Lab 3 Report: Power Supply Design C By: John Klusek Partner: Ryan Conrad Section 006 2/7/12 Introduction

Power supplies are used to take signal from an electrical outlet and transform it into a DC output in order to power electronics. A power supply is composed of an input transformer, rectifier, filter circuit, and voltage regulator. This power supply will take an input signal of 60Hz, 120Vrms, and transform it into a DC signal according to design specification C. Design C requires the output voltage Vo to be +15V +/- 0.5V. At the regulator input, the nominal DC voltage will be Vc = +24V. Additionally, the ripple voltage Vr will be within 15% of Vc and the load resistor will be rated to dissipate 1W. Circuit design

Figure 1: Overview

Figure 1 shows the individual components of the complete power supply. With each successive component, the AC input transforms into a DC output.
R2 V1 U1 4.03 R3 4.03 R1 750

120 Vrms 60 Hz TS_POWER_VIRTUAL 0

Figure 2: Power Transformer

Figure 2 shows our model of a power transformer. This power transformer decreases the magnitude of the input voltage. Our transformer used a turns ratio of 12:1:1. We label the terminal at the top as A, the middle as B, and the bottom as C. Thus, the voltage between each output terminal is roughly 10V = VAB = VBC for a total of 20V = VAC across the load. R1 represents the load resistor and R2 and R3 are resistances due to winding that were determined experimentally. For design C, the load must be placed between AC. Otherwise, the output voltage would be too small. We are using this transformer without a center tap.

D1 V1 20 Vrms 60 Hz 0 1N4935 C1 112uF R1 D3 1N4935 569

D2 1N4935

D4 1N4935

Figure 3: Diode Rectifier with Filter Capacitor

Figure 3 shows the chosen bridge rectifier. This full-wave rectifier is used to take a downstepped sinusoidal input and output a wave that is positive at every point. Figure 7 in the data section shows an example. Since the transformer is being used without the center tap, four diodes are required. If the center tap was used, only 2 diodes would be required for full rectification, but the output voltage would be too low. The output voltage is the voltage across R1. Capacitor C1 modifies that output wave and flattens it. The result is that the output wave becomes a ripple wave with a positive DC offset. This output is labeled Vc and is called unregulated voltage because it has a variation Vr, where Vr is the ripple voltage or difference between Vc max and min. Figure 14 in the data section shows a ripple wave.

R2 272.7 V1 24 V D1 1N4736A D2 1N4738A R1 652.2

Figure 4: Diode Voltage Regulator

Figure 4 is the Diode Regulator. V1 is equivalent to Vc, the output of the filter capacitor. Vc shows a ripple pattern and thus must be further flattened before it can match the specification of 15 +/0.5V. The regulator circuit is a straightforward method to stabilize the voltage. The diodes are specified so that the voltage drop across both is equal to approximately 15V. Since diodes offer variable resistance, but relatively constant voltage drop, their properties flatten the ripple of the voltage. The voltage across load resistor R1 is the final specified DC output.

Figure 5: IC Voltage Regulator

Figure 5 shows a voltage regulator using an integrated circuit. As with the circuit of figure 4, the goal is to take Vc and achieve an output DC voltage of 15V. The capacitors stop oscillation of the voltage, and so are necessary to achieve optimal output. The chip is limited by its power dissipation rating versus the product of the voltage and current across it. Supporting Analysis The parameters of the transformer in Figure 2 were experimentally determined. First, the open circuit voltage between the terminals was found. VAC, the voltage from terminal A to terminal C was measured to be 20.68 VRMS. Next the load resistance was chosen. Since P = V2/R and the load resistance must dissipate 1W, RL = (20.68V*sqrt(2))/(1W). RL = 855.2. We used a 750 2W resistor from the stockroom. The rectifier is designed keeping in mind the voltage limits of the diodes. The peak inverse voltage (PIV) in the circuit is found by applying KVL across the outer loop. PIV = VOC - V. PIV = 20.68V*sqrt(2) 1.1V = 27.05V = 38.25VRMS. The diode is chosen so that the rating is at least double that value. The diode 1N4934 is only rated at 70VRMS, so we chose the 1N4935 with a rating of 140VRMS. The load resistor of the rectifier is chosen using a power calculation. Design specification C tells that the voltage across the load should be 24V. We want the resistor to dissipate 1W, so RL = V2/1W = 24V2/1W = 576. Our resistor was 569. The filter capacitor voltage is given by

Where VM is the max voltage over the load resistor, f is frequency, RL is the load resistance, and Vr is the ripple voltage (15% of Vc). C = (27V)/(2*60Hz*560*0.15*24V) = 112uF. This is the capacitor size recommended to get an appropriate ripple wave. The maximum current through the diodes, iD,max, can be calculated theoretically:

By plugging in VM = 27.6V, RL = 569 , and Vr = 3.4V, the max current is 662mA. Experimentally, we found a measured peak current of 180mA by placing a 1 resistor in series with a diode and measuring the voltage across it. This calculation was repeated in Multisim:

