Major Project Report

Switched Mode Power Supply

Rajiv Gandhi Proudyogiki Vishwavidyalaya Bhopal (M.P) In the partial fulfillment of the requirements of the degree
Bachelor of Engineering In Electrical and Electronics Engineering (2008-2012)

Guided by: Mr. Manish Sehjwani

Submitted by: Pragati Malviya(0808ex081030) Shruti Mittal (0808ex081049) Poornima Shrivastava (0808ex081028)

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CERTIFICATE
This is to certify that Pragati Malviya, Shruti Mittal, Poornima Shrivastava have successfully completed the project on Switched Mode Power Supply during year 2011 in partial fulfillment of the requirement for award of the degree of Bachelor of Engineering in Electrical & Electronics Engineering.

Guided By : Mr. Manish Sehajwani

Approved By: Prof. B.N Phadke Head of Department (Electrical & Electronics)

Internal Examiner:

External Examiner:

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ACKNOWLEDGEMENT

I am very thankful to everyone who all supported me, for I have completed my project effectively and equally grateful to my teacher Mr. Manish Sehjwani, ,who gave me moral support and guided me in different matters regarding the topic. They had been very kind and patient while suggesting me the outlines of this project and correcting my doubts. I thank her for her overall supports. This project could not be successful without the great support and cooperation from individuals and their willingness to share their expertise and knowledge and to devote their precious time to discuss related topics Last but not the least, I would like to thank my parents who helped me a lot in gathering different information, collecting data and guiding me from time to time in making this project .despite of their busy schedules ,they gave me different ideas in making this project unique.

Thanking you

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CONTENTS

Chapter 1..................5
1.1 About The Project.....................................5 1.2 Multiple Output SMPS.....7 1.3 Circuit Diagram........................................................................................................8

Chapter 2..................9
Introduction9

Chapter 310
Comparison Between SMPS & LPS.10

Chapter 411 Working...11 Chapter 5................12

Process Of Operation...................................12

Chapter 6................14
SMPS Topologies.14 6.1 DC-DC Converter..14 6.2 Forward Converter....15 6.3 Flyback Converter...16 6.4 Self Oscillating Flyback Converter16

Chapter 717
Diptrace....17 7.1 Modules.17 7.2 Features.18

Chapter 819
Advantages of SMPS.19

Chapter 9................20
Application of SMPS..................................20

Chapter 10..............21
Conclusion...21

Chapter 11.22
Terminologies...22

References.24

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CHAPTER 1 ABOUT THE PROJECT

The project presented here is based on converting the 220 VAC into suitable DC voltage using a very efficient PWM technology and high frequency DC-DC conversion principle. The convectional step p / step down method using iron core transformer suffers the following drawbacks: 1. Very heavy as compared to a SMPS of same rating. 2. Consumes large space as compared to SMPS of same rating. 3. Low efficiency (around 70%) as compared to highly efficient SMPS (typically upto 95%) 4. No Load & line regulation. 5. Numerous losses like Eddy current losses, Heating losses etc. The above drawbacks of a convectional transformer make it unsuitable for various application and seeks need to use a SMPS. The circuit first converts the mains AC voltage into DC voltage and then this DC voltage is switched at very high rate using some PWM controller IC. This switched or pulsed voltage is given to a ferrite core transformer and converted into very high frequency pulsed DC voltage at its secondary. The MOSFET are used to switch the primary of the transformer. This secondary voltage is then rectified again to get a clean DC voltage. The circuit also consists of a feedback mechanism to control the output DC voltage as per the load conditions. The project consists of the following main sections explained:

1. Input filter and Bridge rectifier: This section consists of a line filter to remove
any voltage surge/spikes from the mains 220 VAC. This filtered AC voltage is then fed to the Bridge rectifier after which this gets converted into about 310 VDC. Since the average DC value of sine wave AC is 2 times. So 220 * 2 = 311.12 V.

2. DC filter section: The rectified DC signal still contains some variation and is
therefore further filtered using some filter capacitors.

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3. PWM Generator IC: This IC (SG3525) is a PWM controller IC which generates

PWM signals and the duty cycles can be controlled so as to change the output of the SMPS. The feedback is provided in this IC to maintain the desired output voltage.

