1.0 INTRODUCTION Insert here an introductory paragraph. 1.

1 Background Information Your document should be in double space format

Power supplies are a means of supplying dedicated loads with the requisite power, be it Alternating Current (AC) or Direct Current (DC). Most analogue and digital electronics systems require regulated DC power supplies. Energy efficiency is a major consideration when designing a power supply. Losses that arise from the conversion of power from a primary source into a required load impose added costs to both system and the user. It is largely the quest for improved efficiency, hence this project. One of the most common power supplies today plugs into an AC socket and provides an isolated single or multiple DC outputs. Converters utilizing a single primary power stage and generating more than one isolated output voltage are called multi-output converters. These circuits provide: a. Isolation: there might be a need to electrically isolate the output from the input. b. Regulated Output: the output voltage must be held constant within a specified range in the input voltage and the output loading. c. Multiple Outputs: positive and or negative multiple outputs that differ in their voltage and current ratings. This study took this project for the following advantages:

ADVANTAGES A. Lower weight and smaller size: Switch-Mode Power Supply (SMPS) operates at significantly higher frequency range due to the high frequency isolation transformer being used as compared to a 50-60 Hz transformer in a linear power supply resulting in a significant reduction in size and weight of switching supplies. B. Higher efficiency: uses a power transistor that is switched rapidly between saturation and cut off, which results in much larger power handling capacity and reduction in heat sinking requirements. The switching element, power transistor is operated in its non-active region resulting insignificant power loss hence high efficiency. C. Broad range of the AC input voltage which is due to the flexibility in the selection of the switching frequency and the transistor duty cycle. SMPS can usually cope with wider variation of input before the output voltage changes. D. Generally cheaper since there is no usage of large power transformers. There is also reduction in volume and power dissipation, smaller material requirements and semiconductor devices.

DISADVANTAGES The main disadvantages of this power supply are the following: A. Only experienced technicians and electricians can construct Switch-Mode Power Supply (SMPS) because of its complexity. B. Electro-Magnetic Interference and Radio Frequency Interference are produced due to the current being switched on and off sharply and due to highfrequency switching. Therefore Proper measures such as Electro-Magnetic
filters and radio frequency shielding are needed to reduce the disruptive interference.

C. SMPS are non-linear in behaviour; therefore they draw current from line resulting in high total harmonic distortion and low power factor.

Where is your justification of why the project is taken up? 1.2 Project specifications
Power supplies are a means of supplying dedicated loads with the requisite power, be it Alternating Current (AC) or Direct Current (DC). One of the most common power supplies today plugs into an AC socket and provides an isolated single or multiple DC outputs. Converters utilizing a single primary power stage and generating more than one isolated output voltage are called multi-output converters. These circuits provide isolation and several output voltages using one high frequency isolation transformer as opposed to individual power modules for each output as it is frequently done in distributed power systems. Modern days regulations promote high power supply efficiency over wide load ranges. A power supply system architecture proposed to meet these new efficiency goals is described in this work. The following specifications are proposed for this project: a. Universal Power Supply with three outputs: I. II. III. b. c. d. e. f. g. +5 V (5%) at 18 A (90 W) +3.3 V (5%) at 5 A (16.5 W) +12 V (10%) at 3 A (36 W)

Total maximum power output = 144 W Minimum output power = 25 W Ripple voltage = 1% p-to-p VOUT, for 5 V and 3.3 V Ripple voltage = 2% p-to-p VOUT for 12 V Efficiency 85% Frequency <100 kHz for EMI considerations.

1.3

Aims and Objectives

The main aim of this project is to design and build a multiple outputs switched mode power supply system proposed to meet high efficiency outputs of about 85%. Specifically, the project will focus on the following: 1. A low power converter that operates multiple modes determined by the power demand. To design and implement the proposed specification details. 2. A prototype with a maximum ripple of 2% at the output. 3. To build a power supply with an isolated feedback loop to regulate the output voltage. 4. Test techniques and performance verifications in addition to the design steps. Need to modify your objectives a bit. See me on this. Also refer to the guide for reference on how to formulate objectives.

