GUJARAT TECHNOLOGICAL UNIVERSITY (GTU)

Vishwakarma Government

Engineering Collegeaffiliated with GTU

AProject Report on

Power Supply Unit

prepared as a part of the requirements for the subject ofDESIGN ENGINEERING – II B B. E. III, Semester VI

(Power Electronics Branch)

Submitted By :-Group: 12

Sr. No. Name of students Enrolment no.

1. LINSON LAZAR 130170124030

2. MEET PIYUSHBHAI PATEL 130170124031

3. RISHABH AGARWAL 130170124052

4. SOUMENDU S CHATTERJEE 130170124056

Anwarul M. Haque (Faculty Guide)

Vipul G PatelHead of the Department

Academic year

(2016-2017)

CERTIFICATE

This is to certify that the Design Engineering 2B (2160001) report entitled “Power Supply Unit” submitted by Linson Lazar (030), Meet Patel (031), Rishabh Agarwal (052) & Soumendu Chatterjee (056) towards the partial fulfillment in Design Engineering 2B (Power Electronics Engineering) of Gujarat Technological University is the record of the work carried out by him under our supervision and guidance. The work submitted has in our opinion reached a level required for being accepted for examination. The results embodied in this Project Work to the best of our knowledge have not been submitted to any other university or diploma.

Date: 13/04/2016

Guided by:

Prof. Anwarul M. Haque

Assistant Professor Department of Power Electronics Engineering

Vishwakarma Government Engineering College, Chandkheda - 382424

Head of Department

Prof. Vipul G. PatelDepartment of Power Electronics Engineering

Vishwakarma Government Engineering College, Chandkheda – 382424

1. Introduction to concept/ idea About team members:-

In our team four persons (1) Linson Lazar (2) Meet Patel (3) Rishabh Agarwal (4) Soumendu Chatterjee Guide and Mentors :-

Prof Anwarul M. Haque He received his B.E (Power Electronics) from Lukhdhirji Engineering College, Morbi, Gujarat, India in 1989 and M. Tech (Electrical) from Manav Bharti University, Solan, Himanchal Pradesh (HP) in 2012. He is pursuing his PhD (Electrical Engineering & Technology) from Jodhpur National University, Jodhpur, Rajasthan since July 2012. He is involved in design engineering since last two years and presently guide all the students of power electronics for DE-1A, 1B, 2A & 2B.

Initial Idea about Design Thinking:-

Design thinking is a problem solving methodology that helps students, faculty members and innovators to

approach today’s problems from a new perspective and methodology. This multi-disciplinary process involves the

involvement of users at an early stage and rapidly leads towards the prototype. This thinking process will provide

practical experience in approaching problems with this innovative methodology. Students will learn key Design

Thinking concepts and then get to apply these concepts working with companies on real examples.

As discussed among team member after having introductory session on Design Thinking, we team members, after

a long discussion, decided to choose a domain for design process. The domain is “Power Supply Unit” by which

we can solve certain Power Electronics sector problems.

Relation of Design Thinking according to academic Point of view

Think out of the box

Design thinking process is interesting

Team work

Find the problems technologically

Solutions keeping Energy Conservation in mind.

Phase 1

Evaluation of Idea

Observation Record sheets (AEIOU Framework)

AEIOU stands for

A – Activity

Activity means the user’s specific activity that user performs on day-to-day or daily basis. Our project have users that are interested in our project and have their wishes fulfilled through our product.

E – Environment

Environment means the situation surrounding our product that may or may not affect directly/indirectly our project. Humid conditions are always not reliable for electrical and electronics products and results in failure of product, and results in reduced lifetime.

I – Interaction

Interaction means the user’s interaction with our product, validate it and give feedback to us.

O – Observation

Observation means the summary or overview of the product that we are going to launch. Analyzing it from every angle and from user’s point of view is necessary.

U – User

Users are the prime concern. Without them, our product will be useless.

Empathy Mapping /framework

Domain area or pre requisite we start with empathy campus is Power Electronics.

Deciding Users (including Selected User) and stakeholders

- Power Electronics Design Engineer (Selected User)- Power Electronics Based Factories- Test and Measurement Based Factories- Mobile/Smartphone Industry techies

Activities of the user and stakeholder

Test the product before bulk production and suggest different methods to improve the damages caused while production

Re-testing the product till no damages found and then suggesting the production team for a bulk production of the product

Checking for damages in the machine used during the product production and repairing them before starting a bulk production

Planning different designs and discussing them with the management team for launching a new product Report latest technologies and new methods used in the product development to the product planning team and

implement them to improve the product

Check the product quality after first round of test production and bulk production Maintain a shift register of the team and report the team members of their weekly shifts.

Stories

Sad Story 1 :-

Once we were making project on BCD counter using IC4510 and the rated supply voltage was 9V. But due to certain conditions it was not enough for the circuit to run and we were trying different configurations, but they didn’t work too and submissions got delayed. The power supply was not reliable. And we ended up buying the components again which increased the cost of our project.