4. MOSFET Driver IC: Since the PWM output from the IC SG3525 is not sufficient to
drive the MOSFETS directly; IR2110 IC is used to drive the MOSFETS safely.

5. Ferrite core transformer: This transformer is capable of transferring the

magnetic energy from the primary to secondary at a very high rate and high efficiency. The core generally can transmit the power at up to 2 MHz rate without heating much.

6. Output Rectifiers: The converted Secondary DC voltage is also pulsed and is

therefore has to be converted in to DC using some fast rectifiers like MUR 860 diodes. This rectified DC is filtered using Few capacitors at the output.

7. Feedback IC: This section consists of an optocoupler IC 817 which conducts when
the output voltage is increased and thereby providing feedback to the PWM controller IC SG 3525.

BLOCK DIAGRAM:-

Advantages of High Switching Frequencies: Continuous current mode operation possible with ultrafast diode.
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 High switching frequencies with identical efficiency: smaller and cheaper passive
components. Absence of reverse recovery : smaller MOSFET and higher reliability.

Multiple output SMPS

Now days, a single equipment may need multiple output power supplies. For example, in a Personal Computer one may need 3.3 volt, 5 volt and 12 volt power supplies. The digital ICs may need 3.3volt supply and the hard disk driver or the floppy driver may need 5 and 12 volts supplies. The individual output voltages from the multiple output power supply may have different current ratings and different voltage regulation requirements. Almost invariably these outputs are isolated dc voltages where the dc output is ohmically isolated from the input supply. In case of multiple output supplies ohmic isolation between two or more outputs may be desired. The input connection to these power supplies is often taken from the standard utility power plug point (ac voltage of 115V / 60Hz or 230V / 50Hz) Generally a common high frequency transformer links the input and output windings and in spite of output voltage feedback all the outputs can not have same regulation because of different loads connected to different outputs and hence different ohmic (resistive) drops in the output windings. Also the coupling between the different secondary windings and the primary winding may not be same causing different voltage drops across the respective leakage inductances. Barring this mismatch in the voltage drops across the resistances and leakage inductances of the secondary windings their output voltages are in proportional to their turns ratios. The turns ratios are properly chosen to give fairly regulated individual output voltages.

ADVANTAGES:
High efficiency, high reliability & Low cost

Maximum Output power of 12W Multiple outputs Universal AC input 85V ~ 300VAC Built-in EMI filter. Low Ripple & Noise Soft start Circuit to limit the AC surge current Optional input & output connectors Compact, light weight and low profile design 7|Page

Short circuit, Over load protection 100% Full load burn-in test

CIRCUIT DIAGRAM

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CHAPTER 2 INTRODUCTION
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Nowadays, the Switched-Mode Power Supply (SMPS) plays an important role in the consumer power market. With its small size, it can be found everywhere from mobile phone chargers to Plasma TVs. It is used to convert the electricity from one voltage/current to the other voltage/current. For a simple example, a mobile phone charger converts the electricity from the plug with around 220VAC to 9VDC to supply the mobile phone. A switched-mode power supply is an electronic power supply that incorporates a switching regulator in order to be highly efficient in the conversion of electrical power. Like other types of power supplies, an SMPS transfers power from a source like the electrical power grid to a load (e.g., a personal computer) while converting voltage and current characteristics. An SMPS is usually employed to efficiently provide a regulated output voltage, typically at a level different from the input voltage. Unlike a linear power supply, the pass transistor of a switching mode supply switches very quickly (typically between 50 kHz and 1 MHz) between full-on and full-off states, which minimizes wasted energy. Voltage regulation is provided by varying the ratio of on to off time. In contrast, a linear power supply must dissipate the excess voltage to regulate the output. This higher efficiency is the chief advantage of a switched-mode power supply.

The major feature of SMPS is the elimination of physically massive power transformers and other power line magnetic. The net result is smaller, lighter package and reduced manufacturing cost, reducing primarily from the elimination of the 50 Hz components.

