i ACKNOWLEDGEMENT
ﻢﯿﺣﺮﻟا ﻦﻤﺣﺮﻟا ﷲا ﻢﺴﺑ
Firstly, a great thank to Allah for giving me strengthens to complete the first phase of my Final Year Project. I am very grateful to lecturers, my family fellow friend that helped me to evaluate this report from the beginning until the end. All the ideas, information and cooperation those are very useful to me in order to complete this EET 444 Final Year Project.
Then, I would like to thank my supervisor, En. Muhd Hatta Bin Hussain and co- supervisor En. Nor Haidar Bin Hashim for giving me guidance through this process final year project. Thank you for your briefing and guidance throughout the whole process of completing this project as well as for teaching the proper technique of study process. All the tips and helps given are highly appreciated.
Also, I would like to thank all other PLV’s and Technician for helps me along my final year project in progression. Without their helps, I will have difficulties in ultimate the final year project.
Last but not least, I also feel affection to all School of Electrical System Engineering staffs and other fellow friends for their helps and moral support that make me more passion in my final year project.
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ii DECLARATION SHEET
I hereby declare that my Final Year Project Thesis is the result of my research work under supervision of En. Muhd Hatta Bin Hussain and co-supervisor En. Nor Haidar Bin Hashim. All literature sources used for the writing of this thesis have been adequately referenced.
Name (in capitals) : MOHD SAUFI BIN JANA AKSAH Candidate number : 071070514
Supervisor : EN. MUHD HATTA BIN HUSSAIN
Title of thesis (in capitals) : DESIGN AND DEVELOPMENT OF 100 W AC-DC FLYBACK CONVERTER
Candidate’s signature: ………. . Supervisor signature: ………...
Date: ……….. Date: …..………
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iii MENCIPTA DAN MEMBANGUNKAN PENUKAR TERBANG BALIK 100 W AC-DC
ABSTRAK
Projek ini adalah berasaskan mereka, membina dan membangunkan penukar terbang balik 100 W AC-DC. Litar ini direka menggunakan perisian PSIM. Ia direka untuk pelbagai nilai masukan AC dan litar ini akan diuji dalam pelbagai bentuk keadaan dan situasi. Penukar bekalan kuasa ini mempunyai julat voltan masukan 110 - 220 V AC dan menyediakan nominal 12 V, 8 A muatan penuh keluaran DC. Reka bentuk ini menggunakan topologi penukar terbang balik dengan menggunakan pengawal PWM UC3844AN sebagai alat kawalan dan suis utama. Penukaran frekuensi berbeza-beza menurut keadaan elektrik dan beban. Projek ini mempunyai kadaran kuasa 100 W dan julat frekuensi 50 - 60 Hz. Objektif utama projek ini adalah untuk membandingkan nilai voltan dan arus melalui pengiraan dan simulasi menggunakan perisian Power Simulator (PSIM) seterusnya mendapatkan keluaran yang malar, julat frekuensi dan kecekapan yang tinggi daripada penukar terbang balik sama ada menggunakan spesifikasi Piawaian Malaysia (MY) atau Piawaian Amerika (US).
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iv DESIGN AND DEVELOPMENT 100 W AC-DC FLYBACK CONVERTER
ABSTRACT
This project basically is to design, built and develop 100 W AC - DC flyback converter. This circuit is design by using PSIM software. It is design for universal AC line input and the circuits will be test under various stated conditions. This Switch Mode Power Supply (SMPS) has the input voltage range 110 - 220 V AC and provides a nominal 12 V, 8 A full load DC output. The design uses a flyback converter topology, with a PWM controller UC3844AN as the main switch and control device. Switching frequency varies according to line and load condition. The project has a rated power of 100 W and a frequency range about 50 - 60 Hz. The main objective of this project is to compare value of voltage and currents from calculation and simulation by using Power Simulator (PSIM) software and obtain constant output, high efficiency and frequency range from the hardware either using specification of Malaysia Standard (MY) or America Standard (US).