Happy Story 1 :-

We used power supply unit as a backup for speed control of small dc motor. Everything was running fine until the power supply got cut off. But luckily we had our power supply unit which gave constant supply to our small dc motor till the supply was resumed.

Conclusion

From this canvas we concluded the following things

- The domain power electronics have variety of applications.- Empathy is understanding user’s feelings, their needs, their requirements and come out to solve the

problems they face in uniform manner.- Without users and stakeholders our project is of no use. If there is no user, nobody will use our product

which will result in loss of our profit and work.

Ideation Canvas /framework

Deciding People :- This section is for the people with whom we are going to test our product and we will note their experience and will try to analyze and evaluate afterwards.

- Power Electronics Design Engineers- Power Control Manager- Commodity Purchase Manager- Product Manager- System Test Engineer

ActivitiesSystem Test Engineer/Power Control Manager

Test the product before bulk production and suggest different methods to improve the damages caused while production

Re-testing the product till no damages found and then suggesting the production team for a bulk production of the product

Checking for damages in the machine used during the product production and repairing them before starting a bulk production

Check the product quality after first round of test production and bulk production

Power Electronics Design Engineer/Product Manager/Commodity purchase Manager

Planning different designs and discussing them with the management team for launching a new product Report latest technologies and new methods used in the product development to the product planning team and

implement them to improve the product

Situation locations and contexts

Defining situation/context/location in ideation canvas. The users are to be relate with the in what situation and at what

location they are working. This will relate more to the user’s activities. We got some ideas about the situations the users are related.

- Voltage level fluctuation conditions of product- Hot and Humid Conditions under which product has to operate- Time to Market and NRE cost considerations- Moulding the Product according to latest technology- Using Test and measurement machines having higher bandwidth- Pressure of creating bulk products of good quality

Props :- Finding the props of the users working in such situation at certain locations will be clicking to some possible solutions those are existing or want some technological changes.

- Integrated Circuits- Connectors- Basic circuit elements like resistors, capacitors, inductors- Printed Circuit Board- Indicators- Semiconductor Switches

Iterations

Various Iterations have been tried with various users and the situations under which they have to work.

Example

1) A design Engineer while designing has to incorporate changes to nullify hot and humid conditions2) While Designing, Product has to be capable of handling various voltage fluctuations, either due to faulty supply to

product or due to changes in load side.3) Design engineers has to continuously kept evolving the product to reduce the power losses and keeping in pace

with market innovations and latest technologies.4) Test Engineers have to use high bandwidth machines while testing and they have to keep track of range of

frequencies a product can produce, otherwise their test results won’t be applicable and will be faulty.5) Test Managers also have to maintain the quality of product for bulk production while reducing the time to

produce, otherwise the company won’t be able to completely harness the market potential.

Based on these iterations following problems have been identified

1) Humidity and environmental conditions greatly affect the design of product.2) Environmental conditions causes design cost to increase and delays the product launch.

3) Faulty distribution lines available with the user can cause product to fail.4) In absence of basic template available designers have to redesign the product after every few months.5) To reduce the power losses designers rethink the product after few months.6) High Bandwidth machines are required for testing.7) Product’s range of highest order harmonics have to be taken care of, otherwise it will be difficult to test and

new machines have to be bought.8) While bulk production, unit cost has to be kept low while balancing other factors, to have competitive edge.9) Quality of bulk product is important and it has to be taken care of.10) Continuous testing of all machines is required at various stages of production and designing, from planning to

bulk production, so high quality T&M equipments are required

Product Development Canvas /framework

Purpose :- It states the purpose of our project. That is, what we are actually meant to do and what we will be capable of providing features to customers. The major purposes of this project are

- To provide uninterruptible power supply with various voltage levels. - Reduce heating effects- Reducing losses- Power Factor improvement- 24x7 support

People :- People are required to use our product, test it and give feedback to us. For our project we decided to let these people have our product’s first hand experience.

- Power Electronics Design Engineers- Computer Users- Power Electronics Based Factories- Test and Measurement Based Factories

Product Experience :- It means that what experience users will have once the product launches into the market. It includes

- User Friendly Support- Comfortability and Convenience- Low Power Consumption- Automatic Control

Product Features :- The features that are being provided in Power Supply Unit. They are

- Mobility- Compactness- Different Indications- Short Circuit Protection- Overload Protection- Closed Loop Control with filters

Product Functions :- Functions states the functions to be performed by Power Supply Unit in order to achieve maximum reliability and ease of use. The Product Functions are as follows

- It will warn about any incoming warnings through indicators- It will try to reduce the power consumption as low as possible- It may have digital data display system

Components :- The components used in Power Supply Unit are listed here. They are as follows

- DPA424 IC- Zener Diode TL430- HPCL817A optocoupler- Basic circuit elements (resistors, capacitors and inductors)

Customer Revalidation :-

Customers are our prime concern. They will use our product only if it satisfies all their needs and requirements. We need to cover all the customer’s interests in order to sell our product efficiently and effectively. One of our customers was happy with our product as it fulfilled most of his requirements. He required this for domestic/general use. We continued to validate our product with him and h reported certain negligible instability in our product. When tested with oscilloscope it was giving irregular (but negligible) waveshapes at certain period. We looked into that matter and found that disturbing element that was causing this instability. We replaced that component with appropriate value and the system started to work normally again.

