are welcome Bibin.
Bibin Edmond says
hi swagatam,
what will be the power dissipation of R5 ?
if the voltage is 4.7 and R5 is 3.5 ohms.. current is 200milliamps.. ?
Swagatam says
Hi Bibin,
To get the exact value, Multiply o.6 with the max short circuit current at the output.
Bibin Edmond says
sorry swagatam , i didn't get u.. whats that 0.6 and max short circuit current.. ? i'm using this circuit to charge a battery…
Bibin Edmond says
Hi swagatam,
as u said above on previous replies.. i changed the circuit like this image for charging 4v 1ah battery.. and pls help me to find the power rating of that resistor too…
Regards,
Bibin Edmond
Swagatam says
Hi Bibin,
I thought You wanted to know about the correct wattage of R5.
0.6 is the base triggering voltage of the transistor, divide it with the maximum safe charging current limit.
Swagatam says
for getting the wattage of R5 you can multiply 0.6 with the specified safe charging current limit value.
Swagatam says
i.e 0.6 x 0.2 = 0.12 watts or 1/8 watts, so a 1/4 watt will be enough.
Bibin Edmond says
Yes Swagatam,
i want to know the Correct wattage for R5.. coz i used 1/4 watt resistor on this circuit and its getting hot while charging the battery…
Bibin Edmond says
Ok thanks swagatam…
Actually what is happening here.. i mean in this circuit.. !
when the load (ie: battery) tries to draw more current from the circuit ie(>200).. ?
Swagatam says
it means the transistor is not conducting at 0.6V….so may be you can take 0.7 in the above calculations….the easiest method is to make it a 1 watt, that'll solve everything.
Bibin Edmond says
Ok swagatam…i'll try to increase the wattage..
thanks yaar..
bibin Edmond
Bibin Edmond says
Hi swagatam,
please refer this pic IMAGE
what's that sign means.. ?
do we have to connect it with negative of the alternator ( or source).
Swagatam says
Hi Bibin,
It's the ground or the negative for the output loads, do not connect this with the input negative line, otherwise R5 will not work.
You may remove R4, it's not required, replace it with a wire link.
Bibin Edmond says
oh alright…. ! Thanks swagatam.. for ur gr8 support.. !
Regards,
Bibin Edmond
Bibin Edmond says
Swagatam,
Can we add a led indicator with this CIRCUIT… When the battery is fully charged it will light up or down.. ?
or we need a separate voltage comparator circuit for led indication ?
Swagatam says
Hi Bibin,
there's no option for charging indicator in this circuit, you will have to employ opamps for getting indications.
Saratoga Iron Works says
I am interested in using this circuit to stabilize the voltage on my 1939 chris-craft. I am using an 8 volt battery so I would want to stabilize at 9.2 volts. What changes to your circuit would you recommend for this application? Thanks! Steve
Swagatam says
OK, you may try the circuit that's given in this article, or alternatively you may check out the following circuit:
https://homemade-circuits.com/2012/04/how-to-make-solar-battery-charger.html
adjust the given preset to get the required 9.2 volts at the output of the circuit, once adjusted the output will get clamped at that level, irrespective of the source fluctuation.
Swagatam says
no changes would be required in the indicated circuits assuming the charging current to be within 5amps or the battery around 40AH
Rahim Radhuan says
hi swagatam,
can i used MJe2955?
Swagatam says
yes can be used….please see the simplified version also.
Abu-Hafss says
Hi Swagatam
All cars/trucks are equipped with a Voltage Regulator which supply regulated to the battery and the entire electrical system of the vehicle.
Earlier these voltage regulator were mechanical relay type, installed as an individual component. But nowadays, these v/regulators are mostly electronic type (much simpler based on three transistors) and are built within the alternator.
Furthermore, all the gadgets are duly protected with their respective fuse.
I wonder what extra benefit we can get with above-mentioned circuits.
Swagatam says
Hi Abu-Hafss,
the above designs hopefully show a simpler approach to making these devices, anybody who may be interested to manufacture them or has a damaged system in his car can try this design.
Dan says
Hi Swagatam…
Do you mean to say that the above-mentioned circuit can replace a car's damaged voltage regulator? Or do you have a specific automotive voltage regulator circuit design that can be used to replace damaged alternator's built-in regulator?
