INTELLIGENT POWER BACKUP BOX FOR PC

(IPBB)

By

Kiramat Ullah
EE123034

Usman Zia
EE123038

A Final Year Report submitted to the

DEPARTMENT OF ELECTRICAL ENGINEERING
In partial fulfillment of the requirements for the degree of
BACHELORS OF SCIENCE IN ELECTRONIC ENGINEERING

Faculty of Engineering
Capital University of Science and Technology
Islamabad
July, 2016
 Copyright  2016 by CUST Student

All rights reserved. Reproduction in whole or in part in any form requires the prior
written permission of Kiramat Ullah and Usman Zia.

ii
We dedicate this project to Allah Almighty who blessed us with knowledge and
strength to make this project. Than we dedicate this project to our Supervisor, all
faculty members, Lab Engineers and Lab Technicians who supported us is every
manner both educationally and financially. Finally, we dedicate this project to our
parents, siblings and friends who supported us and increased our moral strength
through every thick and thin.

iii
 DECLARATION
It is declared that this is an original piece of our own work, except where otherwise
acknowledged in text and references. This work has not been submitted in any form
for another degree or diploma at any university or other institution for tertiary
education.

Kiramat Ullah
EE123034

Usman Zia
EE123038

July, 2016

iv
 C ERT I F ICA T E O F AP P RO VA L
It is certified that the project titled “Intelligent Power Backup Box for PC” carried out
by Kiramat Ullah, Reg. No.EE123034 and Usman Zia,Reg. No. EE123038, under the
supervision of Dr. Muhammad Ashraf, Capital University of Science and Technology,
Islamabad, is fully adequate, in scope and in quality, as a final year project for the
degree of BS in Electronic Engineering.

Supervisor: -------------------------
Dr. Muhammad Ashraf
Associate Professor
Department of Electrical Engineering
Faculty of Engineering
Capital University of Science and Technology, Islamabad

HOD: ----------------------------
Dr. Noor Muhammad Khan
Professor
Department of Electrical Engineering
Faculty of Engineering
Capital University of Science and Technology, Islamabad

v
 ACKNOWLEDGMENT

We forever owe utmost gratitude to Almighty-ALLAH whose divine light and

warmth provided me the inspiration, faith and strength to carry on my work.

We express my sincere and deep sense of gratitude to Dr. Muhammad Ashraf for his
guidance, valuable suggestions, immense help, encouragement and friendly behavior
throughout the working of this dissertation.

We are also grateful to all the members of evaluation committee for giving valuable
suggestions and advices for evaluating me from time to time. We humbly express
our sincere thanks to all the faculty members and the staff of ELECTRICAL
ENGINEERING Department for their constant assistance and providing the pleasant
working conditions in the complete duration of the dissertation work.

We are thankful to all my friends, teachers, lab engineers and lab technicians for their
helping attitude and constant encouragement. We cannot conclude this
acknowledgement without mentioning my parents. It would not be possible for me to
complete this dissertation work without their love, encouragement and support.

Kiramat Ullah (EE123034)

Usman Zia (EE123038)

vi
 ABSTRACT

Uninterruptable supply of power to critical devices like personal computers (PC’s) is

a major issue in countries like Pakistan where ten to 12 hours of load-shedding in a
day is a normal routine because of power shortage. Hence large organizations and
academic institutions often must implement costly generator back-up systems. This
results in frequent power outage intervals.

Idea behind our project is to solve this common problem at academic institutions like
universities and provide uninterruptable supply of power during the small interval
during which power switches from main supply to back-up generator. Hence during
class lectures, presentations or daily work on personal computers people should not
face frequent restarts. In proposed project, we are designing a small device that is
cheaper and easily installable with personnel computers. It provides power
intelligently to the system. Proposed solution will provide seamless transfer of power
from main supply (WAPDA) to secondary source (Generator) and PC will not reboot
during power interruption. Detection part in the design continuously monitors the
present state of the PC and the main AC power supply. DC-DC provides the backup
power on the signal that is generated by detection part. IPBB only provides the
backup if and only if the PC is in working state and there is power interruption.

