FORM -2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE
Specification
(See Section 10; rule 13)
DC CHARGING APPARATUS COOPER CORPORATION PVT. LIMITED
an Indian Company of L-3 Addf. MiDC, Post Kodoli, Satara -415 001, Maharashtra, India.
NAME OF THE INVENTORS
1. Cooper, Zal Sam
2. Nath, Yogendra
3. Bangalore, Vijayakumar Sachidanandam
4. Nadaf, Irshad Mirasaheb
The following specification particularly describes the invention and the manner in
which it is to be performed.

FIELD OF THE DISCLOSURE
The present disclosure generally relates to systems and methods used for charging.
Particularly, the present disclosure relates to Direct Current (DC) charging apparatus.
BACKGROUND
Electrical generator sets supply electrical power in remote locations or in locations where access to standard utility power is unavailable. Generator sets can also provide a source of back-up energy in the event of a utility power failure. Some generator sets are sized such that they can be moved from one place to another. Such portable generator sets generally consist of an internal combustion engine coupled to a synchronous alternator or a direct-current DC generator.
Conventionally, the engine of a generator set has to operate at a constant speed, regardless of the load, to provide a usable source of power. The constant operation of the engine generates extra noise and fuel consumption is high, even when the actual usage of power from the generator set is light (or even unloaded).
The telecommunication equipment like telecom towers, transmitters, receivers and other instruments need to operate continuously for delivering uninterrupted services to the customers.

Generally, the telecommunication installations have DC battery banks or inverters to maintain the continuity of delivery of the service during any emergency or power failure. These DC battery banks are charged by AC mains and generators. Some of the limitation of usage of AC supply for charging the battery banks are frequency/ voltage fluctuations; requirement of transfer switch; and power loss during the conversion of AC to DC.
In the known prior arts no technology is available to economically produce and distribute highly reliable high capacity DC power for use in the telecommunication sector. The use of DC quality power is much more reliable, inexpensive and would result in tremendous saving of power so it would be extremely desirable to extensively utilize scaleable DC power.
There has been a lot of development in improving the systems for charging telecom battery banks by improving their design and construction. The drawbacks of the conventional systems include bulky size, noisy operation, and poor efficiency. Therefore there is felt a need for a system and an apparatus to provide compact, noise free and efficient generator set for charging DC battery banks, particularly for telecom equipment.
OBJECTS
Some of the objects of the invention are as under:
An object of the present invention is to provide a Direct Current (DC) charging apparatus.

Another object of the invention is to provide a DC charging apparatus for charging batteries.
Still another object of the invention is to provide a DC charging apparatus that is cost effective.
Also, an object of the present invention is to provide a DC charging apparatus that reduces the cost of the alternators significantly, at least 30 less as compared to the cost of the prior art alternator.
Yet another object of the invention is to provide a DC charging apparatus which is energy efficient.
Still another object of the invention is to provide a DC charging apparatus which operates with less vibration and noise.
Still one more object of the invention is to provide a DC charging apparatus which is reliable and compact in size.
These and other objects of the present invention are dealt in a great extent by the accompanying drawings and the descriptive matter, in which there are illustrated exemplary embodiments of the invention.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a Direct Current (DC) charging apparatus is disclosed. The DC charging apparatus includes at least one internal combustion engine, at least two sets of alternators and a driving

