Professional Documents
Culture Documents
Bachelor of Technology
In
Electrical & Electronics Engineering
By
L.HARIKA (07241A0204)
N.JYOTHSNA DEVI (07241A0235)
B.NIHARIKA (07241A0240)
Under the guidance of Mr.M.SRIKANTH
(Assistant Professor)
ACKNOWLEDGEMENT
We
would
like
to
articulate
our
deep
gratitude
to
our
project
guide
L.HARIKA
N.JYOTHSNA DEVI
B.NIHARIKA
CERTIFICATE
This is to certify that the project report entitled 7.5W NON ISOLATED
FORWARD CONVERTER that is being submitted by L.HARIKA,N.JYOTHSNA,
B.NIHARIKA
Mr.P.M.SARMA
Mr. M.SRIKANTH
HOD, EEE
GRIET, Hyderabad
GRIET, Hyderabad
(Internal Guide)
ii
ABSTRACT
The project 7.5W NON ISOLATED FORWARD CONVERTER is intended to
modern electronic systems require high quality, small, lightweight, reliable and efficient power
supplies. Linear power regulators, whose principle of operation is based on a voltage or current
divider, are inefficient. This is because they are limited to output voltages smaller than the
input voltage, and also their power density is low because they require low frequency(50 or 60
Hz) line transformers and filters. Linear regulators can however provide a very high quality
output voltage. Electronic devices in linear regulators operate in their active modes, but at
higher power levels switching regulators are used. Switching regulators use power electronic
semiconductor switches in ON and OFF states. Because there is a small power loss in those
states, switching regulators can achieve high energy conversion efficiencies.
Modern power electronic switches can operate at high frequencies. The higher the
operating frequency , the smaller and lighter the transformers, filter inductors, and capacitors.
In addition , the dynamic characteristics of converters improve with increasing operating
frequencies.
The forward converter is a switched mode power supply(SMPS) circuit that is used
for producing isolated and controlled dc voltage from unregulated dc input supply. The
forward converters are applicable for, low power frequency supplies, low cost multiple- output
power supplies , isolated gate drivers etc.
This project consists of a combination of startup circuit, maximum pulse width
circuit, controller circuit, power circuit of power converter, feedback circuit. These circuits are
used to control of switching pulse width using feedback circuit and controller by PWM
technique
iii
CONTENTS
Page.No
ACKNOWLEDGEMENT
ii
ABSTRACT
iii
LIST OF FIGURES
v-vi
NOMENCLATURE
vii
CHAPTER 1
INTRODUCTION
CHAPTER 2
FORWARD CONVERTER
10
11
13
14
17
18
CHAPTER 4
SIMULATION RESULTS
19
CHAPTER 5
HARDWARE RESULTS
24
CHAPTER 6
6.1 Applications
31
6.2 Limitations
6.3 Advantages
CHAPTER 7
FUTURE SCOPE
32
APPENDIX
REFERENCES
44
iv
55
LIST OF FIGURES
FIG NO.
PAGE.NO
2.1
2.2
2.3
3.1
3.2
Start-up circuit
3.3
10
3.4
Power circuit
11
3.5
11
3.6
12
3.7
Feedback circuit
13
3.8
Control circuit
14
3.9
17
3.10
18
4.1
Simulation circuit
20
4.2
Input voltage
22
4.3
Gate voltage
22
4.4
Output voltage
23
4.5
Output current
23
5.1
24
5.2
Gate voltage
25
5.3
Switch voltage
26
5.4
Ramp voltage
27
5.5
Output voltage
28
5.6
29
5.7
30
LIST OF TABLES
TABLE NO.
4.1
vi
PAGENO.
21
NOMENCLATURE
Np
Ns
Edc
Input voltage
Vs
Supply voltage
Duty cycle
Vop
Output voltage
Fs
Switching frequency
Rt
Limiting resistor
Ct
Limiting capacitor
vii
CHAPTER 1
INTRODUCTION
Modern electronic systems require high quality, small, lightweight, reliable and
efficient power supplies. Linear power regulators, whose principle of operation is based on a
voltage or current divider, are inefficient. This is because they are limited to output voltages
smaller than the input voltage, and also their power density is low because they require low
frequency(50 or 60 Hz) line transformers and filters. Linear regulators can however provide a
very high quality output voltage. Electronic devices in linear regulators operate in their active
modes, but at higher power levels switching regulators are used.
