Engineering Design 2 REGULATED POWER SUPPLY PCB PROJECT. Alexander Knapik S Kosta Goulas S Due: Friday

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1 Engineering Design 2 REGULATED POWER SUPPLY PCB PROJECT Alexander Knapik S Kosta Goulas S Due: Friday Class: Monday 5:30pm 7:30pm

2 AIM The purpose of this experiment is to design a Regulated Power Supply that contains overload protection, using the ALTIUM schematic designer and pcb designer. The constructed power supply was then tested using a Digital Storage Oscilloscope and Digital Multimeter to ensure that a value of 3.3V +/- 2% was achieved in the output stage of the power supply. METHODOLOGY The first step in achieving the desired aim was to design the PCB using the ALTIUM PCB Designer environment. A template of 70mm x 80mm was used as the spacing constraints for the PCB design. The components were then sketched onto ALTIUM s schematic environment, ensuring that correct footprints were associated with the component parts as so the correct sized holes may be drilled to accommodate the component parts required. Then, the components were imported to the PCB designer so as to place the components in such a way that neatness and manufacturability was ensured. The second step was to select the correct values of the components in order to achieve this, the data sheets of the MOSFET, LM3524 PWM Chip and LM358N sheet were used to calculate values for resistors R9,R11,R12, R13,R16,R17 and Capacitors C6, C9 and C10. The other values were calculated as according to the design specifications such as, the source voltage coming from a 240V:12V plug pack transformer, a minimised Voltage ripple of <2%, Incorporated 1A Overload current limiting. Finally, the completed design was then tested with a Digital Storage Oscilloscope, and measurements to determine the effectiveness of the power converter were measured. Such measurements included the operation of the Buck Converter Functionality, Output Voltage Regulation, and the Overcurrent Protection. Fig 1 Power Block Diagram OPERATION The first step in the power supply is to apply the input voltage of 12V rms. This input voltage is first passed through the full wave Diode rectifier, where during the negative cycle of the 12V RMS, the

3 diodes, D4 and D5 become negatively biased, allowing the other diodes to release voltage, effectively creating a pulsating DC output[1]. The outputted rectified voltage is then passed through a smoothing capacitor [C1] where a voltage ripple is obtained. The rectified voltage is then passed through the Buck Converter component of circuit, where a regulated output is to be created from the rectified voltage [2]. This is achieved through the use of the MOSFET switch. When the MOSFET switch is closed (i.e. On), the D3 diode becomes reversed biased and current begins to flow to the output stage [3], whilst at the same time supplying current to the 150uH inductor and charging the C3 capacitor. When the MOSFET switch enters the off period the charged capacitor becomes the main source of charge for the load whilst the inductor slowly releases current back into the circuit until the next period of charge which is governed by the duty cycle[4]. Simultaneously, the R2 and C5 components, form a snubber circuit which suppress the voltage spike [5] caused by the opening of the MOSFET. At the final stage of the circuit, the C4 capacitor acts as a smoothing capacitor, which aims to reduces the ripple effect of the output voltage, keeping the regulated output voltage steady at the desired 3.3V +/- 2%. Additionally, whilst the output voltage is being delivered, a feedback loop is in operation. The feedback loop, which is governed by the LM3524 and LM358N chip is used as a means to protect the circuit from overcurrent (which is via the OP AMP in LM358N) and Overvoltage (via the LM3524 PWM chip). This data is then fed back into the MOSFET. SELECTED COMPONENT VALUES Resistors Resistor Value Remarks Resistor Value Remarks R1 100Ω Voltage divider in series with R5 in order to have a voltage drop of more than 5V across itself. R2 330Ω Snubber circuit resistor tuned to minimize harmonic resonation and voltage spikes R3 16kΩ Voltage divide in series with R6 R4 62Ω Current limiting resistor for LD1 R10 10kΩ Voltage divider in series with R8 in order to have a voltage drop of 2.5V across itself. R11 10kΩ Biasing Resistor for operational amplifier. R12 8.2kΩ Voltage divider in series with R18. R13 1.6kΩ Biasing resistor for operational amplifier. R5 180Ω Voltage Divider in series with R1 R6 51kΩ Voltage Divider in series with R6 to R14 750Ω Biasing resistor for operational amplifier. R15 11kΩ Biasing resistor for operational amplifier.