mechanism. The at least two sets of alternators are arranged in parallel, wherein alternators within the sets are connected in series. The driving mechanism is adapted to drive the alternators. The driving mechanism includes at least one flywheel, at least one pulley and at least two belts. The at least one flywheel is connected to the at least one engine. The at least one pulley is connected to the at least one flywheel. The at least one belt is adapted to connect the pulley to the alternators for driving the alternators.
In one embodiment of the present invention, the DC charging apparatus further includes a radiator and a cooling fan for dissipation of engine heat generated. Typically, a silencer is used for reducing noise generated in said DC charging apparatus.
Additionally, a tail pipe is connected to the silencer and adapted to discharge the engine exhaust gases to the surroundings.
Further, a plurality of anti vibration mounts is adapted to facilitate mounting of the at least one engine thereon for reducing the vibrations generated by the at least one engine.
In one embodiment of the present invention, an alternator mounting bracket is used for supporting the alternators thereon and to hold the alternators firmly.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The invention will now be explained in relation to the accompanying drawings, in which:
FIGURE 1 illustrates an outer perspective view of a Direct Current (DC) charging apparatus, in accordance with one embodiment of the present invention;
FIGURE 2 illustrates a front view of the DC charging apparatus of Figure 1 depicting internal parts of the DC charging apparatus;
FIGURE 3 illustrates a perspective view depicting internal components of the DC charging apparatus of Figure 1;
FIGURES 4 and 5 illustrate perspective views of the DC charging apparatus of Figure 1 in use position, for charging DC battery banks of a telecom equipment;
FIGURE 6 illustrates a circuit diagram depicting arrangement of four alternators of the DC charging apparatus of Figure 1, in accordance with one embodiment of the present invention; and
FIGURE 7 illustrates a graph depicting output performance of the DC charging apparatus of the present invention with respect to alternator speed.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The invention will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.
The present invention provides a Direct Current (DC) charging apparatus for charging batteries. The DC charging apparatus of the present invention is cost effective. The DC charging apparatus of the present invention reduces the cost of the alternators used in a DC charging apparatus. More specifically, the DC charging apparatus of the present invention replaces a high capacity alternator that has significantly higher cost with a plurality of small capacity alternators. The plurality of small capacity alternators is arranged in a way such that it provides same power as that of a single big capacity alternator. However, the combined cost of the plurality of small capacity alternators is significantly low than that of a single high capacity alternator, at least 30% less as compared to the cost of the prior art alternator. Also, the DC charging apparatus of the present invention requires less space and reduces noise and vibration.
The diagrams and description hereto are merely illustrative and only exemplify the invention and in no way limit the scope thereof.
Referring to FIGURES 1 - 7, a Direct Current (DC) charging apparatus 100 is described in accordance with one embodiment of the present invention. The DC charging apparatus 100 includes an outlet means for air (hot air) 2 (illustrated in Figure 2), an air filter 4 (illustrated in Figure 2), a canopy 6 (illustrated in Figure 2), upper intake louvers (2 nos.) 8 (illustrated in Figure 2), lower intake

louvers 10 (illustrated in Figure 2), a tail pipe 12 (illustrated in Figure 3), a silencer 14 (illustrated in Figure 3), a radiator 16 (illustrated in Figure 3), a cooling fan 18 (illustrated in Figure 3), an engine 20 (illustrated in Figure 3), a flywheel 22 (illustrated in Figure 3), a belt 24 (illustrated in Figure 3), a pulley 26 (illustrated in Figure 3), a plurality of alternators 28 (illustrated in Figure 3), a base frame 30 (illustrated in Figure 3), an alternator mounting bracket 32 (illustrated in Figure 3), a plurality of anti vibration mounts (4 nos.) 34 (illustrated in Figure 3).
In one embodiment of the present invention, the DC charging apparatus 100 is a 48 V Direct Current (DC) Generator Set which is housed under a canopy 6. The canopy 6 is provided with an outlet means for air (hot air) 2; the upper intake louvers (2 nos.) 8; the lower intake louvers 10; and the air filter 4.
The enclosure (not particularly referenced) is also provided with the tail pipe 12, the silencer 14, the radiator 16, the cooling fan 18, the engine 20, the flywheel 22, the belt 24, the pulley 26, the plurality of alternators 28 (4 nos.), the base frame 30, the alternator mounting bracket 32 and the anti vibration mounts (4 nos.) 34.
The Engine 20 may be any type of engine, such as a Diesel Engine, a petrol engine and the like, that is coupled to the alternators 28. The main drive comes from the engine 20 with adequate load (power in KW) arid rotates the four alternators 28 with the help of the flywheel 22, the pulley 26 and the belt 24. The four alternators 28 are driven by the belts 24 connected to the pulley 26, which is coupled with the flywheel 22.