CHAPTER 3 COMPARISON BETWEEN SMPS & LPS

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Features

SMPS

Linear Power Supply

Efficiency

65-75 %

25-50 %

Temperature rise

20-40oC

50-100oC

Ripple value

Higher 25-50 mV

Even 5 mV possible

Overall regulation

0.3 %

0.1 %

Magnetic material

Ferrite core

Stalloy or CRGO core

Power

About 60 W\kg

20-30 W\kg

Transient response

Slower (in ms)

Faster

Complexity

More

Less

CHAPTER 4 WORKING
The Switched Mode Power Supply owes its name to the dc-to-dc switching converter for conversion from unregulated dc input voltage to regulated dc output voltage. The 11 | P a g e

switch employed is turned ON and OFF (referred as switching) at a high frequency. During ON mode the switch is in saturation mode with negligible voltage drop across the collector and emitter terminals of the switch where as in OFF mode the switch is in cut-off mode with negligible current through the collector and emitter terminals. On the contrary the voltage-regulating switch, in a linear regulator circuit, always remains in the active region. By varying the duty cycle or frequency of switching, we can vary the stored energy in each cycle and thus control the output voltage. Higher efficiency is obtained since only the energy required is pumped to maintain the load current hence no power dissipation.

Like a linear power supply, the switched mode power supply too converts the available unregulated ac or dc input voltage to a regulated dc output voltage. However in case of SMPS with input supply drawn from the ac mains, the input voltage is first rectified and filtered using a capacitor at the rectifier output. The unregulated dc voltage across the capacitor is then fed to a high frequency dc-to-dc converter. Most of the dc-to-dc converters used in SMPS circuits have an intermediate high frequency ac conversion stage to facilitate the use of a high frequency transformer for voltage scaling and isolation. The high frequency transformer used in a SMPS circuit is much smaller in size and weight compared to the low frequency transformer of the linear power supply circuit.

CHAPTER 5 PROCESS OF OPERATION

In case of SMPS with input supply drawn from the ac mains, the input voltage is first rectified and filtered using a capacitor at the rectifier output. The unregulated dc 12 | P a g e

voltage across the capacitor is then fed to a high frequency dc-to-dc converter. Most of the dc-to-dc converters used in SMPS circuits have an intermediate high frequency ac conversion stage to facilitate the use of a high frequency transformer for voltage scaling and isolation.

Input rectifier stage: If the SMPS has an AC input, then the first stage is to convert
the input to DC. This is called rectification. The rectifier circuit can be configured as a voltage doubler by the addition of a switch operated either manually or automatically. This is a feature of larger supplies to permit operation from nominally 120 V or 240 V supplies. The rectifier produces an unregulated DC voltage which is then sent to a large filter capacitor.

Inverter stage: The inverter stage converts DC to AC by running it through a power

oscillator, whose output transformer is very small with few windings at a frequency usually chosen to be above 20 kHz. The output voltage is optically coupled to the input. The switching is implemented as a multistage MOSFET amplifier to achieve high gain.

Voltage converter and output rectifier: If the output is required to be isolated

from the input, the inverted AC is used to drive the primary winding of a high-frequency transformer. This converts the voltage up or down to the required output level on its secondary winding.

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Regulation: A feedback circuit monitors the output voltage and compares it with a
reference voltage. Depending on design & safety requirements, the controller may contain an isolation mechanism such as opto-couplers, to isolate it from the DC output.

Transformer Isolation from mains

Unregulated direct voltage

Conventional power supply without stabilization

Transformer Isolation from mains

Liner voltage regulator

Conventional power supply with stabilization of the output voltage Switching supplies in computers, TVs and VCRs have these opto-couplers to tightly control the output voltage.

CHAPTER 6 SMPS TOPOLOGIES

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The working principle of an SMPS essentially determines its characteristics and production cost. There are mainly four types of SMPS: D.C. to D.C. Converter Forward Converter Flyback Converter Self-Oscillating Flyback Converter

D.C. to D.C. Converter:

Block diagram of D.C. to D.C. converter (SMPS) :

