NG3S909 - Advanced Manufacturing Systems Assignment

Assignment Task

Full Wave Bridge Rectifier Circuit with various EMI filters

Full Wave Bridge Rectifier converts AC to DC. EMI in AC-DC conversion begins with conducted currents into the input. Conducted EMI can also appear as common-mode or differential mode noise at various stages during power conversion. Different components are used at each stage in power conversion to reduce conducted EMI. EMI filters can be used to clean up the conducted EMI (noise) throughout a power conversion system. The full bridge rectifier with shunt capacitor filter 

Tasks

1. You are required to create a schematic of a full bridge rectifier on Proteus against above figure and specifications and analyse the output signals without and with EMI filters. The EMI filters which you will use are CL, LC, π and T filters. You will place each filter at the output of bridge and analyse the results.

2. Simulate your schematic and compare the results of all the rectifier type and find which filter type is best and why?

3. Create PCB layouts for each rectifier type considering the requirements from the following specification.

• Keep the trace routing as short and as direct as possible. The shorter the routing, the less potential there is of generating EMI.
• Keep the traces for routing as wide as possible too. The wider the trace, the lower the inductance, which will also help to minimize EMI.
• Route high-current lines at 45 degrees instead of at right angles. Could you investigate and draft why 45 degree is better than 90 degree?
• Develop a 3D of your PCB using 3D visualizer.

4. Construct an FMEA for this product.

5. Discuss the necessary arrangements for handling this product so it stays safe from ESD.

6. In a PCB manufacturing industry the excessive heat test is performed to test high temperature capability. Excessive heat can lead to warping in the lengths, widths and thicknesses of different PCB layers and disruption of circuit lines. Excessive heat test is one of the important quality control factor. During testing phase, project team performed the PCB capability study. In Analyse phase collected 20 sets of PCB temperature samples with a subgroup size of 4.

Calculate the mean (X) and range value (R) for each subgroup and develop the X bar and R charts. From the calculation results and charts, do you think the process is controlled or out-of-control? Ensure the charts are clearly labelled. 

7. Calculate the mean (X) and range value (R) for each subgroup and develop the X bar and R charts. From the calculation results and charts, do you think the process is controlled or out-of-control? Ensure the charts are clearly labelled.

8. For the Lean assembly, total operation time is 16 mins, and the customer demand for that period is 24 units. We can see that we have an estimated average inventory level of 12 units before the operation and average inventory level of 10 units after the cycle time (C/T

• Calculate Takt time?
• Calculate the waiting times before and after the 8s cycle time, shown by ‘?’ in figure 3?

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