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v TABLE OF CONTENT
Page
ACKNOWLEDGEMENT i
APPROVAL AND DECLARATION SHEET ii
ABSTRAK iii
ABSTRACT
iv
TABLE OF CONTENT v
LIST OF TABLE x
LIST OF FIGURE xi
LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE xii
CHAPTER 1 INTRODUCTION
1 Introduction 1
1.1 Problem Statement 1
1.2 Objectives of the project 2
1.3 Scope of the project 2
1.4 Importance of project 2
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 3
2.2 What is Switch Mode Power Supply (SMPS) 4 - 5
2.2.1 Classification 5
2.2.2 Theory of operation 5
2.3 What is flyback converter 6
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vi
2.3.0 Analysis of flyback converter 7
2.3.1 Pulse-Width Modulation (PWM) 10
2.3.2 Switching device 12
2.3.3 Transformer 14
2.3.4 Non-Linear Loads 15
CHAPTER 3 METHODOLOGY
3.1 Introduction 16
3.2 Method description 17
3.2.1 Project Definition and Planning 17
3.2.2 Research and Investigation 17
3.2.3 Study the Software 17
3.2.4 Concept Generation 17
3.2.5 Prototype 19
3.3 Designing The Circuit 19
3.3.1 Material of the project 19
3.3.2 Parameter’s Calculation 21
3.3.3 Circuit Operation 29
3.3.4 Rectifier and Filter 30
3.3.5 Power Switching And Control 33
3.3.6 Flyback Converter Efficiency 34
3.4 Construct hardware 34
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vii CHAPTER 4 RESULT AND DISCUSSION
4.0 Introduction 36
4.1 Result
4.1.1 Simulation using Power Simulator (PSIM) 37
4.1.2 220 V AC Input, 50 Hz 43
4.1.3 110 V AC Input, 60 Hz 46
4.2 Discussion 49
CHAPTER 5 CONCLUSION
5.1 Summary 51
5.2 Recommendation 52
5.3 Commercialize 52
REFERENCES 53
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viii APPENDICES
Appendix A(i) Appendix A(ii)
CURRENT MODE PWM CONTROLLER
SHINDENGEN D3SB60 DIODE BRIDGE RECTIFIER FQA6N90C_F109 900V N-Channel MOSFET
1N5400 - 1N5408 SILICON RECTIFIER DIODE
1N4151 SILICON EPITAXIAL DIODE
1N4148 SILICON EPITAXIAL DIODE
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ix LIST OF TABLES
Tables No. Page
3.0 Components in designing of Flyback Converter 20
3.1 Pin’s parameter of PWM UC 3844AN 26
4.0 Voltages and current for circuit of 100 W AC-DC Flyback Converter 41 4.1 Value from CH1 and CH2 to obtained value of Pulse Width 45 4.2 Value from CH1 and CH2 to obtained value of risetime 46 4.3 Value from CH1 and CH2 to obtained value of Pulse Width 47 4.4 Value from CH1 and CH2 to obtained value of risetime. 49
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x LIST OF FIGURES
Figures No. Page
2.0 Theory of SMPS 5
2.1 Schematic of a flyback converter 6
2.2 Two configurations of a flyback converter 7
2.3 Flyback converter with transformer equivalent circuit model. 8 2.4 Flyback converter waveforms in continuous conduction mode. 10
2.5 A pulse wave of Pulse Width Modulation 11
2.6 Schematic MOSFET symbol 13
2.7 Transformer symbol 14
2.8 Sinusoidal voltage and non-sinusoidal current waveform 15
3.0 Flow Chart 17
3.1 Voltage node and current flow in the circuit of flyback converter. 23
3.2 Current flow in bridge diode rectifier (1) 31
3.3 Current flow in bridge diode rectifier (2) 31
3.4 Waveform of flyback converter 33
3.5 First stages in construct a flyback converter 35
3.6 Final stages in construct a flyback converter hardware. 35
4.10 Completed circuit design 37
4.11 Input voltage waveform from the simulation of PSIM 38
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xi 4.12 Input current waveform from the simulation of PSIM 38 4.13 Input direct current i1 waveform from simulation of PSIM 39 4.14 Input direct voltage v1 waveform from simulation of PSIM 39 4.15 Input voltage v6 taken using simulation of PSIM 40 4.16 Input current i6 taken using simulation of PSIM 40
4.17 Final output voltage waveform 41
4.18 CH1- 220 V AC/50Hz. CH2- 12 V DC output voltage. 43
4.19 Pulse Width for CH1(Vin) 44
4.20 Pulse Width measurement for CH2 (output) 44
4.21 Measuring the risetime using Cursor 1 and 2 for CH1. 45 4.22 CH1- 110 V AC/ 60Hz. CH2- 10 V DC output voltage. 46 4.23 V pk-pk 10 V DC output voltage at CH2 when injected 60 Hz frequency 47
4.24 Pulse Width for CH2(Vout) 48
4.25 Measuring the risetime using Cursor 1 and 2 for CH1. 48
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xii LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE
V Volt
W Watt
R Resistance
I Current
Ω Ohm Π Phi
AC Alternate Current
DC Direct Current
PSIM Power Simulator PWM Pulse Width Modulator SMPS Switch Mode Power Supply EMI Electromagnetic Interference
Hz Hertz
D Duty cycle
P Power
µ Micro
PF Power factor
BD Bridge diode rectifier
T Time
MY Malaysia Standard
IEC Europe Standard
CH1 Channel 1 CH2 Channel 2
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xiii