Here, the primary power received from AC main is rectified and filtered as high voltage DC. It is then switched at a huge rate of speed approximately 15 kHz to 50 kHz and fed to the primary side of the step-down transformer. The step-down transformer is only a fraction of the size of a comparable 50 Hz unit thus reliving the size and weight problems. The output at the secondary side of the transformer is rectified and filtered. Then it is sent to the output of the power supply. A sample of this output is sent back to the switch to control the output voltage. SMPS rely on PWM to control the average value of the output voltage. The average value of the repetitive pulse waveform depends on the area under the waveform. As load increases, output voltage tends to fall. Most switching power supplies regulate their output using the method called Pulse Width Modulation (PWM). The power switch 15 | P a g e

which feeds the primary of the step-down transformer is driven by the PWM oscillator. When the duty cycle is at 50%, then the maximum amount of energy will be passed through the step-down transformer. As the duty cycle decreases the power transmitted is less hence low power dissipation. The Pulse Width signal given to the switch is inversely proportional to the output voltage. The width or the ON time of the oscillator is controlled by the voltage feedback from the secondary of the rectifier output and forms a closed loop regulator. Since switching regulator is complex, modern IC packages like Motorola MC 3420/3520 or Silicon General SG 1524 can be used instead of discrete components.

Forward Converter:
In a forward converter the choke carries both current both when the transistor is conducting as well as it is not. The diode carries the current during the OFF period of the transistor. Therefore, energy flows into the load during both the periods. The output voltage Vo can only be less than Vs in this circuit. The choke stores energy during the ON period and also passes some energy into the output load. The diode serves two functions. 1. It provides a discharge path for the choke so that, when the transistor switches opens, there is no arcing due to the induced high voltage. 2. It provides a path for the current in the coil to decay.

Flyback Converter:

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In the flyback converter, the energy is stored entirely in the magnetic field of the inductor during the ON period of the switch. The energy is emptied into the output voltage circuit when the switch is in the open state. The output voltage depends upon the duty cycle.

Self-Oscillating Flyback Converter:

Self-Oscillating Flyback Converter is the most simple and basic converter based on the flyback principle.

It is constant output power converter. The output voltage reduces as the load increases and vice versa. It is suitable for low power output applications due to its inherent nature of operation and may be used with advantage up to an output power of 150 W. It has high output voltage ripple.

CHAPTER 7
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DIPTRACE
DipTrace is EDA software for creating schematic diagrams and printed circuit boards.

Modules used :

Component Editor Pattern Editor Schematic Design Editor PCB Layout Editor

Component Editor allows you to make new parts and libraries. Pattern Editor Schematic allows you to make new patterns. Schematic Capture with multi-level hierarchy and export to PCB Layout. PCB Layout PCB design with an easy-to-use manual routing tools, shape-based auto router and auto-placer .

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DipTrace provides the following features:

Easy to learn user interface: To design a schematic, simply select and place components onto your document and connect them together using the wire and bus tools.. Smart placement and auto-placement features: After converting Schematic to PCB layout, place board outline and arrange components. Easy to use manual and powerful automatic routine: DipTrace PCB software includes 2 automatic routers i.e. Shape-based and Grid-based. Here we are using Grid-based software. Grid Router can also make single-layer boards with jumper wires. Advanced Verification Features: Schematic and PCB design modules have number of verification features that help control project accuracy on different design stages. 3D PCB Preview: DipTrace PCB Layout module includes 3D preview feature which shows you how your completed project will look like. This feature uses hardware graphics acceleration, so you can change colors and rotate/zoom/pan board in real-time. 2500+ package 3D models are available for free and you can use any models in VRML 2.0 or 3DS formats. Import/Export Features: Package modules allow you to exchange schematics, layouts and libraries with other EDA and CAD packages like DXF, Eagle, P-CAD, PADS, OrCAD. DipTrace Schematic Capture and PCB Layout also support Accel, Allegro, Mentor, PADS, P-CAD, Protel and Tango netlist formats. Manufacturing output formats: DipTrace provides support for a number of different manufacturing output formats. Standard component libraries: DipTrace package includes component and pattern libraries which contain 100,000+ components from different manufacturers. Creation of your own libraries : Component and Pattern Editors allow to design your own symbols and patterns. To create complete components simply connect them together using Component Editor.