My alternator's built-in regulator is damaged thus I would like build my own which is capable of charging my battery at a maximum rate but with all the necessary features found in all built-in regulators.
Your help would be highly appreciated.
Swagatam says
Hi Dan,
The circuits explained in the above article are extremely reliable and advanced with their discussed voltage regulation features.
You can try the last circuit using the IC LM196 for replacing your car's damaged unit.
However I am assuming the function of the car voltage regulator to be just voltage regulation only, and not something more complex than this, like monitoring the alternator field winding triggering states etc which the above circuits won't be able to do.
I'll research more on this and try to get an appropriate answer soon.
Anonymous says
thanks for all this posts……now i want to make a ckt which can turn off the switch (a wall switch controlling a 3 point plug is connected)using a wireless remote..so i can turn off the switch without touching the switch …
Swagatam says
you can try this circuit:
http://easy-electronic-circuits.blogspot.in/2013/09/uhf-fm-remote-control-transmitter.html
Gordonhbm says
Hi, I have an old car that has a dynamo with only a standard cutout. i.e. no voltage or current control other than an adjustable third brush in the dynamo to control the maximum current output to 11 amps. When the battery is discharged following starting the maximum voltage generated for a short period is about 17 to 18 volts.
I want to use an electronic ignition system and this is designed to operate between 8 and 16 volts. I would like to put a voyage stabiliser in the positive feed to the ignition to control at about 13 to 14 volts. I estimate that the amount of current taken by the coil and electronics would be 6 to 7 amps. What circuit would you advise please to very robust under these conditions.
Swagatam says
You can try the last circuit shown in the above article using IC LM196. According to me this will perfectly suit your needs.
Gordonhbm says
Hi, Thank you for your reply.
Doe the fact that I am using a dynamo rather than an alternator make any difference to your recommendation?
Does the ideal spec you quoted at the start apply to this circuit?
Will it handle the continuous load of 6 to 7 amps and does the ic need a heat sink?
Gordonhbm says
Hi, Thanks for your advice.
1. Does it make any difference that a dynamo and not an alternator is being used in my case?
2. Does the ideal specification you quoted, particularly the current overload protection, apply.
3. Can it safely handle the continuous load of 6 to 7amps?
Swagatam says
1. It won't make any difference.
2.you will have to include T2, R4, R5 stage as shown in the first circuit for getting the current control feature, if it's absolutely critical.
3. LM196 is rated to handle upto 10 amps, so it's safe.
Swagatam says
yes a heatsink would be required for the IC for efficient working of the device.
Swagatam says
more info about the IC can be found here:
https://homemade-circuits.com/2013/04/15v-10-amp-adjustable-voltage-regulator.html
Daniel Moeller says
This looks like what I've been shooting for to stabilize the system voltage in my truck. Is your circuit designed to connect in parallel to the charging cable, or in line so all system current passes through it?
Swagatam says
It depends whether you want to stabilize the entire electrical of the vehicle or just a single gadget. If it's the entire system then the voltage must pass through the circuit, if it's for a particular device such as a battery, then it could be positioned in between the source and the battery.
However the above circuit is applicable for 12V vehicles only, if your truck operates at this voltage then you can try the second design in the above article.
Rolando Avecilla says
How will it effect my voltage regulator in my motorcycle?
Swagatam says
It will work good in your motorcycle as well.
champion says
In your circuit there are input and output, how to change this circuit so we just have 2 wire connected to – & + battery?
Swagatam says
the input side needs to be connected to the battery (+)(-) and the output side with the load or whatever electrical/ electronics you may be having in your car….briefly, the circuit should be in the middle of the battery and the car electrical units, the supply needs to pass through the circuit before reaching the car gadgets.
Swagatam says
actually the (-) of the battery and all the loads could be made common and joined to the car chassis….only the positive from the battery needs to be connected with the input (+) of the circuit and the output (+) from the circuit can join with the car gadgets for powering them with the desired stabilized supply
Sunday Owen says
your project are very educative and i want to please use component like crystal in your project so that we can understand their usage in oscillation.thank you sir..
Swagatam says
thank you, I'll surely consider your request.
Anonymous says
What is the wattage of 240 ohms resistor (R3) in the simplified version?
Swagatam says
it is 1/4 watt
John Rider says
Can i use this circuit to my 110cc motorcycle?
Swag says
yes you can!!