Professional Documents
Culture Documents
Yash Patel
(100574630)
Letter of transmittal
To: Louis Bertrand
From: Yash Patel
Date: 14th April 2015
Re: Power Supply Report
I am pleased to submit this report in partial fulfillment of the requirements for the CAD
1133 CAD for Electronics course in the Electro-Mechanical Engineering Technology
program at Durham College. The report details the design, construction and testing of an
electronics workbench power supply.
The attached report is of my own creation. It includes the work of others used by
permission and properly attributed, and I have reviewed its entire contents before
submitting it for grading. I understand what is meant by the terms "academic integrity" and
"plagiarism" and guarantee that I am abiding by Durham College's Academic Integrity
Policy #ACAD-101.
Sincerely,
Yash Patel
Abstract
This project is made mainly to reduce 120 VAC to usable DC voltage. This project is to make a
power supply that can plug direct into the wall, produce a fixed 5V output, and two variable voltage
output which can be adjust from 0 to +15V or from 0 to -15V. Also there should be a switch to turn
the power supply on and off; a LED to indicate whether the power supply is on or off; and a fuse
that can protect the power supply.
In this project Multisim is used to test and learn how the circuit functions. Eagle CAD is used to
create a PCB for the power supply. Base on the Eagle drawing, a PCB was developed. All the
components were putted on the PCB by soldering. A metal box was specially made for the power
supply base on the given templates. After assembly the power supply, a neat, organizes power
supply with all the functions that expected was made.
Acknowledgements
Thanks for Mehul Chaudhri. He helped me to print the transfer sheet and answer me a lot of
questions about how to use Eagle. Without him remained me the due day of all the different things,
now I may still stuck at somewhere else. Also thanks for the people that from some other courses. I
not even know their names. When I drilling the holes on the box, they teach me how to change the
drill so that I can fit the box under the drill. They are nice and friendly. Thanks for every teachers,
classmates, and friends that have helped me. Without all the helps, my board will not even exist. So
thanks for everyones help, I really appreciate all the helps.
Contents
ABSTRACT..................................................................................................................................................III
ACKNOWLEDGEMENTS.........................................................................................................................IV
CONTENTS...................................................................................................................................................V
LIST OF FIGURES....................................................................................................................................VII
1
INTRODUCTION...............................................................................................................................1
1.1
1.2
1.3
1.4
LAYOUT OF REPORT...............................................................................................1
2.1
DRAFT SCHEMATIC.................................................................................................2
2.2
2.3
2.4
2.5
FIXED 5V REGULATOR...........................................................................................6
2.6
2.7
3.1
3.2
3.3
3.4
4.1
ENCLOSURE DESIGN.............................................................................................15
4.2
ENCLOSURE FABRICATION...................................................................................17
5.1
5.2
ENCLOSURE ASSEMBLY........................................................................................18
5.3
6.1
SUMMARY OF RESULTS........................................................................................22
6.2
RECOMMENDATIONS.............................................................................................22
REFERENCES/BIBLIOGRAPHY.............................................................................................................23
APPENDICES...............................................................................................................................................24
List of Figures
Introduction
This section shows the schematic of the power supply, and how the different parts of circuit
operated.
The transformer on the left of figure 3 is used to step down the 120VAC voltage that comes from
the wall. The four diodes on the left of the schematic in figure 3 are two full wave rectifiers to
rectify the AC voltage from the transformer to positive or negative DC voltages. The 7805, LM317,
and LM337 are voltage regulators used to produce fixed +5 volts, positive variable voltage from 0
to +15 volts, and negative variable voltage from 0 to -15 volts.
Figure 2 : Hand Drawn Schematic of Power Supply Divide into different section
10
DC voltage.
Rectify
Rectifier is used to rectify the AC voltage so that only the positive or the negative voltage
was appeared at the output. A full wave rectifier can be built by using two diodes and a
center tape transformer which is demonstrated in figure 4 and figure 5. At the same time,
only one of the two diodes is forward bias, the other diode is always reverse bias. So there
will always be only the positive voltage at the cathode of the diodes, since diodes only allow
the current flow from the anodes to the cathodes.
11
U1
D1
XSC1
V1
0.5 A
120 Vrms
60 Hz
0
T1
4.1
1N4001GP
Ext T rig
+
R1
1M
D2
_
B
A
+
1N4001GP
Filter
As shown in figure 5, a 2200uF capacitor is used to filter the waveform. The input voltage
will keep charging and discharging the capacitor, so the output waveform will be smoothed.
The larger the value of the capacitor, the smoother the output waveform will be. The
demonstration circuit is shown in figure 6 in multisim. From figure 6 we can see that the
output waveform is almost a straight line, which is a 20VDC voltage with a small AC ripple.
The same as for the rectifying, two of these capacitors are needed for positive and negative
voltages.
U1
D1
XSC1
V1
0.5 A
120 Vrms
60 Hz
0
T1
4.1
1N4001GP
D2
R1
100
C1
2200F
Ext T rig
+
_
B
A
+
1N4001GP
12
Output waveform
after rectify and
filter
Input waveform
The positive supply voltage is applied to 7805 voltage regulator. The common pin of the
voltage regulator will be simply tied to the ground. Therefore the output voltage will be
fixed at positive 5 volts. The diode D10 that connected to the output of the voltage regulator
is to protect the circuit. In the normal operation of the circuit the diode will be reverse bias,
so there will be no current flow through it. When the voltage on the output of the voltage
regulator goes below the ground, the diode will be forward bias to short the short the output
and protect the circuit. The capacitor that parallel connected with the diode is for smooth the
output waveform.
The resistor R8 which series connected with the LED is to limit the current that flow
through the LED to protect the LED. The current that flow through the LED is 21.5 mA
(I=V/R=(5V-0.7V)/200=21.5mA).