CHAPTER 8
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ADVANTAGES OF SMPS

High efficiency of 65-75 % because of low heat dissipation. Low Temperature rise of about 20-40oC. As transformer is of ferrite core, hence the unit is light in weight. Protection against excessive output voltage by quick acting guard circuits. Reduced harmonic feedback into the supply main. Isolation from main supply without the need of large mains transformer. Generations of low and medium voltage supplies are easy. Overall Regulation of 0.3% , better than Linear Power supply. Switching supplies can change an unregulated input of 24 V into a regulated output of 1000 V d.c. Higher output power of 60 watt/kg. Provide the user with a means to vary the output. Can get constant output at variable input. SMPS is compact and hence easily portable. Stabilize the output against the influence of source, load, temperature changes and Time effect. Output is short circuit protected. Various advantages of High Switching Frequencies as described above.

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CHAPTER 9 APPLICATIONS
PC Power Supply: Personal Computers (PC) and embedded system based control applications require power supplies with multiple outputs delivering stiffly regulated and isolated DC voltages at different levels such as 5 V, +3.3 V and 12 V AM Radio Applications : A 50 W resonant SMPS with coreless transformer for AM radio applications above the AM band (1.7 MHz), to avoid switching disturbances and radio signal interferences, where a half-bridge LLC/LLCC resonant converter topology is designed and realized together with a resonant gate driver. Voltage Regulator Module: The voltage regulator module is an essential part of any PC motherboard. It generates the voltages required to run a specific microprocessor. Telecommunications Applications: It is used in mobile communication base stations, switching stations, mobile phone chargers etc. Audio applications: Silicon-on-insulator is a unique technology for high voltage power MOSFET devices that allows reducing switching losses significantly. Together with new emerging HF power ferrite grades the operation of smps around 3 MHz has become a promising option to replace the bulky line transformers of compact audio sets. Reduction of common mode noises: A filter with SMPS is a solution for common mode noises. The design of an SMPS which has three outputs has been presented after that common mode noises have been determined and then these noises have been tried to be reduced by the filter. Other Applications: Consumer electronics: TVs, DVD players, Video recorders, Set top boxes, Satellite receivers, Chargers and External power supply units. Electronic DP: PCs, Servers, Monitors, Notebooks Industrial electronics: Open and Closed loop control engineering, Measuring instruments, Auxiliary power supplies, Battery chargers, Security System, Support Supplies with PLC etc

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CHAPTER 10 CONCLUSION
A Switching mode power supply 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 the two states, on or off. The advantage is that the switch dissipates very little power in either of this two states and power conversion can be accomplished with a minimal power loss, which equates to high efficiency. SMPS, Designs relay upon the efficiency of a switch to control amount of power with relatively little losses. The primary advantage of the switching mode power supplies is then can accomplish power conversion and regulations at 100% efficiency given ideal parts. All power losses are due to less than ideal parts and power loss in the control circuitry.

FUTURE TRENDS:
Most commercial switch mode power supplies in the market today operate in the range 10 KHz to 50 KHz. There is now growing trend in research work and new power supply designs in increasing the switching frequencies upwards to 100 KHz and above. The reason being to reduce even further the overall size of the power supply in line miniaturization trends in electronic and computer systems. MOSFETs inherit lack of storage and fall time affects when turned off. Therefore MOSFETs are now increasingly replacing BJTs in new designs operating at much higher frequencies. But still the intrinsic characteristics of the MOSFET produce a large on resistance which increases excessively when the devices breakdown voltage is raised. Therefore, power MOSFET is only useful up to voltage ratings of 500V. Another new device likely to displace the BJT in many high power applications is the insulated gate transistor. This device combines the low power drive characteristic of MOSFET with the low conduction losses and high blocking voltage characteristic of the BJT. Therefore the device is highly suited to high power, high voltage applications. In future, more and more integrated power devices will be introduced so simplifying board layout and reducing component count. The driving force in every manufacturers design will always be the combined component and production costs. Therefore, any new device or topology will have to justify its implementation based on mainly commercial criteria.

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CHAPTER 11 TERMINOLOGIES
AC power supply: A PSU that generates an AC output voltage also called inverter.