Proposed solution is a very cheap and small size Intelligent Power Backup Box. This
Box has single input and single output and it is easily installable between PC and
main switch just like a laptop battery charger. In future, proposed solution can be
designed on large scale for multiple computers and with higher power ratings.

vii
 TABLE OF CONTENTS

DECLARATION .................................................................................. iv
ACKNOWLEDGMENT ........................................................................ vi
ABSTRACT .......................................................................................... vii
TABLE OF CONTENTS ..................................................................... viii
LIST OF FIGURES............................................................................... 11
LIST OF TABLES ................................................................................ 12
LIST OF Abbreviations ......................................................................... 13
INTRODUCTION ................................................................................. 14
1.1 Overview .................................................................................................... 14
1.2 Project Idea ................................................................................................ 15
1.3 Purpose of the project ................................................................................ 16
1.4 Project Specifications................................................................................. 16
1.5 Applications of the Project......................................................................... 17
1.6 Project Scope ............................................................................................. 18
1.7 Project Plan ................................................................................................ 18
1.8 Report Organization ................................................................................... 19
LITERATURE REVIEW...................................................................... 20
2.1 Related Technologies ................................................................................. 20
2.1.1 SB14.2 Transformer .................................................................... 20
2.1.2 Relay ........................................................................................... 21
2.1.3 LM311......................................................................................... 21
2.1.4 Logic gates .................................................................................. 21
2.1.5 FETs ............................................................................................ 22
2.1.6 SG3525 IC .................................................................................. 22
2.2 Related Projects ......................................................................................... 22
2.2.1 Uninterruptable power supply (UPS) [1] ................................... 22
2.3 Related Studies........................................................................................... 24
2.3.1 Power Supply .................................................................................... 25
2.3.2 DC-DC converters ........................................................................... 25
2.4 Limitations of Earlier Work ....................................................................... 25

viii
 2.5 Summary .................................................................................................... 25
Chapter 3 ............................................................................................... 26
PROJECT DESIGN AND IMPLEMENTATION................................ 26
3.1 Design of the Project Hardware ................................................................. 26
3.1.1 Project Block Diagram & Description ........................................ 26
3.1.2 Design of controller part ............................................................. 27
3.1.3 Battery rating selection ............................................................... 28
3.1.4 DC-DC Boost converter Design ................................................. 28
3.2 Analysis Procedure .................................................................................... 29
3.3 Implementation Procedure ......................................................................... 29
3.4 Details about hardware .............................................................................. 30
3.5 Details of final working prototype ............................................................. 30
3.6 Summary .................................................................................................... 31
Chapter 4 ............................................................................................... 32
TOOLS AND TECHNIQUES .............................................................. 32
4.1 Function Generator .................................................................................... 32
4.2 Digital Oscilloscope ................................................................................... 32
4.3 Power supply .............................................................................................. 33
4.4 Software(s), simulation tool(s) used .......................................................... 33
4.4.1 Proteus professional .................................................................... 33
4.4.2 PCB Wizard ................................................................................ 34
4.5 Summary .................................................................................................... 34
Chapter 5 ............................................................................................... 35
PROJECT RESULTS AND EVALUATION ....................................... 35
5.1 Presentation of the findings ....................................................................... 35
5.2 Hardware results and problems.................................................................. 35
5.3 Results with scenarios ................................................................................ 36
5.4 Comparison of Initial Targets and Achievements ..................................... 36
5.5 Limitations ................................................................................................ 37
5.6 Summary ................................................................................................... 37
Chapter 6 ............................................................................................... 38
CONCLUSION & FUTURE WORK ................................................... 38
References ............................................................................................. 39

9
Appendices ............................................................................................ 41
Appendix A ............................................................................................................ 41
Pin configuration of LM311[1] .................................................................. 41
Pin configuration of Relay ......................................................................... 41
Pin configuration of LOGIC GATE 7402 ................................................. 42
Pin configuration of LOGIC GATE 7408 ................................................. 42
Appendix B ............................................................................................................ 43

10
 LIST OF FIGURES

Figure 2.1: SB14.2 ..................................................................................................... 260

Figure 2.2 LM311 ........................................................................................................ 21
Figure 2.2: IRF 3205 ................................................................................................... 22
Figure 3.1: Block Diagram of our Design ................................................................... 26
Figure 3.2: Rechargeable battery ................................................................................ 22
Figure 3.3: Proteus Schematic of controller part........................................................ 30
Figure 4.1: Function Generator .................................................................................. 32
Figure 4.2: Digital Oscilloscope ................................................................................. 32
Figure 4.6: Power supply ............................................................................................ 33
Figure 4.10: Proteus professional ............................................................................... 33
Figure 4.11: PCB Wizard ............................................................................................ 34
Figure 5.1: Transformer core saturation..................................................................... 35
Figure 5.2: 3525 Output .............................................................................................. 36