1.4

Scope and Limitations

This study is aware that every product designed runs into some problems. It is important to identify potential problems of the project so that proper measures can be taken to avoid the problems or to minimise the effect of the problem. Some of the challenges that might be experienced in this study include: a. Selection of the optimum switching frequency: estimation of the efficiency can only be achieved if the losses based on frequency and material constants of the core are taken into consideration. b. Reduction of transformer losses. c. Integrating feedback loop to switching controller. When the load increases, the controller will need to sense the difference in real time and make adjustments within the next time step within the circuit. d. Accurately simulating transformer and switches within the converter

2.0

Literature Review 2.1 Conceptual Literature

According to Rashid (1993), Power Supplies which are used extensively in industrial applications are often required to meet the following specifications: a. Isolation between the source and the load b. High power density for reduction of size and weight c. Controlled direction of power flow d. High conversion efficiency e. Input and output waveforms with a total harmonic distortion for small filters f. Controlled power factor if the source is an Alternating Current (AC) Additionally Rashid mentioned that depending on the type of output voltages, the power supplies can be categorized into two types being the Direct Current (DC) and Alternating Current (AC). Based on the type of conversion techniques and the direction of power control, both the AC and DC power supplies can be subdivided into three categories being the switched mode power supply, resonant power supply and the bi-directional power supplies. This work is focused on the switched mode power supply type. A switching-mode power supply (SMPS) is a power supply that provides the power supply function through low loss components such as capacitors, inductors, and transformers and the use of switches that are in one of two states, on or off. (Jerrold Foutz, 2008). Additionally, Mohan (1995) highlighted that (as opposed to the linear power supply, in switching mode power supply, the transformation of Dc voltage from one level to another is accomplished by using dc-to-dc converter circuits). This mode of operation results in lower power dissipation since the power devices are not required to operate in their active region. Much of Mohans work has highlighted the positive factors that have contributed to the emergence of switching mode power supplies. These factors include, increased switching speeds, higher voltage and current ratings and a relatively lower cost of these devices. Some studies, however, have taken a different approach by looking not so much on the advantages of the SMPS, but focusing more on its related problems. For instance, Foutz (2008), mentions that the primary design problem of the SMPS is how to interconnect the lossless components such as the inductors, capacitors and transformers and control the switches so the desired results are obtained. He added that another design problem is to select, design, or overcome the performance characteristics of less than ideal components. Foutz (2008), however, claimed that the design process can only be successful when a proper topology and control has been

chosen that exceed the performance requirements and when protection techniques, parts selection, and derating have been used that exceed the required reliability. Can you put in more discussion on the relevant theories? Say component types and characteristics, different designs, among others.

2.2 Related Literature

The use of Wikipedia is being discouraged. From Wikipedia, (2009), there are two types of regulated power supplies available being the SMPS and the linear power supply. The reason for choosing one another is influenced by the table below that compares the two: Features Linear Power Supply Switched Mode Power Supply If a transformer is used, large Smaller due to higher Size and Weight
due to low operating frequency. Smaller if transformer less Efficiency, heat, and power If regulated, output voltage dissipation is regulated by dissipating excess power as heat resulting in a typical efficiency of 30-40%; if unregulated, transformer iron and copper losses significant. Unregulated may be diode Complexity and capacitor; regulated has a voltage regulating IC or discrete circuit and a noise filtering capacitor. operating frequency (typically 50 kHz - 1 MHz) Output is regulated using duty cycle control, which draws only the power required by the load. In all SMPS topologies, the transistors are always switched fully on or fully off.

Consists of a controller IC, one or several power transistors and diodes as well as a power transformer, inductors, and filter capacitors. high-frequency EMI/RFI produced due to the Radio Frequency Mild interference may be current being switched on Interference generated by AC rectifier and off sharply. diodes under heavy current loading, while most other supply types produce no high-frequency interference Electronic noise at the Unregulated PSUs may have Noisier due to the switching output terminals a little AC ripple frequency of the SMPS. An superimposed upon the DC unfiltered output may cause component at twice mains glitches in digital circuits or frequency (100-120 Hz). noise in audio circuits. Electronic noise at the input Causes harmonic distortion Very low cost SMPS may terminals to the input AC, but couple electrical switching relatively little or no high noise back onto the mains frequency noise. power line, causing interference with A/V equipment connected to the same phase. Non power-

Power Factor

factor-corrected SMPSs also cause harmonic distortion. Low for a regulated supply Ranging from low to medium because current is drawn since a simple SMPS without from the mains at the peaks Power Factor Correction of the voltage sinusoid. draws current spikes at the peaks of the AC sinusoid.

