DC-AC Power Inverter

Project
 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 Description
Voltage Convert 12VDC to 120 VAC
Power Provide 300 W continuous
Efficiency > 90% efficiency
Waveform Pure 60 Hz sinusoidal
Total Harmonic Distortion < 5% THD
Physical Dimensions 8 x 4.75 x 2.5
Cost $175.00
 Main Components
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 PWM Control Circuit
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 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
PWM Oscilloscope Waveform
Prototype Device as Built
 Half-bridge Converter
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 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
Half-bridge Oscilloscope Readings

Prototype Device As Built

 Transformer
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 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
DC-DC Converter Schematic
 DC-DC Converter Testing

Simulation Device As Built

 Sinusoidal PWM Controller
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 Sinusoidal PWM Circuit
Last Semester:
PIC18F452 too many unused
ports
Insufficient dead-time in PIC
program caused cross-
conduction in full-bridge
inverter

This Semester:
Chose PIC18F252 fewer
unused ports
Programmed 500ns between
each control pulse
 Software Flow Diagram
Initialize
all
variables
no 300 duty cycle yes
Count0 = 300 (300 duty cycles)
values?

Output 1 = high, Output 2 = low

Output 1 = low, Output 2 = high

Read duty cycle table (increment pointer)

Decrement Count0 by 1
Duty cycle and sampling period timer

no One Sampling yes

no Has duty cycle yes Period?
been reached?
Sinusoidal PWM Drive Pulses

Simulation Device As Built

 Full-bridge Inverter
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 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
Simulation vs. Actual (unfiltered)

Simulation Device As Built

Frequency Spectrum Before Filtering

Simulation Device As Built

60 Hz 60 Hz
18 kHz
18 kHz
 Low-pass Filter
12 VDC Input
(from vehicle battery)

PWM Control Half-bridge

Transformer
Circuit Converter

Low-pass Full-bridge Sinusoidal PWM

Filter Inverter Controller

120 VAC,
60 Hz, 300 W
Output
 Low-pass Filter

2nd order L-C filter

Filters to retain a 60 Hz
fundamental frequency
Few components
Handle current
Wind inductor (fine tune)
DC-AC Full-bridge Inverter Schematic
 Final Output Testing

Simulation Prototype
Frequency Spectrum After Filtering

Simulation Device As Built

 PCB Layout

Dimensions: 7.5 x 6.5 x 2.5

Packaging
 Status and Goals

Continue working with PCB

Fine tune filter
Improve packaged appearance
Attempt to further reduce costs