Switching regulators use power electronic semiconductor switches in ON and OFF
states. Because there is a small power loss in those states, switching regulators can achieve high
energy conversion efficiencies.Modern power electronic switches can operate at high
frequencies. The higher the operating frequency , the smaller and lighter the transformers, filter
inductors, and capacitors. In addition , the dynamic characteristics of converters improve with
increasing operating frequencies.
Isolation describes the electrical separation between the input and output of a dcdc converter. An isolated dc-dc converter uses a transformer to eliminate the dc path between its
input and output. Non-isolated dc-dc converter has a dc path between its input and output. Nonisolated dc-dc converter designs usually employ ICs specifically intended for that purpose.
The forward converter is a DC/DC converter that uses transformer windings to buck
or boost the voltage. The forward converter is widely used with output power below 200W,
though it can be easily constructed with a much higher output power. The limitations are due to
the inability of the power transistor to handle the voltage and current stresses. The circuit uses
two transistors that are switched ON and OFF simultaneously. The diode are used to restrict the
maximum collector voltage to Vs. Therefore the transistor with low voltage rating can be used.
1
Unlike the flyback , the forward converter requires a minimum load at the
output. Otherwise , excess output can be produced. To avoid this situation , a large load
resistance is permanently connected across the output terminals. Because the forward converter
does not store energy in the transformer, for the same output power level, the size of the
transformer can be made smaller than that for the flyback.
The output current is reasonably constant due to the action of the output
inductor and the free wheeling diode D2. As a result, the output filter capacitor can be made
smaller and its ripple current rating can be much lower than that required for the flyback.
Varying the duty cycle K can control the output voltage of a converter. There
are commercially available PWM(pulse width modulation) integrated circuit(IC) controllers that
have all the futures to built a PWM switching power supply using a minimum number of
components.
CHAPTER 2
FORWARD CONVERTER
FORWARD CONVERTER:
The forward converter is a DC/DC converter that uses transformer windings to
buck or boost the voltage. Forward converter is a switched mode power supply (SMPS) circuit
that is used for producing isolated and controlled dc voltage from the unregulated dc input
supply. A forward converter uses a controllable switch, MOSFET and the switching frequency
is in the range of 100kHz.
input voltage is applied to the low pass filter circuit preceding the load.
The primary winding current enters through its dotted end while the secondary
current comes out of the dotted side and their magnitudes are inversely proportional to their
turns-ratio. Thus, as per the assumption of an ideal transformer, the net magnetizing ampereturns of the transformer is zero and there is no energy stored in the transformer core.
When switch S is turned off, the primary as well as the secondary winding
currents are suddenly brought down to zero. Current through the filter inductor and the load
continues without any abrupt change. Diode D provides the freewheeling path for this
2
current. The required emf to maintain continuity in filter-inductor current and to maintain the
forward bias voltage across D comes from the filter inductor L itself. During freewheeling
2
the filter inductor current will be decaying as it flows against the output voltage (V ), but the
op
presence of relatively large filter capacitor C still maintains the output voltage nearly
constant. The ripple in the output voltage must be within the acceptable limits.
The supply switching frequency is generally kept sufficiently high such that
the next turn-on of the switch takes place before the filter inductor current decays significantly.
Needless to say, that the magnitudes of filter inductor and capacitor are to be chosen
appropriately .For better understanding of the steady-state behavior of the converter, the circuits
operation is divided in two different modes, mode-1 and mode-2. Mode-1 corresponds to the on
duration of the switch and mode-2 corresponds to its off duration.
start conducting simultaneously with the turning on of the switch. The primary and secondary
winding currents and voltages are related to their turns-ratio (N / N ), as in an ideal
P
transformer.Fig.2.2 (a) shows, in bold lines, the current carrying path of the circuit and Fig.2.2(b)
shows the functional equivalent circuit of mode-1. As switch S closes, diode D in the secondary
1
circuit gets forward biased and the input voltage, scaled by the transformer turns ratio, gets applied
to the secondary circuit. Diode D does not conduct during mode-1, as it remains reverse biased.
2
Ns
Edc during mode-1. This voltage is shown across points P and N in Fig.
Np
2.2(b) and it is the maximum achievable dc voltage across the load, corresponding to = 1. Mode-1
can be called as powering mode during which input power is transferred to the load. Mode-2, to be
called as freewheeling mode, starts with turning off of the switch S.