From table___ above, it can be seen that the two types of power supplies have their advantages and disadvantages, therefore when choosing one; the designer should incorporate methods that will reduce its negative aspects. Mohan (1995), summarised the advantages of the SMPS over the linear power supply into two main points being: a. Reduction in power loss which results in a higher energy efficiency in a range of 70-80%. Moreover, a transistor operating in on/off mode has a large powerhandling capability compared to its linear mode. b. The size and weight of switching supplies is significantly reduced since a highfrequency isolation transformer is used, as compared to a 50-60Hz transformer in a linear power supply. A transformer's power handling capacity of given size and weight increases with frequency provided that hysteresis losses can be kept down. Therefore, higher operating frequency means either higher capacity or smaller transformer. Wikipedia (2009). On the negative side, Mohan mentioned that switching power supplies are more complex, and proper measures must be taken to prevent EMI due to high frequency switching. From the above discussions it can be seen that the advantages of the switching power supplies over the linear power supply outweigh their shortcomings, therefore SMPS is preferred over the linear power supply. Different authors highlighted that the efficiency of the SMPS is usually affected by the method of DC-DC converter implementation. Nelson (2007) stated that when designing SMPS, the DC-DC converters in which the output is not isolated from the input should be avoided. He compared three topologies that can be considered when designing SMPS. Nelson highlighted that the common features of these topologies are that they all have a duty cycle of 50% and that their outputs are isolated from the input. These topologies include; a. Half bridge Converter: this implementation has an advantage of high efficiency of about 85% at 500W, and the knowledge of the transformer design is not important. However it has a disadvantage of switching losses and unstable voltages from capacitors on the primary side. b. Full-Bridge topology: this converter has an efficiency of about 85% at 1000W. It is the most efficient converter and is able to handle high power applications. Its drawback is that the efficiency is achieved at high power, and it has high switching losses.

c. Push-Pull converter: has an efficiency of 85% at 350W. This implementation is advantageous because it is easy to switch. Its main disadvantage is that its switches require higher voltage and it usually experiences voltage spikes. From the discussion by Nelson, it can be concluded that a successful and high efficient SMPS requires the proper converter. Any figure you want to present?

2.3 Synthesis
Much work of the authors cited above stresses the positive aspects of the Switch Mode Power Supply as compared to the linear power supplies. In addition to the positive aspects mentioned, the right converter, which is one of the important part of SMPS, should be implemented. The review of related literature from different authors has helped this study chose the method of research for this project.

3.0

MATERIALS AND METHODS

3.1 Technical proposal

Label your figures,tables, or graph. Use the cite, present, and interpret format The following flow chart in figure_____ illustrates the design steps proposed for this project:
Determine the project specifications

Topology definition

Input configuration definition

Transformer design

Choice of mode of control

Design of output filter

Discuss your figure

Theory of operation
The following block diagram in figure____ summarises the process of an AC-DC Switch Mode Power Supply:

Ac 60-Hz

EMI FILTER

INVERTER CHOPPER

OUTPUT TRANSFOMER

OUTPUT RECTIFIER AND FILTER

DC OUTPUT

CHOPPER CONTROLLER

Do this in paragraph form 1. EMI filter is used at the input to prevent the conducted EMI into the circuit. 2. An unregulated DC voltage is produced by the diode rectifier and it sent to a
large filter capacitor.

3. 4. 5. 6.

At the inverter stage, DC voltage signal is connected to the AC. The frequency is usually chosen to be above 20 kHz so that it is inaudible to humans. The high frequency output transformer converts the inverted AC to the required output level on its secondary winding. The AC output is rectified and is then smoothed by a filter consisting of inductors and capacitors. The rectified output from the transformer is regulated by means of a feedback control loop that employs a pulse width modulation (PWM). In this stage the control voltage is compared with a saw tooth waveform at the switching frequency. When the duty cycle of the switches on the primary side of the transformer, the voltage level will remain constant. The electrical isolation in the feedback loop is provided through an isolation transformer. An additional

non-switching power supply for standby is added because the feedback circuit needs power to run before it can generate power. The final control circuit will be stated in the next part of the report. The following figure______ shows the flow chart implementation of controlling the output voltage using PWM:

Compare output voltage

Yes

Is output equal to reference ? No

No

Is Output lower than reference?