Reject, Redesign, Retain :-

Redesign-

- Digital filters should be used- Digital Display should be included

Retain-

- Closed loop Control- Overload Protection- Short circuit Protection- Different Voltage Level Outputs- Isolation Between Input and Output Side- Various Test Points in PCB

Customer Validation with customer

Customers are our prime concern. They will use our product only if it satisfies all their needs and requirements. We need to cover all the customer’s interests in order to sell our product efficiently and effectively. One of our customers was happy with our product as it fulfilled most of his requirements. He required this for domestic/general use. We continued to validate our product with him and h reported certain negligible instability in our product. When tested with oscilloscope it was giving irregular (but negligible) waveshapes at certain period. We looked into that matter and found that disturbing element that was causing this instability. We replaced that component with appropriate value and the system started to work normally again.

Product solution with its functions, features and components.

We analyzed our product from every angle and included features and functions that customer demanded. We’ve included the warning system about any incoming warnings through indicators. We’ve tried to reduce the power consumption by using quality components and design has also been taken care of. Including digital display is nowadays required to have accurate control over device.

- Mobility- Compactness- Different Indications- Short Circuit Protection- Overload Protection

- Closed Loop Control with filters

Redesigned features and components

Digital filters - A digital filter is a system that performs mathematical operations on a sampled, discrete-time signal to reduce or enhance certain aspects of that signal. A digital filter system usually consists of an analog-to-digital converter to sample the input signal, followed by a microprocessor and some peripheral components such as memory to store data and filter coefficients etc. 

Digital Display - A display device is an output device for presentation of information in visual or tactile form. Examples of digital displays are LCD, Plasma, Segment displays, etc…

Final product solution

The final product solution includes the appropriate value of circuit elements and providing accurate closed loop control with proper feedback system which will result in reliable and optimized system (Power Supply Unit).

Phase: 2

1) Material Requirement-

Printed Circuit Board with FR4 masking. Size= 2” x 3” DPA424 switch HCPL317 optocoupler ic TL431 zener diode Capacitors, resistors, diodes and LEDs

2) Manufacturing Process-

The power supply unit can be thought of as to be divided into four sections. These sections are shown as blocks in the above generalized block diagram of power supply unit. The input filter, the power modulator & isolation, the output filter and control section are the four sections that form the main structure of power supply unit.

The input filter filters out the AC components from input supply and fulfills transient requirements of power supply. The power switch and isolation circuit chops the DC voltageaccording to control signal generated by control circuit and transfers the energy at the secondary of transformer. Output available from transformer is rectified, filtered and made available as output to load circuit. The output filter also sends a feedback to the control section of the unit which can either be a microcontroller or arduino controller etc by means of an optocoupler.

3) Design Specifications-

Input Voltage= 24V DC ± 20% Output Voltage= +15V/-12V or ±12V or ±9V (As required) Efficiency ≥ 80% Regulation (Line and Load)= 5% Overload capacity= 20%

4) Future Advancements-

• Gate Driver unit For Thyristors

• Frequency Measurement Unit

5) Learning Needs Matrix

PSU is based on theory of closed loop control of output voltage and thus provides stable load voltage. Various Mathematical requirements are there for this product like Transfer Function solution and state

matrix. Multisim Ultiboard is required for simulation of schematic and pcb designing. Various Applications of this product are-

1) Motor Speed Control2) Measurement Devices/Oscilloscope3) Other Common Applications

6) Challenges faced while implementing the unit-

Electrical faults Overload demands

Bottom Layer

Top Layer

Schematic Diagram

Component Values

C2 0.1uC3 0.1uCo3 0.1uCin 0.1uCSF1 0.1uCcross 0.1uC1 10uCo2 10uCo5 10uC1A 10uC4 470pC5 100pC6 2.7nC7 220nCo1 220uCo4 220uCf 1u/50VCf1 47uR1 ShortedR2 250kR3R4 22eR5 100/110R6 62.3R7R8 5.9R9 1kR10 51kR11 15k

Rl1 2.2kRl2 2.2k

Pot 5k

Din 1N4007D1 Fr104/106D2 Fr104/106D4 Fr104/106D5 Fr104/106

TVS1 MCV681K05DS

LED1 RedLED2 Green

Opto HCPL817A

ZENER TL431ILPR

DPA SWITCH DPA 424

Connectors Screw Terminals

Conclusion :

The final product solution includes the appropriate value of circuit elements and providing accurate closed loop control with proper feedback system which will result in reliable and optimized system (Power Supply Unit).