Electronics Design for Industry Course
Introduction Project
DC/DC converters are almost incorporated into every modern electronic device. They are found in
PCs, Laptops, cell phones, home appliances, industrial automation equipment, hand tools, and etc.
Project:
Form Team of 4 members
Select one topology of the ones you studied during the course (Buck or Flyback).
Design the power circuit subject to the following:
Step-Down
Input Voltage range 20V to 30V
Output Voltage Regulated +10V
Load Current 0.1A min to 0.5A max
Switching Frequency > 50kHz
Conduction Mode CCM, ΔI < 40%
Output Voltage Ripple < 1%
Protection Functions Over current
Current mode Shunt resistor ---- slope compensator
Undervoltage lockout
Overtemperature
Soft start
Based on your design, select the appropriate power semiconductors, passive components, and
PWM controller.
You may use any locally available PWM controller chip (e.g., TL494, UC3844, or LM2575)
1. Verify your design using LTSpice simulation using the actual part numbers of the selected
transistor, diode and controller IC to get the required waveforms listed below.
2. Using your design calculations, construct a Hardware circuit for your converter on
breadboard.
(optional): you can construct your converter circuit on PCB
Using MATLAB SIMULINK build a large signal ideal model of your converter and
simulate the different operating points and record the results as requested below
3. Modify you SIMULINK large signal model to add the non idealities for the diode and
transistor using the datasheets for your components to get the values of the non ideal terms of
the components used in your hardware circuit. simulate the different operating points and
record the results as requested below to get the required waveforms listed below.
(optional): use MATLAB to get the model Transfer function (Vout/D) and design a closed
loop Proportional-Integral PI controller
Test your circuit under varying input voltage and load current conditions.
Compare the experimental results with results from:
LTSPICE switched model simulation
Large signal ideal model on SIMULINK
Large signal non ideal model on SIMULINK
Hardware implementation circuit board
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Deliverables:
1) A PDF document containing:
1. Converter type and specifications.
2. Detailed power and PWM controller circuits step-by-step design.
3. Details of ALL selected components with justification.
4. Clear circuit schematics showing component part numbers and values.
5. A photo and detailed description of the experimental setup.
6. Clear oscilloscope screen captures for the circuit currents and voltages under different test
conditions.
7. Simulation and experimental results (clear images with white background) at different supply
and load conditions showing (at least):
a. Inductor current waveforms.
b. Semiconductor devices (Transistor and Diode) current and voltage waveforms.
c. Output voltage ripple waveforms.
d. Losses in different circuit components.
e. Converter efficiency plots.
• ƞ Vs. D
• ƞ Vs. Iload
8. Comments on experimental results and comparison with simulation results.
9. Component datasheets as appendices.
2) A prototype circuit with the implemented converter.
Circuit should be carefully and neatly connected on a breadboard or well soldered to a PCB. The
equipment available in the Open Lab (power supplies, oscilloscopes, electronic loads, etc.) can be
utilized during project construction and testing. On the test day you will need to show that:
1 the converter is operating on the entire input voltage range.
2 the output is regulated against line and load disturbances.
3 Inductor current and load voltage ripples are within specifications at rated load.
4 Semiconductors are not overstressed.
5 Overcurrent protection is operational.
Notes:
1) Components such as power transistors, fast recovery diodes, and PWM controllers can be
easily found at several local component stores such as (this is an example list):
ram-e-shop.com
makerselectronics.com
free-electronic.com
https://uge-one.com/?product_cat=&s=smps&post_type=product
2) Converters addressed in this project have inductors that need to carry DC currents. In most
cases, off-the-shelf inductors can be used. In many situations, however, inductors need to be
custom tailored for the specific converter.
3) In LTSpice simulation, if you don’t find an exact model of the part you need, use an equivalent
part. For instance, you may use a MOSFET with specifications near to that of the final
implementation. The PWM controller can be replaced with opamps for example.
Deadline
From 10 - 12 May simulation deadline
17-19 May breadboard deadline
Breadboard or PCB Hardware circuit and simulation final report: Exact deadline will be
confirmed later approximate deadline, 22-25/05/2024
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