Yes

Decrease duty cycle

Increase duty cycle

In this study, multiple outputs of the SMPS are required. Therefore the following block diagram of SMPS with three regulated outputs is added to the main circuit:

Feedback DC (unregulated)

Dc-AC stage

Rectifier + Filter

Vout1

(The schematics for the circuit diagrams will be included in the next part of the report.)

3.2 Methodology (still to be continued and analysed)

This study used market research to find out what kind of switched mode power supplies (SMPS) are there in the market. The study found out that most SMPS in the market are of poor efficiency and mostly expensive.

3.3 Equipment/Facilities/Software Software

The study will employ various softwares to design, simulate and convert the schematics into the PCB layout for assembly. The softwares include: 1. ISIS 7 professional and Pspice: these softwares will be used for drawing schematic diagrams and obtaining the results from the simulated diagrams. This study proposed four schematics for: the input power design circuit DC-DC converter circuit Feedback loop Multiple Outputs 2. Dip-Trace software: it will be used for the conversion of schematics into the Printed Circuit Board (PCB) layout. 3. AUTO CADD software: it will be used for drawing the external layout of the project packaging.

List of components (still to be revised)

COMPONENT RATINGS QUANTITY Estimated

Ceramic Capacitor Ceramic Capacitor Ceramic Capacitor Ceramic Capacitor Ceramic Capacitor Ceramic Capacitor Aluminium Capacitor Diode Diode, dual schottky Diode, zener Diode, schottky Diode, fast Diode, Zener Diode, ultrafast Diode, Schottky Fuse clips Connector, binding post, insulated Terminal Block, 2pin Terminal Block, 3pin Inductor, SMT Transformer, 1primary, 2 secondary MOSFET, N-Channel Optocoupler Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor

100pF, 50V 100pF, 500V 2200pF, 50V 2.2F, 25V 330pF, 50V 0.1F, 50V 560F, 25V 6A, 600V 30A, 35V 10V, 1W 1A, 40V 1A, 600V 12V, 1W 200V, 6A 30V, 30A

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Red and black, 2 15A 15A, 5.1mm 1 15A, 5.1mm 1 100H, 0.53A 1 1 500V, 8A 1 5300V, 100% 1 CTR 1k, 0.1W, 1 1% 39.2k, 0.1W, 1 1% 43k, 1W, 1% 1 4.7k, 0.1W, 1 1% 750, 0.1W, 1 1% 10k, 0.1W, 1 1% 150, 0.1W, 1 1% 1k, 2W, 5% 1 4.7k, 1 0.125W, 5% 1k, 0.1W, 1% 1 0.39, 1W, 1% 1 200, 1% 0.1W, 1

Costs (Rm) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 2.00 6.00 3.00 3.00 30.00 100.00 40.00 ? 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50

Switch, SPDT Short Jumps XFMR, gate drive

Vertical mounted

PC- 1

6.00 1.00 ? 90.00 40.00 3.00 Rm360.00

1 1 primary, 2 1 secondary Transformer 2 primary, 2 1 secondary Low power, BICMOS current mode SO-8 1 PWM Prescion adjustable shunt regulator SOT23-5 1 TOTAL ESTIMATED AMOUNT

References
1. Mohan,E., 1995. Power Electronics: Converters, Applications and Design. 2nd Ed. USA: John Willey and Sons, INC. 2. Rashid, M., 1993. Power Electronics: Circuits, Devices and Applications. 2nd Ed. Prentice Hall International, Inc. 3. Rashid, M., 2007. Power Electronics Handbook. 2nd Ed. Academic Press. 4. Nelson, L., 2007 High Voltage DC Converter. [Online] URL: [email protected] Accessed: 12/02/2010 Updated: 26/04/07 5. Balogh, L., 2006 Design Review: high density DC-DC converter. Texas Instruments. 6. Walker, E., 2005 Design Review: step-by-step approach to AC Line-Powered Converters. Dallas: Texas Instruments