4 R7 have 2.5V across itself. 100mΩ Load Resistor for the voltage output R16 1kΩ Timing resistor determining the frequency at which the circuit turns on at. R8 10kΩ Voltage Divider in series with R10 R9 27Ω Feedback resistor for operation amplifier R17 51kΩ Compensation resistor, suggested value by manufacturer. R18 910Ω Voltage divider in series with R12 in order to have 200mV across itself. Capacitors CX VALUE REMARKS C1 2.2mF Large value capacitor is used to smooth out the voltage output from the full bridge rectifier. The larger value, the smoother the voltage but at more cost. This is an adequate value. C2 100nF A smaller disc ceramic used in conjunction to the large capacitor, a standard value. C3 1mF Another large value capacitor is needed to smooth out to further smooth out the voltage connected to the output pins. C4 100nF A smaller disc ceramic used in conjunction to the large capacitor, a standard value C5 2.2nF Snubber circuit capacitor tuned to when the frequency of ringing across the high frequency diode D3 halved. C6 1nF Component value suggested by manufacturer. C7 100uF Output voltage capacitor, as it is working with a low current, there is no need for a high value. C8 100nF A smaller disc ceramic used in conjunction to the large capacitor, a standard value C9 10nF Timing resistor determining the frequency at which the circuit switches on at. C10 10nF A small capacitor used to smooth out the output of the operational amplifier.

5 Other Inductor 150uH - RESULTS Figure 2-33 Ohm Load; Jumper on Position 2 and 3 Figure Ohm Load; Jumper on Position 2 and 3

6 Figure 4-33 Ohm Load; Jumper on Position 1 and 2 Figure Ohm Load; Jumper on Position 1 and 2 As displayed by figures 2 to 5, the Power Supply circuit was operating as required, with most of the Load displaying a maximum ripple of 80mV with the exception of the 3.3Ohm load with jumper positions 1 and 2, which experienced a 160mV ripple spike. Additionally, a Multimeter measurement was taken and it was observed that on the output stage, a DC voltage of 3.30V exact was obtained, which further enforces the fact that the Power Supply was operating at the required specifications. Additionally, this proves that the Buck Converter component of the chip is working correctly as a DC voltage is outputted at 3.36V. It was also observed [not pictured] that when an overload with a 68ohm resistor at the 1A limit was applied to the circuit, the system shut down indicated by the drop in the duty cycle. This is also displayed in figures 2 and 3 where the OpAmp is displaying an attempt to drop the duty cycle in order to compensate for the load.

7 Fig 6 - Collector Pins LM3524 Header Position 2 and 3 (NO LOAD) Fig 7 Oscillator Output, Header Position 2 and 3 (NO LOAD) Fig 8 Open Collector, Header Position 2 and 3, (3.3Ohm Load)

8 Fig 10. Oscillator Output, No Header Position 2 and 3 (3.3Ohm Load) Fig 11. Open Collector, Header Position 2 and 3, (33Ohm Load) Figures 6 to 11 provide an insight into the operation of the PWM LM3524 chip. The purpose of the chip is to ensure that error enabling a steady state control of the output voltage [6]. As can be observed from figures 6,8 and 11, the duty cycle tends to decrease as the load increases on the chip, where the duty cycle is changing to compensate and reduce the error between a reference voltage prior to the output, then feeding the IC outputs back into the circuit as a means to drop the reference error from the comparator oscillator output in figures 7 9 and 10 and the sample output voltage to ensure that the optimal amount of voltage is being delivered at the output.

9 Fig 12. Voltage Transient Spike with harmonic resonation Fig 13. Voltage resonation close-up without capacitor or resistor. Fig 14. Voltage Resonation with 2.2uF capacitor and no resistor. Fig 15. Snubber Circuit in operation with 2.2uF and 330ohm resistor.

10 This observation of voltage spikes and ringing across D3 are due to the nature of high frequency semiconductors, where the switching occurs at a much faster rate than the FET.[7] As the power FET is switched off, the inductor builds up a large amount of current which is then dissipated into D3.[8] The IRF9520 was able to switch at ~78kHz which is slightly off the expected value of 100kHz; as observed in figures 12 to 15, however, with no snubber as in Figure 12 and 13 the diode was shown to operate at 616kHz. In order to half the resonance frequency, a 2.2uF capacitor was used in conjunction with a short circuit in place of a R2. This had the effect of increasing the period from ~1.63us to ~3.92us, decreasing the frequency of oscillation from 613kHz to 255kHZ as shown in figure 14. With a 330ohm resistor in series with the capacitor in figure 15, it can be seen that the ringing has been effectively snubbed, the oscillation is effectively removed, and the large voltage variation associated with it is as well. Appendix: For the resistor voltage divider network across the FET, there needed to be at least 5V voltage drop across the FET, dissipated in R1. It is also ideal to have 50 to 100mA across R1. As the voltage source was 14.3VRMS, this would reach a DC voltage of roughly 19V which could reach a minimum of roughly 15V. At 15V I (R1) = V /R let I(R1) = 50mA, V (R1) = 5V = 5/R1 R 1 = 5/0.050 = 100Ω V (R2) = 10V I (R2) = I(R1) = 50mA R 2 = V /I = 10/0.05 = 200Ω 180Ω, rounding down to keep V (R1) 5 V At 19V V (R1) = V in* R1 19* 100 = 6.79V R1 + R2 = 280 I (R1) = V /R = 6.79/100 = 67.9mA V (R2) = V in V (R1) = = 12.2V The non-inverting input of the LM3524DN PW Modulator requires 2.5V. By using the same values, the voltage will be halved over each resistor, and by using a high value, the current can be kept low. V (R8) = V (R10) = V in* R8 2R8 let R8 = 10kΩ I (R8) = I(R10) = V /R = 2.5/10, 000 = 250uA The operational amplifier had to be designed such that with header pins configured to 1-2, there would be a maximum current limit of 500mA and with position 2-3, a maximum of 1A until the PWM duty cycle would reach 0%, turning off the circuit. There would need to be a divider circuit in order to obtain 200mV input to the PWM Chip.