5
mode and isolates the output section of the circuit from the transformer and the input.
to flow through the parallel combination of the load and the output capacitor.
During mode-2, there is no power flow from source to load but still the load
voltage is maintained nearly constant by the large output capacitor C. The charged capacitor
and the inductor provide continuity in load voltage. However since there is no input power
during mode-2, the stored energy of the filter inductor and capacitor will be slowly dissipating
in the load and hence during this mode the magnitudes of inductor current and the capacitor
voltage will be falling slightly.
In order to keep the load voltage magnitude within required tolerance band, the
converter-switch S is turned on again to end the freewheeling mode and start the next
powering mode (mode-1).
Under steady state, loss in inductor current and capacitor voltage in mode-2 is
exactly made up in mode-1. It may not be difficult to see that to maintain load voltage within
the desired tolerance band the filter inductor and capacitor magnitudes should be sufficiently
large.
The switching frequency of a typical forward converter may thus be in the
range of 100 kHz or more. Control over switch duty ratio, which is the ratio of ON time to (ON
+ OFF) time, provides the control over the output voltage V .
O
CHAPTER 3
BLOCK DIAGRAM OF FORWARD CONVERTER
BLOCK DIAGRAM:
12
13
14
CIRCUIT DESCRIPTION
STARTING POWER SUPPLY:
The starting power supply is obtained from D1(IN4148) and C1(10uF)
OSCILLATOR SECTION:
R8 and C2 determine the switching frequency. The switching frequency is given by
Fs = 1.11/RtCt = 100KHz
REFERENCE VOLTAGE
The internal reference is 5V. The circuit uses a reference voltage of 2.5V through the
potential divider R10 and R11.
15
DUTY RATIO
The input voltage is in the range of 10 to 15. The output of the boost converter is designed
for 17V. The range of duty ratio is from 0.56 to 0.37.
MAIN INDUCTOR
The rated current is 0.5A. the ripple current is chosen as 0.05A. With maximum on time
of 0.33us, at input voltage of 15V, this gives an inductor value of 2000uH(approx) with the
turns ratio of 3, the primary is 15 turns and secondary is 45 turns.
The power MOSFET has to carry about 1A and block about 20V. the device chosen is IRFZ44.
The output capacitor C4(220uF) limits the voltage ripple to about 1% (0.17V).
The natural frequency of the converter is
Natural frequency =
1
LC
16
17
Pin no.1 and 16 are the non inverting input pins and pin no.2 and 15 are the inverting
input pins. The pins 15 and 16 are grounded.
Pin no.4 is the dead time control which is used to decide the minimum ON time.
Pin no.5 and 6 i.e Rt ,Ct values decides the ramp frequency.
Pin no.3 is the compensation pin. The feedback of the op-amp is fed to the compensation
pin. From this pin, when the error amplified voltage is greater than 2.7V then it is fed to
maximum pulse width circuit.
18
CHAPTER 4
SIMULATION RESULTS
The simulation is done using the MATLAB software.
Introduction to MATLAB
MATLAB is a high level technical computing language and interactive
environment for algorithm development, data visualization, data analysis and numeric
operation using the MATLAB product, for can solve technical computing problems faster than
with programming language, such as C, C++ and FORTRAN.
We use MATLAB in a wide range of application, including signal and image
processing, communications, control design test and measurement, financial moderator and
analysis, and computational biology. Add on tool boxes extend the matlab environment to
solve particular classes of problems in these application area.
19
Table 4.1 result table showing output voltages for different input values
INPUT VOLTAGE
OUTPUT VOLTAGE
10V
17.04
11V
17.18
12V
17.38
13V
17.64
14V
17.84
15V
17.90
21
INPUT VOLTAGE
22
OUTPUT VOLTAGE
CHAPTER 5
HARDWARE RESULTS
MOUNTED PCB BOARD
24
GATE VOLTAGE
25
SWITCH VOLTAGE:
26
RAMP VOLTAGE
27
OUTPUT VOLTAGE
28
29
30
CHAPTER 6
6.1 APPLICATIONS OF FORWARD CONVERTER
Low power switch-mode power supplies (cell phone, stand by power supply in PCs).
Low cost multiple output power supplies( e.g. main PC supplies < 250W).
High voltage supply for the CRT in TVs and monitors (the flyback converter is often
combined with horizontal deflection drive).