11
 LIST OF TABLES

Table 1: Project Specifications .................................................................................... 16

Table 2: Resource Allocation....................................................................................... 22

Table 3: Project Timeline ............................................................................................ 29

Table 4: Comparison of Targets and Achievements .................................................... 36

12
 LIST OF Abbreviations

IPBB Intelligent Power Back Box

PLC Programmable Logic Controller
UPS Uninterruptable power supply
PC Personal Computer
DC Direct Current
AC Alternating Current
PF Power Factor
CT Current Transformer
OP-Amp Operational Amplifier
SPDT Single Pole Double Throw
Ms Mille-seconds

13
Chapter 1
INTRODUCTION

In our industry and in our daily life there are many devices that need constant power
backup for smooth operation. In our country, power interruption is major issue but to
avoid the power interruption electricity generators are used as secondary source but it
takes a time span of 1 to 3 minutes for the generators to start and power the loads.

To compensate this time, span of power interruption we have designed a device IPBB
which will avoid power interruption and will provide backup intelligently and
efficiently. Presently we have targeted power interruption issue for personal
computers. Some backup systems that already exist include

 Offline UPS
 Line instructive UPS
 Online UPS
 Mobile Phone Power Bank.

The device is named Intelligent Power Backup Box (IPBB). It is an innovative device
which is capable of sensing the current state of the device that is whether the device is
in working state or shutdown or powered off on which IPBB will decide whether it
should provide backup or not.

Following are the rules which are considered important while designing a power
backup device.

 It should provide power efficiently.

 It should avoid the system to shut down due to switching transitions.
 System should not be damaged by backup supply.

1.1 Overview
Our designed device, Intelligent Power Backup Box (IPBB) will operate as follows:

The System is working and there is power interruption. The backup will keep the
system to work normally for at least 5 minutes. In all other conditions, the IPBB will
remain off.

14
IPBB is intelligent in a sense that it constantly monitors the state of the personnel
computer. It decides to provide backup to PC if and only if the PC is in working state
and main AC power is cut off. This device acts as a bridge between WAPDA supply
and the secondary electricity generator. It smoothly shifts PC from WAPDA to
generator. By use of this device with PC, PC never experiences the state of power
interruption as a result we avoid the data corruption or operating system failure.
There are three different parts of our IPBB.

 Detection and controller part

This part detects the present state of the PC, whether the PC switched OFF,
Shutdown or in working state. On power interruption this part generates a
signal only when PC is working and there is power interruption to activate the
power backup part.
 Battery charger
Battery charger is an SMPS which charges the battery up to 19 V in 60
minutes.
 DC-DC convert (output power part)
This part is the backbone of the IPBB which provides backup of 5 minutes
approx. It consists of DC-DC boost converter which steps up the 16V DC to
284V DC and after rectification it is fed to PC.

1.2 Project Idea

Design an IPBB to provide power backup to personal computer which will operate on
following condition.

 IPBB will provide backup only

 PC is running and there is power interruption

 IPBB will not provide backup if

 User switch OFF the PC

 PC is shut down by user and

o Supply switch is OFF

15
 o Supply switch is ON

The other requirement of our project was to design a cheap solution because UPS
(uninterrupted power supply), a solution existed in the market already. Another
challenge for this project was to design an optimized and user friendly installable
product having single input and single output which would be easily inserted between
main switch and the PC power supply.

To avoid PC reboot it was also requirement of the project to design a solution which
would never give a chance to PC reboot in case of power failure.

1.3 Purpose of the project

Purpose of our project is to solve a very common problem in our university and other
similar institutions that is due to load shedding or power interruption during class
lectures, presentations or daily work on personal computers we have to wait for the
backup generator power supply (approx. 5 minutes) after every one hour every day.
We have solved this issue by designing a very cheap and small size Intelligent Power
Backup Box.

1.4 Project Specifications

Specifications of the proposed project are as under:

Table 1: Project Specifications

Power rating 100W

Output voltage 280V DC
Backup Time 5 minutes
Charging time for batteries 30 minutes
Switching time Less than 10ms

 The power rating of our device is 100W because the PCs used in our university
consume almost 90W at full load and we kept a safe side of extra 10W for any
abnormal case.
 The output is 280V DC because the average value due to ramp at PC input is 260V
and PC works on DC voltage without any issue because the step of the PC power
supply is to rectify.