XSC1
Tektronix
P G 1 2 3 4 T

D1 1N4935 V1 U1 R3 C2

R1 1

D2 1N4935

4.03 120 Vrms R4 60 Hz TS_POWER_VIRTUAL4.03 0 D3 1N4935

112uF R2 569 D4 1N4935

Here, we find a current of 242mV/1 = 242mA. Four parameters were needed in the diode regulator of figure 4: IZmin, IZmax, Ri, and RL. IZ in general is the current through the diode. Ri is R2 in figure 4 and RL is R1. KCL tells that Ii = IZ + IL. To find IZmax, note that the current is at a maximum when RL is infinite. We are given PZ = 0.5W. Since PZ = VZ*IZmax, IZmax = 0.5W/15V = 33mA. We choose IZmin to be 30% of IZmax, so IZmin = 0.3*33mA =~ 10mA. We want Ri to be chosen so that the voltage drop across it is the difference between Vc and VZ. Thus, Ri = (24V-15V)/33mA = 272.7. RL can be determined by Ohms law. Rl = 15V/23mA = 652.2.

Data All transformer open circuit voltages were measured using a DMM. VAB = 10.372V VBC = 10.374V VAC = 20.680V The voltage across the load with the load resistor was VSC = 20.46VRMS. The load current is I = 20.46V/750 = 27.3mA. This can be used to find the winding resistance. RW = (VOC VSC)/(2(I)) = (20.68 20.46)/(2(26.3mA)) = 4.03.

Figure 6: Rectifier Input

Figure 7: Rectifier Output

Figure 8: AB no load

Figure 9: AB with load

Figure 10: BC no load

Figure 11: BC with load

Figure 12: AC no load

Figure 13: AC with load

Figure 14: Vc

Figure 15: Shunt Regulator w/o load

Figure 16: Shunt regulator w/ load

Figure 17: IC regulator w/o load

Figure 18: IC Regulator w/ load

Figure 19: IC regulator with Ripples

The percent regulation of the IC can be calculated by comparing voltages under full load and under no load. We found VL(no load) = 15V and VL(full load) = 14.9V. % Regulation = 100%(15V-14.9V)/15V = 0.67%

We also found the factor by which the IC reduces ripple voltage. 5.6 V is the ripple at the capacitor. The oscilloscope gives Vr = 56mV at IC output. So ripple is reduced by a factor of 5.6V/56mV = 100. The percent regulation of the diode circuit can be calculated by comparing voltages under full load and under no load. We found VL(no load) = 15.1V and VL(full load) = 14.9V. % Regulation = 100%(15.1V-14.9V)/15V = 1.3% We also found the factor by which the diode circuit reduces ripple voltage. 5.6 V is the ripple at the capacitor. The oscilloscope gives Vr = 900mV at circuit output. So ripple is reduced by a factor of 5.6V/900mV = 6. Results show that the IC was more effective in regulating the voltage, thus it should be used unless there are disadvantages like cost or power dissipation. With no heatsink, the IC can only dissipate 1-2 Watts. In our supply, IZmax = 33mA, the maximum power through the IC should be roughly (24V15V)*33mA = 0.297W. We expect the IC should operate under the circuit conditions. When the load resistance gets too low, IC power dissipation drops off. We tested various resistor values until ripple appeared strongly in the output voltage. This occurred at 49.7. P = V2/R shows that the power over the IC was (24V-15V)2/50 = 1.62W. Thus, the dissipation limit was likely reached and IC failed to regulate the voltage output. Discussion Power considerations were an important component of this lab. The supporting analysis and data sections show power calculations to determine appropriate resistors and diodes. For every component we used, we tried to choose components that would survive conditions up to twice their expected maximum load. The resistors from the stockroom were specially rated to survive 1-2 Watts of load. % Error = 100*(Theoretical Measured) / Theoretical One parameter of interest is the max diode current iD in the rectifier. The value of iD is crucial to choosing rated diodes. When iD was measured experimentally, we found iD = 180mA. Theoretically, iD was 662mA. The percent error was 72.8%. In Multisim, the max current value was 242mA. It makes sense that the actual value was lower because the theoretical calculation did not take into account resistances of the diodes. Non-ideal diodes have resistances that will lower the total current. We will now compare our results to the specifications of Design C. The DC output voltage was to be 15V +/- 0.5V. Using the IC regulator, our voltage was 14.9V +/- 0.056V, which is within the specification. Using the diode regulator, the output was 14.9V +/- 0.5V. This output exceeds the bounds of the specification by 0.1V. Although 14.9V is close to 15V, the ripple of 1V makes the output vary too much. For this reason, the IC regulator is recommended when practical.

At the regulator input, Vc was 25.8, while the nominal voltage was to be 24V, for 7.5% error. The ripple voltage was 3.4, which was within 15% of the specified 24V. Error at the regulator input is less important because the regulator will reduce the voltage regardless. However, our nominal voltage was within the correct neighborhood. Summary and Conclusions A power supply consists of 4 main parts: transformer, rectifier, filter capacitor, and voltage regulator. The transformer takes an input sine wave and changes its magnitude. The rectifier takes the output of the transformer and makes the output of the wave generally positive as seen in Figure 7. The filter capacitor takes the rectified wave and makes a ripple wave as seen in Figure 14. Finally, the voltage regulator flattens the ripple wave into something that appears to be a DC voltage. This lab showed that many major parts of a power supply can be replicated using simple components like diodes, resistors, and capacitors. Using the given design, we were able to achieve results either near the specified range using the diode rectifier or well within the range using an integrated circuit.