D1
1N4004GP
V1
120Vrms
60Hz
0
D3
1N4004GP
C1
2200F
U1
LM7805CT
LINE
VREG
VOLTAGE
COMMON
T1
C3
10F
D5
1N4004GP
R1
200
+
4:1
D2
1N4004GP
D4
1N4004GP
C2
2200F
LED1
5.003
U2
DC 10MOhm
V
For the voltage regulator LM317, the output pin should be always 1.25V higher than the
adjust pin. So there will always be about 10mA flow through R2 from top to the bottom
(I=V/R=1.25V/120=10.4mA). Since there is almost no current flowing into the adjust pin,
the current flow through R1 is almost the same as the current flow through R2 which is
10mA. So the voltage drop across R3 will increase with the value of R1. When R1 is set to
15k, the voltage drop across R1 will be about 15V (V=I*R=10.4mA*15k=15.6V) as
shown in figure 10. When R1 is set to 0, the voltage drop across R1 will be about 0V
(V=I*R=10.4mA*0=0V).
R3 limits the current flow through D3 and D5, so that the two diodes can work properly.
Without R3, the voltage drop across D3 and D5 will be forced to -20V.Every diode will has
about 0.7V voltage drop across when it is forward bias. So D3 and D5 will have totally
about -1.4V voltage drop across them which means the voltage of the cathode of D5 is about
-1.4V. This voltage put down the voltage at the output of 1.4V, which is almost the same as
the voltage drop between the adjust pin and the output pin of LM317. So the output is
almost the same as the voltage drop across the R1. Therefore, the output can be adjusted to
0V (1.25V-1.4V=-0.15V).
14
U3
LM7805CT
Key = Space
+
-
0.089
5.005
18.767
C5
D10
U4
RL
10F
1N4004GP
DC 10MOhm
100
V
U55.005
DC 10MOhm
U6
T1
DC 10MOhm
COMMON
D1
D2
C1
1N4004GP
1N4004GP
2200F
AM1
0.5A
V1
120Vrms
60Hz
0
LINE
VREG
VOLTAGE
SW1
F1
U2
DC 10MOhm
U1
LM117HVH
4.3
Vin
R1
120
Vout
ADJ
C2
10F
D3
D6
D7
1N4004GP
1N4004GP 1N4004GP
D5
U71N4004GP
DC 10MOhm
+
-
-0.863
D4
1N4004GP
VM1
15.814
U8
R3
DC 10MOhm
1.5k 100 %
Key=A
16.669
R2
1k
CAD 1133 Winter 2015
Week 2: Primary, Rectifier, Filter and 5V Regulator
STARTER FILE
15
XSC1
V1
Ext Trig
+
_
V3
5.6V
R1
10k
Vpos
R4
1.5k 50 %
Key=A
U1
3
V2
20V
Vneg
2
4
S1
R2
10k
UA741CD
C1
1000F
R3
120
REF
VIN VOUT
Key = Space
Filtered_Negative
VREF
REG1
LM337
16
This section shows the schematic in Eagle, different layers of the PCB, and how the PCB
was made.
17
18
19
20
21
This section shows the drawing for box production and the process to produce the box.
22
front close to the front face. Use the right size drills or punches as labeled on the templates
to drill or punch the holes. Center punches the holes before drilling.
Some big holes need to punch more than once to get the desire size or shape. The 7 holes on
the front face for the voltage output need to punch twice to get the shape as drawing on the
template. Make sure the left and right sides of those holes are flat so the output connecters
will not shift when the connecters are rotating. The rectangular hole that on the front face
need to punch all the way around the rectangle to get the right shape.
After punching and drilling. Use water to take off the three templates and the glue. Use file
flatten the holes or make the size of the holes slightly bigger to fit in the components. File
slowly and use the components to test the size of the holes, so the holes will not be too big.
Either use a larger size drill to deburred or use a file to flatten the edge.
24
25
Solder the DC, 20V, J1, J2, and P2 of the panel meter to set it for 20VDC range. Connect +5V to
+V, positive adjustable voltage to IN, and ground to V and GND as shown in the figure 19.
Use multimeter to measure the adjustable voltage. Adjust the potentiometer at the back of the panel
meter till the readings of the multimeter and panel meter are the same. Put the cover of the box on.
26
Screw the four screws on the both sides to secure it. Stick the four rubber feet at the four corner of
the bottom of the box.
range. Turn the potentiometer fully clockwise, +14.93V is on the positive adjustable output. Turn
the potentiometer fully anticlockwise, -0.02V is on the positive adjustable output. Turn the
potentiometer to some random position, the different between the magnitudes of the positive
adjustable voltage and the negative adjustable voltage is less than 0.03V. All expected functions of
the power supply are achieved
28
6.2 Recommendations
From my point of view I would like to say that my power supply is not working after trouble
shooting it many times. I realized that I should have to do my work step by step and then I
can be able to find my problem. My mistake was that I placed all the component and solder
it and then tried to trouble that complicated circuit. One of the best way to get the power
supply work is that I should remake it right from the beginning.
29
References/Bibliography
CIRE Principle of Electronic (by V K MEHTA & ROHIT METHA)
CAD for electronic textbook having the eagle software information in it.
DC connect slide picture.
https://www.fairchildsemi.com/datasheets/LM/LM7805.pdf
https://www.sparkfun.com/products/107
http://www.chegg.com/homework-help/definitions/operational-amplifier-4
30
Appendices
Appendix A: Complete Schematic
31
Drawing of the PCB. Black part is where the copper is placed in the circuit board.
32
Top layer of the PCB to get the idea where the actual components is to be placed.
33
34
35