EE328 - Power Electronics Design Project Assignment

Assignment Task

Objective

The power supplies provide a dc voltage, i.e. +5V, +12V etc., for the active components in electrical circuits. They can also be used to charge the rechargeable batteries; such as lead-acid, Ni-MH or Li-ion. Adjustable types of the power supplies are essential equipment for experiments in laboratories. The objective of the project is to design, simulate a 15V/2A adjustable power supply.

Design Problem Statement

Your design should not cause safety risk for the loads connected to the output. Therefore, think about possible safety risks and learn how to protect the loads from those risks. The cost should be as low as possible. Therefore, keep the BOM (Bill of Materials) price of your design as small as possible. Other design specifications are described below in detail.

Design requirements:

1. DC input voltage (Vin) is 24V25%, i.e. between 18Vdc and 30Vdc.

2. The nominal DC output voltage (Vout) is 15V, but it will be adjustable between 1.5V to 15V by a potentiometer or trimpot.

3. If Vin then the power supply should stop PWM operation which makes the output voltage is zero. For this purpose, an under-voltage lockout circuit should be designed and integrated into the your circuit.

4. The output voltage ripple must be lower than 0.5% at full load.

5. Short circuit protection (SCP): The device should be protected against the short circuit at the output terminal. After removing the short circuit, device should not start automatically. It should need a disconnection/reconnection procedure of the input voltage source to recover.

6. Overload protection (OVP): The device should be protected against overload. If the load current exceeds the maximum current limit of the power supply (i.e. 2A) for a certain period (at least >100ms) the power supply shutdown suddenly. After removing the overload, device should not start automatically. It should need a disconnection/reconnection procedure of the input voltage source to recover.

7. All the internal supply voltages (i.e. +3V3, +5V and +15V single-ended supplies etc.) required by the internal opamps etc. must be obtained from the input voltage Vin. Using an additional power source is not allowed. (Remember that the input voltage can be as high as 30 V!)

8. Switching mode converter topologies (Buck, buck-boost etc.) should be used in the design. Linear voltage regulator ICs, such as 78xx, LM317 etc., are not allowed.

9. Select suitable components (C, L, Mosfet, diode, opamp, potentiometer, trimpot etc.) from the market that fits your design. Explain in the report what are the reasons of your selection. 

10. Draw the circuit schematic by KiCad EDA schematic capture. Use the selected components from the market. If your component does not included in the schematic library, manually add it to the library.

11. Draw the 2 layer pcb board of the design using KiCad pcb layout. Obtain the 3D view of your pcb from KiCad pcb layout and include it in your report.

12. Generate a BOM list from KiCad EDA schematic capture (Printed circuit board (pcb), aluminum heatsinks, case, screws, bolts and cables etc. will be excluded in the BOM list.). The BOM list should include at least the part number (i.e. TL431 etc.), the schematic reference (i.e. C1, C2, R2 etc.) of the component (DPAK, SOIC8 etc.), the link to the datasheet page of component and US$ price for 1000 pcs.

13. Calculate the BOM price for your design. Target BOM cost for the design is 10$/converter for 1000 piece. Do not oversize the components, otherwise the BOM price may increase. 

Proposal preparation

• Prepare a proposal for the project, which contains brief information about the project, project team, design requirements, work plan, and project time schedule etc.
• Each team should consist of 3 students, and the task of each student should clearly be defined in the project proposal.
• Select one team member as contact person. The contact person will send the proposal and all other reports on behalf of the team.

Project

a. A cover, which includes the course and project name, contact information of team members, duty of each member in the project.

b. Short information about the adjustable power supplies and its technologies

c. Introducing the switching converter topology which is used in the design. 

d. Analytical design details and component selection calculations. 

e. Verification of design using PSIM and LTSPICE (Tests described above). Compare the results at each step with the calculated values (50p)

f. The schematic and PCB (Top and bottom side view and 3D) of your design using KiCad EDA. 

g. BOM list and total BOM cost of your design. The goal for BOM is lower than 10$. (The BOM list can be taken from the schematics of KiCad EDA)

h. Conclusion.

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