Common Mode Noise: The component of noise that is common to both the live and neutral conductors with respect to the ground. Constant Voltage Power Supply: A power supply design to regulate the output voltage for changes in line load, ambient temperature, and drift resulting from time. DC-DC Converter: SMPS that convert a dc input voltage to a different dc output voltage. DC Power Supply: A PSU that produces DC output voltage, i.e. a voltage of a fixed polarity and specific value which can be variable though Efficiency: Ratio of output power to input power. It is generally measured at full load and nominal line condition. External power supply: a PSU that is located outside of the equipment and can sometimes power more than one electronic device Isolation: Absence of DC current pass between two circuits. In a PSU isolation is provided by transformers. Commercially available AC-DC PSU are normally isolating. Low input voltages DC-DC PSU, such as a car phone charger, are often non-isolating. Linear power supply: A PSU that regulates the output parameter usually output voltage by varying voltage drop across an electronic component placed in series with the load. Load Regulation: Variation of the output voltage due to a change in the output load, with all other factors held constant. It expressed as a percentage of the nominal DC output voltage. MOSFET: Metal Oxide Silicon Field Effect Transistor. The device of choice for the main switch in many SMPS, having much better switching characteristics than BJTs. Noise: It is the random component of undesired divisions in output voltage. Usually specified in combination with ripple.

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Offline power supply: A PSU that processes electric power directly from AC line without using line frequency transformer. Such supply can still be isolating if it uses highfrequency transformer in one of its power conversion stages an example of isolating offline PSU is a switching power supply of a computer. Power supply: A device that transfers electric energy from one form to another using electronic circuit. A common application of power supplies is to convert mains AC power into low-level DC voltages required for equipment. PSU: power supply unit. Pulse Width Modulation: A method of voltage regulation used in switching supplies where the output is controlled by varying the width, but not the height, of a train of pulses that drive a power switch. Regulated Power Supply: A PSU that maintains a given output parameter usually output voltage to within specified limits under varying operating conditions, such as input line, output load, and ambient temperature. SMPS: Switch mode power supply is a PSU that incorporates power transistors that are continuously switching on and off with high frequency in order to provide the transfer of electric energy. An output parameter (usually output voltage) is controlled by varying duty cycle, frequency or a phase shift of these transitions. SMPS frequency can vary typically from 20 kHz to several MHz. Topology: The design type of converter, indicating the configuration of switching transistor, utilization of the transformer, and type of filtering. UPS: Uninterrupted power supply is a PSU that continues to supply electricity to the load for limited period of time during a loss of utility's power or when the line voltage varies outside normal limits. UPS is normally implemented with a backup battery & an additional DC-AC inverter. Voltage converter: Technically it can be the same as a power supply, except the term "converter" is often used for a single-stage switching regulator. A typical off-line SMPS may consist of several cascaded voltage converters. The term converter also often implies that it is a sub-assembly of PSU, which may need additional components such as EMI filters, protective devices, housing, etc.

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REFERENCES

http://www.ieee.com /POWER ELECTRONICS SPECIALISTS CONFERENCE 2006.PESC

06, 37TH IEEE http://www.ieee.com /TELECOMMUNICATIONS E NERGY CONFERENCE 1985,INTELEC 85, 7TH IEEE http://www.ieee.com /POWER ELECTRONICS & APPLICATIONS 2005, EUROPEAN CONFERENCE http://www.ieee.com /POWER ELECTRONICS CONFERENCE 2002, TECHNICAL PROCEEDINGS 8TH IEEE http://www.ieee.com /E LECTRICAL & ELECTRONICS ENGINEERING , 2009. ELECO 2009 http://www.linear.com /SWITCHING REGULATOR DC-DC http://www.diptrace.com http://www.alldatasheets.com http://www.smps.us http://www.powerdesigners.com / DC-DC CONVERTER BASICS http://www.ask.com /JEEVES SEARCH SOLUTION OPTIMIZER FOR SMPS APPLICATION- MASTER THESIS BY WITOOM SINTANAVEVONG (INFO & MEDIA TECHNOLOGIES ), MUNICH, FEB 2006 DC-DC CONVERTER VERSION II , EE, IIT KHARAGPUR BY DR. DINKAR PRASAD http://www.wikipedia.com http://www.google.com /IMAGES
http://www.seminarprojects.com http://www.engineersgarage.com

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