EL-06 [Filename: DC_PWR.

DOC]

August 9, 1995

DC Power Supply Design and Printed Circuit Board Layout

Contributor: Affiliation Address:

Telephone: Facsimile: Email: Type: Student time: Location:

Rob Jarman Electrical Engineering University of Technology, Sydney PO Box 123 Broadway NSW 2007 Australia +61 2 330 2368 +61 2 330 2435 robj@ee.uts.edu.au Design Problem 5 to 7 weeks Take home

Summary This is intended to be distributed to junior electrical engineering students in the early weeks of semester as a design problem. Students work individually from a given scenario to complete the electrical analysis and printed circuit board layout for a simple DC power supply. Material required to be covered includes transformers, diode rectification, capacitive filtering and voltage regulation. As the material is completed, students have an immediate application to test their analytical skills in selecting components to meet the specification. The Printed Circuit Board (PCB) design has some constraints including physical dimensions, mounting holes and single sided design. Students need to research vendor catalogues to determine the component package outlines and pin spacing. Alternatively, these could be supplied as an additional handout to students. Component overlays can be obtained from PCB CAD packages. The PCB design is usually completed by hand on an overhead projector transparency film using permanent markers. An extension exercise is included, students are to develop an over-voltage protection circuit to be connected to the output of the DC supply. ABET Descriptors Engr. Sci Content: Type: Elements: Features: Constraints: Effort: Electrical, circuits, electronics System, component Establish requirements, analysis, synthesis Design methodology, detailed system descriptions Safety, reliability Individual

EL-06 [Filename: DC_PWR.DOC]

August 9, 1995

DC Power Supply Design and Printed Circuit Board Layout

Students shall work independently on the project. A 110VAC 60Hz renewable energy power generator system requires a DC power supply module. The module is to provide a variable DC voltage signal proportional to the AC voltage generated as well as supplying a fixed 5VDC to supply the electronic system controller. The variable DC signal is used by the electronic system controller as a feedback system to monitor the voltage being generated. As the voltage generated increases or decreases, the DC voltage increases or decreases. The specification for this module is 1VDC per 12VAC and the maximum current drawn by the feedback circuit is 10mA. The electronic system controller uses TTL and CMOS Integrated Circuits which require a regulated 5VDC 2% supply, maximum current load is 500mA. A dual secondary transformer is already specifications are : input voltage output voltage VA rating available and assumed to be suitable. Its 110V AC 15V 0V 15V 0V 40VA

Select a suitable circuit topology and specify component ratings. Design a printed circuit board layout for the module using component dimensions and pin spacing obtained in local vendor catalogues. The design constraints are that the PCB be as small as possible, interconnecting terminals must be provided, it must have some means by which it is mounted in a control panel, it must be single sided (copper on one side only) and all components for the circuit (excluding the transformer) should be mounted on the PCB. Optional extension exercise Design a circuit and specify the components necessary to ensure that the voltage sensitive TTL components in the electronic system controller are protected against voltages greater than 5.5VDC.

EL-06 [Filename: DC_PWR.DOC]

August 9, 1995

DC Power Supply Design and Printed Circuit Board Layout

Project deliverables A report is required detailing the analysis and selection of components for your design. The PCB layout should include a component overlay under the transparancy for assessment purposes.

Evaluation Criteria Detailed report (Word Processor) Drawings (CAD or suitable quality hand) PCB layout: dimensions, layout of components, interconnection, thermal, track and pad size, circuit protection, mounting arrangement Circuit operation: will it work, size and ratings of components, analysis, limits of operation, prediction of waveforms around the circuit Optional exercise: analysis, ratings of components, limits of operation

EL-06 [Filename: DC_PWR.DOC]

August 9, 1995

DC Power Supply Design and Printed Circuit Board Layout Engineering Notes: To begin with, students typically have a hard time understanding all of the requirements of this design problem. As each week passes, more material is covered and students see an immediate application for the knowledge they are learning. A block diagram is useful to help students understand how and where in the system the DC power supply module fits in.
Renewable Energy Source 240V 50Hz Generator

Consumer

Transformer

5VDC fixed voltage regulator

1VDC per 12VAC

DC power supply module

Electronic system controller

The renewable energy source could typically be hydro or wind, the generator could be a self exciting type. Typically considered in the assessment of the circuit design include calculation and justification for the transformer primary winding fuse protection, transformer output winding connection, rectifier diode selection, filter capacitor selection, regulator selection, decoupling and transient capacitors, regulator protection diodes, thermal analysis of regulator power dissipation. Typically considered in the assessment of the printed circuit board design includes: interface/interconnection methods, component selection, component layout, thermal layout, solder pad size, track width, PCB dimensions, PCB mounting technique, minimize area of PCB, consideration of assembly, repairable design.

EL-06 [Filename: DC_PWR.DOC]

August 9, 1995

DC Power Supply Design and Printed Circuit Board Layout

The optional extension exercise is included for students who might need an extra challenge. Discrete designs using zeners and SCRs are typical, also available is a range of ASICs.

Intended learning outcomes for students from this project include: Development of the circuit and component selection in electrical engineering science. Development of skills in determining the specifications of a project. Application of analysis skills to a problem in a physical context. Development of synthesis skills in determining a solution to the problem. Exposure to best practice PCB layout and assembly techniques for safety and reliability.

EL-06 [Filename: DC_PWR.DOC]

August 9, 1995