Specifically, referring to Figures 3 and 6, the DC charging apparatus 100 of the present invention includes two sets of alternators arranged in parallel, wherein the alternators 28 within these sets are connected in series. Accordingly, the circuit diagram of the DC charging apparatus 100 of the present invention includes four alternators of 24V X 100A each. Each set of the alternators of the present invention includes two alternators connected in series, thereby obtaining an output of 24V X 200A. Further, each of these sets are connected in parallel, thereby obtaining the output of 48V X 200A (9.6Kw) by using a full wave rectifier along with a filter circuit.
Function of the Filter Circuit is as follows:
The charge technique of the battery is not only charging and discharging but also to improve the quality of charge/discharge and prolongs its operation life span. The filter (reduces the AC pulse) is added in the system in order to eliminate the harmonic component and advance response speed.
Each alternator 28 has a built in voltage regulator and diode bank that gives a maximum of 24 volts DC output at 100 Amps for the charging of batteries. Hence, the alternators 28 connected in series give an output of 24 Volt x 200 Amps. Since, there are two sets of systems connected in parallel, the output of the complete system becomes 48 Volt x 200 Amps = 9.6 KW. In accordance with another embodiment of the present invention, the output of the complete system of 9.6 KW can be obtained by using eight alternators of 12 Volt x 50 Amps capacity.
The radiator 16 and the cooling fan 18 as shown in FIGURE 3 are provided for the dissipation of heat from the engine 20. The Silencer 14 is connected to the

engine 20 for discharging the exhaust gas during the operation. The tail pipe 12 is fabricated with the silencer 14, which leads out from the housing and provides a path for the exhaust gases to get discharged out of the canopy 6.
The engine 20 is mounted on four anti vibration mounts 34, which reduce the effect of vibrations at the time of operation. An alternator mounting bracket 32 is also provided that supports the four alternators 28 and holds them firmly. The whole setup of the DC Charging apparatus 100 rests on a robust and stable base frame 30.
In one embodiment of the present invention, the specifications of the DC charging apparatus 100 are as follows;
1) Type of Engine 2 CYL DIESEL NA ENGINE, 1500 rpm
2) Model 2A1D1C
3) IS Rating A
4) Rating at Site Conditions (if required by user) 9.6 KW(10KVA)
5) Direction of Rotation CLOCKWISE FROM FLYWHEEL [According to IS: 7451 (Part IV)] END
6) No. of arrangement of cylinders 02! INLINE VERTICLE [According to IS: 7451 (Part IV)]
7) Stroke FOUR STROKE
8) Bore (mm) 87
9) Stroke (mm) 100
10) Cubic Capacity (liters) 1.2
11) Nominal Compression Ratio 19:1
12) Fuel injection equipment ELECTRONIC
13) Governor Type ELECTRONIC
14) Filter Type
a) Air DRY TYPE-

b) Fuel Filter WET TYPE
c) Lubricating Oil Filter WET TYPE
15) Recommended Fuel Oil Specification COMMERCIAL HIGH SPEED
DIESEL
16) Fuel Oil Tank Capacity 75 LITRES
17) Lubrication Oil Specification 15W40, CF4
18) Mode of Starting, Apparatus Required STARTER MOTOR
19) Weight of Engine 185 KG
20) Performance Curves as per IS: 10000 PERFORMANCE CURVES (Part VI)-1980 at Standard Reference ENCLOSED
Condition Specified in IS: 10000 (Part II)-1980
21) Accessories on Engine as tested and for COOLING FAN
which a power allowance has been made
in the manufacturer's calculation of site rating
22) Voltage of Electrical System 12VOLTS, 75 Ah
23) Maximum Permissible Back Pressure BACKPRESSURE - 55mm of HG in the Exhaust System and Maximum INTAKE DEPRESSION - 150mm Permissible Intake Depression OF WATER COLUMN
24) Type of Governing, with speed drop, SYNCHRONISED if required. If for variable speed range
and the idling speed
25) Method of cooling and the specified rates LIQUID COOLING
of water and oil circulation (WATER+COOLANT)
26) Nominal Output of 4 Alternators 48V-200A
27) Rated Revolution of Alternator 6000 rpm
28) Maximum Speed RPM 10,000 rpm
29) Cit in Speed 1060 rpm
30) Polarity BI-POLAR
31) Over Speed Test 14,000 rpm FOR 0.5 MINUTES