High voltage generation (e.g. for xenon flash lamps, lasers, etc).
Duty cycle must be kept below maximum (0.5) to avoid the saturation of transformer.
Magnetic current must be reset to zero at the end of each cycle otherwise the transformer
can be driven into saturation which can cause damage to the switching device.
Low weight and smaller size come about because operation is at a significantly higher
frequency range and the inductive elements are vastly smaller and much cheaper.
Higher efficiency occurs because the power transistor is swtched very rapidly between
saturation (FULL ON) and cut off (FULL OFF) and there is very little power dissipation
and it follows there are reduced heat sinking requirements.
Reduced costs occur owing to the absence of large bulky power transformers, a huge
reduction in volume and power dissipation, smaller material requirements and also smaller
semiconductordevices
31
CHAPTER 7
FUTURE SCOPE
The simulation is done in the MATLAB by using ideal components without using
the actual IC TL494. But the inbuilt behaviour is implemented to get the appropriate results.
Extensive study can be made by simulating actual IC TL494 to get accurate results.
Extensive study can be made on:
Frequency response of the forward converter can be analysed and design of compensator
can be made to get stable closed loop response.
Though some of the issues have not been solved but they have been highlighted as
potential areas in which more refinements are required.
32
APPENDIX (A)
DATA SHEET OF UC494C
FEATURES
DESCRIPTION
This entire series of PWM modulators each provide a complete pulse width
modulation system in a single monolithic integrated circuit. These devices include
a 5V reference accurate to
both voltage and current sensing, an externally synchronizable oscillator
with its linear ramp generator, and two uncommitted transistor output
switches. These two outputs may be operated either in parallel for singleended
operation or alternating for push-pull applications with an externally
controlled dead-band. These units are internally protected against doublepulsing
of a single output or from extraneous output signals when the input
33
BLOCK DIAGRAM:
34
CONNECTION DIAGRAMS
36
37
ELECTRICAL CHARACTERISTICS:
Unless otherwise stated, over recommended operating free-air temperature range,
VCC = 15V, f = 10kHz, TA = TJ.
ELECTRICAL CHARACTERISTICS:
Unless otherwise stated, over recommended operating free-air temperature range,
VCC = 15V, f = 10kHz, TA = TJ
38
39
Note 1: Duration of the short circuit should not exceed one second.
Note 2: Frequency for other values of CT and RT is approximately f
1.1
RTCT
Note 3: Standard deviation is a measure of the statistical distribution about the mean
as derived from the formula:
n
Xn X2
n 1
n
.
40
41
42
IMPORTANT NOTICE
Texas Instruments and its subsidiaries (TI) reserve the right to make changes to their products
or to discontinue
any product or service without notice, and advise customers to obtain the latest version of
relevant information
to verify, before placing orders, that information being relied on is current and complete. All
products are sold
subject to the terms and conditions of sale supplied at the time of order acknowledgement,
including those
pertaining to warranty, patent infringement, and limitation of liability.
TI warrants performance of its semiconductor products to the specifications applicable at the
time of sale in
accordance with TIs standard warranty. Testing and other quality control techniques are
utilized to the extent
43
TI deems necessary to support this warranty. Specific testing of all parameters of each device is
not necessarily
performed, except those mandated by government requirements.
CERTAIN APPLICATIONS USING SEMICONDUCTOR PRODUCTS MAY INVOLVE
POTENTIAL RISKS OF
DEATH, PERSONAL INJURY, OR SEVERE PROPERTY OR ENVIRONMENTAL
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WARRANTED TO BE SUITABLE FOR USE IN LIFE-SUPPORT DEVICES OR SYSTEMS
OR OTHER
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In order to minimize risks associated with the customers applications, adequate design and
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TI assumes no liability for applications assistance or customer product design. TI does not
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semiconductor products or services might be or are used. TIs publication of information
regarding any third
partys products or services does not constitute TIs approval, warranty or endorsement thereof.
44
APPENDIX (B)
DATA SHEET OF IRFZ44
45
46
47
48
49
50
51
52
53
56
54
REFERENCES
[1] Rashid, Power Electronics Handbook, 2001 Edition.
[2] Wikipedia : www.wikipedia.com
[3] www.onsemi.com
[4] www.datasheetarchive.com
[5] www.national.com/powerdesigner
55