11 R 18 was given as 810Ω, V R18 = 200mV l et V out of amp = 2V V R12 = 1.8V = V in R12 * R18+R12 = 2* R R12 2 * R * R 12 = 1.8 * 810 R 12 = 8200Ω R 9 was given as 27kΩ l et R15 = 11kΩ Position 1-2: Max 500mA, R14 R15 I sense + = IR = 0.5 * 0.1Ω = 50mV V out Isense+ = 1 + [ (R9) / ( (R15 * R14) / (R15 + R14) ) ] 2 /0.05 = 1 + [(27, 000) / ( ( 11, 000R14) / (11, R14) ) ] = 40 R 9/39 = [R15 * R14] / [R15 + R14] R 14 = [ (R9 R15) / ( V out * Isense+ 1 ) ] / [ R15 (R9 / ( V out Isense+ 1) ) ] R 14 = [ ( 27k * 11k ) / 39 ] / [ 11k (27k / 39) ] R 14 = Ω Position 2-3: Max 1.0A, R13 R15 I sense + = IR = 1.0 * 0.1Ω = 100mV V out Isense+ = 2 /0.10 = 20 = 1 + [ (R9) / ( (R15 * R13) / (R15 + R13) ) ] R 13 = [ (R9 R15) / ( V out * Isense+ 1 ) ] / [ R15 (R9 / ( V out Isense+ 1) ) ] R 13 = [ ( 27k * 11k ) / 19 ] / [ 11k (27k / 19) ] R 13 = kΩ With the VSense output voltage, we want 2.5V going into the Inverting Input of the LM3524DN chip. We can achieve this with a voltage divider. L et I = 50uA R 6 = V /I = 2.5 / 50 * 10 6 = 50kΩ 51kΩ V (R3) = = 800mV R 3 = V /I =.8 / 50 * 10 6 = 16kΩ To be able to drive the LED safely, we need a current limiting resistor. V oltage drop across LED = 2.2V M aximum current = 20mA

12 L et I = 18mA V = = 1.1 R = V /I = 1.1 / = 61.1Ω 62Ω For the timing capacitor and resistor, in the datasheet there was a graph which could be used to determine the frequency at which the circuit would turn on at. f = 100kHz t = 1/100kHz = 10uS A t 10uS, C T = 10nF & RT = 1 kω REFERENCES [1 ] [2 ] [3 ] [4 ] [5 ] [6 ] Visual Electronics Company, "Visionics," Visual Electronics Company, 12 December [Online]. Available: Rectifier1.html. [Accessed 14 October 2016]. B. McGrath and D. Holmes, "Lab 5: Buck Converter Construction and Evaluation," RMIT University, Melbourne, W. Storr, "Switch Mode Power Supply," AspenCore Inc., 10 March [Online]. Available: [Accessed 14 October 2016]. E. Coates, "Switch Mode Power Supplies: Buck Converters," Learn About Electronics, 31 March [Online]. Available: [Accessed 2016 October 14]. Illinois Capacitor Inc., "RC Snubber (SMPS)," Electronic Components Association, Lincolnwood, Maxim Integrated Products, "DC - DC Converter Tutorial," Maxim Integrated, 29 November [Online]. Available: [Accessed 14 October 2016]. [7] Severns, Rudy. Design Of Snubbers For Power Circuits. 1st ed. Cornell Dubilier, [online]. Available: [Accessed 14 October 2016]. [8] Regulated Power Supply. RMIT University. N.p., [Online] Available: ET2257_Project_Description_2016_UPDATED%282%29.pdf. [Accessed 14 October 2016].

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