32) Maximum Ambient Temperature at Operation 80° C (maximum)
33) Direction of Rotation CLOCKWISE (VIEWED FROM
PULLEY SIDE)
In one embodiment of the present invention, the fuel consumption test results for the DC charging apparatus 100 of the present invention having power rating 10KVA (9.6 KVA) are as follows:

LOAD
(%) FUEL CONSUMPTION ALTERNATOR
CURRENT
(Amp) VOLTAGE (Volts)

f Kg/hr Lit/hr

10 0.80 0.95 19.94 48V - DC
25 0.93 1.09 49.71 48V - DC
50 1.35 1.59 99.68 48V - DC
75 1.71 2.01 149.53 48V - DC
100 2.28 2.68 199.56 48V - DC
FIGURE 7 illustrates a graph depicting output performance of the DC charging apparatus 100 of the present invention with respect to the alternator speed. In the graph, X-axis represents RPM and Y-axis represents output current in amps. The testing of the performance of the DC charging apparatus 100 is carried at an ambient temperature of 28° C. Accordingly, as per Figure 7, as the RPM of the alternator increases from 1000 rpm to 6000rpm, the output current also increase from 0 amp to 200 amps.
The DC charging apparatus 100 of the present invention can be effectively used in the telecommunication devices like telecom towers, transmitters and receivers. More specifically, the DC charging apparatus 100 of the present invention is used for charging the telecom battery of the telecommunication devices like telecom towers, transmitters and receivers. Although the invention has been described herein above in relation to a DC Charging apparatus for

charging Telecom batteries, the DC charging apparatus 100 of the present invention may be used for charging any type of DC energy storage device.
TECHNICAL ADVANCEMENTS
The Direct Current (DC) charging apparatus in accordance with the present invention described herein above has several technical advantages including but not limited to the realization of:
• a DC charging apparatus;
• a DC charging apparatus for charging batteries;
• a DC charging apparatus that is cost effective;
• a DC charging apparatus that reduces the cost of the alternators significantly, at least 30% less as compared to the prior art alternator cost;
• a DC charging apparatus which is energy efficient;
• a DC charging apparatus which operates with less vibration and noise; and
• a DC charging apparatus which is reliable and compact in size.
The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions

and quantities fall within the scope of the invention and the claims unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

We Claim:
1. A Direct Current (DC) charging apparatus comprising:
• at least one internal combustion engine;
• at least two sets of alternators arranged in parallel, wherein alternators within said sets are connected in series; and
• a driving mechanism for driving said alternators, said driving mechanism comprising,
o at least one flywheel connected to said at least one
engine; o at least one pulley connected to said at least one
flywheel; and o at least two belts adapted to connect said pulley to
said alternators for driving said alternators.
2. The DC charging apparatus as claimed in claim 1, further
comprising a radiator and a cooling fan for dissipation of engine
heat generated.
3. The DC charging apparatus as claimed in claim 1, further comprising a silencer for reducing noise generated in said DC charging apparatus.
4. The DC charging apparatus as claimed in claim 3, further comprising a tail pipe connected to said silencer and adapted to discharge the exhaust gases to the surroundings.

5. The DC charging apparatus as claimed in claim 1, further comprising a plurality of anti vibration mounts adapted to facilitate mounting of said at least one engine thereon for reducing the vibrations generated by said at least one engine.
6. The DC charging apparatus as claimed in claim 1, further comprising an alternator mounting bracket for supporting said alternators thereon and to hold said alternators firmly.