Professional Documents
Culture Documents
Team Members
Daniel Martin
Min-Chiat Wee
Team Leader
Jason Horner
Abstract
Design a switch-mode power supply that converts 12 VDC to 120 VAC Pure sinusoidal waveform with 60 Hz frequency 300 W continuous output
Problem Statement
Problems:
Inexpensive inverters are very inefficient due to a high harmonic content of the output signal Pure sine wave inverters have a high cost per watt ratio
Solution:
An inexpensive inverter that produces a near perfect sine wave output
Design Constraints
Name
Voltage Power Efficiency Waveform Total Harmonic Distortion Physical Dimensions Cost
Description
Convert 12VDC to 120 VAC Provide 300 W continuous > 90% efficiency Pure 60 Hz sinusoidal < 5% THD 8 x 4.75 x 2.5 $175.00
Main Components
12 VDC Input (from vehicle battery)
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
PWM Controller
Produces two complementary pulses to control half-bridge transistors Problem:
Voltage dropped less than 170VDC when the input voltage was decreased
Solution:
A feedback network was added for voltage regulation
Half-bridge Converter
12 VDC Input (from vehicle battery)
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
Half-bridge Converter
Chops the 12 VDC to produce a 12 V, 100 kHz, square pulse Problem:
IRF740A MOSFETs has an Rds(on) = 0.55, resulting in high power losses.
Solution:
Chose IRF530 MOSFETs with an Rds(on) = 0.16
Transformer
12 VDC Input (from vehicle battery)
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
Step Up Transformer
Steps up voltage from 12 VAC to 340 VAC Problem:
Initial transformer had high internal capacitance leading to failure of device
Solution:
Custom ordered a transformer to fit our design constraints
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
This Semester:
Chose PIC18F252 fewer unused ports Programmed 500ns between each control pulse
yes
Full-bridge Inverter
12 VDC Input (from vehicle battery)
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
Full-bridge Inverter
Converts 170 VDC to a 120 Vrms, 60 Hz, sine wave
IRF740A MOSFETs
Vdss = 400 V Id = 10 A Rds(on) = 0.55
Device As Built
60 Hz
18 kHz
Low-pass Filter
12 VDC Input (from vehicle battery)
Half-bridge Converter
Transformer
Low-pass Filter
120 VAC, 60 Hz, 300 W Output
Full-bridge Inverter
Low-pass Filter
2nd order L-C filter
Filters to retain a 60 Hz fundamental frequency Few components Handle current Wind inductor (fine tune)
Component Costs
Item
PIC18F252 transformer driver inductor capacitor inductor MC34025 MOSFET capacitor MOSFET 40 MHz oscillator diode capacitor capacitor Misc. capacitor resistor diode
Quantity
1 1 2 1 1 1 1 2 1 2 1 5 2 5 x 2 1 1
Price
$2.66 $2.20 $3.60 $1.71 $1.59 $1.59 $1.40 $2.34 $1.17 $1.58 $0.70 $1.65 $0.40 $0.55 $17.81 $0.20 $0.02 $0.02
Total
$41.19
PCB Layout
Packaging
Acknowledgements
Dr. Yaraslov Koshka Dr. Mark Kinsler Dr. Mike Mazzola Dr. Raymond Winton Dr. Herb Ginn Jim Gafford Robin Kelley Len Cox Jessie Thomas
Any Questions?
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