16
  The secondary source (Electricity generator) takes a time span of 2 minutes on
average. To have a safe side we designed backup for 5 minutes for any abnormal
condition.
 Our switching time is less then 10ms because PC reboots if there is power failure of
more than 10ms. To avoid PC, reboot this specification of device important.

1.5 Applications of the Project

The Applications of this project are many depending upon its design calculations;
some of them are as follows:

 To provide backup for PLC panels in industries.

 To provide backup to personal computers at any place.
 To provide backup to any device operating on DC power.
 To provide power backup in data server rooms.
 To provide interruption free backup in ICUs and specially a backup for the
ventilators in hospitals.

In industries like PCB fabrication plants, cement manufacturing plants and many
more like these, PLCs are most commonly use. In latest models of PLCs there is
backup facility but in previous models there is no power backup and as a result due to
power failure, program gets corrupted in PLCs and production stops. To overcome
this issue without switching to latest models because it is a costly solution IPBB is
best solution for this problem.

In university admission exams, class rooms and in daily work of routine we mostly
use PCs for efficient management of time but due to power interruption the data
suddenly gets loosed and we can’t do anything. To overcome this issue IPBB is the
easiest, cheap and optimized solution.

In data server rooms it is compulsory to provide 24-hour constant supply without any
power interruption in those places IPBB is applicable.

In hospitals especially in ICUs where ventilators are used for the patients, supply of
power is extremely necessary without any failure. IPBB can provide such solution.

17
1.6 Project Scope
Power backup for specially computer systems is common requirement in almost all
places its major scope of application is at those places where electricity generator is
used as secondary source due to its limited time duration for providing backup.

1.7 Project Plan

Detailed plan of proposed project and resource allocation is shown in tables below:

Table 2. Distribution of Tasks in Part I & II

Tasks TIME DURATION

Part-I

Literature Survey 4 Weeks

Controller Designing fabrication 4 Weeks

Battery Rating Selection 2 Week

Report Writing Part-I 2 Week

Part-II

Battery Charger designing and fabrication 3 Weeks

DC-DC Boost converter design 2 Weeks

DC-DC Boost Converter Fabrication 4 Weeks

Project Integration and Testing 2 Weeks

Report Writing Part-II 1 Week

18
 Table 3: Resource Allocation

Sr. No. Tasks Allocation of Resources

1 Design calculations Usman Zia

2 Battery rating selection Kiramat Ullah
3 Software simulation Usman Zia
4 Practical implementation Kiramat Ullah
5 Fabrication Usman Zia

1.8 Report Organization

In this chapter the overall introduction about IPBB is discussed. In chapter 2, we will
discuss about the literature review. In chapter 3, the project design and
implementation methods will be discussed. In chapter 4, all the tools and techniques
that will be used for our design will be provided. In chapter 5, the results and
evaluation of our project will be provided. And in chapter 6, conclusion of the project
is discussed.

19
Chapter 2

LITERATURE REVIEW

In this chapter, discussion about related studies and work to our project will be done.
These works or papers were very important to study because we have to use these
technologies in our project in different way. So, to understand their working, their
study was important.

2.1 Related Technologies

2.1.1 SB14.2 Transformer

SB14.2 is an isolated transformer used frequently in switch mode power supplies,

converters and inverter circuits. It has two primary windings and one secondary
winding. Its major role is in switching circuitry. It’s both primary windings are used
one after another and rectangular waveform of high amplitude is obtained at
secondary side. It’s one primary winding gives in phase output and the other one
gives 180 degree out of phase output. But both have same voltage gain of almost 23.
This transformer has a very small core area as a result it saturates very early. To avoid
this saturation, we operate it at high frequency above 50 KHz. [1]

Figure 2.1: SB14.2

20
2.1.2 Relay

Relay is an electrically operated switch used to shift a circuit from one power source
to the other. The make and break operation for this electrically operated switch
depends on the excitation of its winding. If it is not exciting then it is connected to
normally close and when excited it is connected to normally open. We are using
SPDT (single pole double throw) relay of five terminals. In which common pole is
connected to either of two. [5]

2.1.3 LM311

LM311 is a voltage comparator for low input current and voltages. We used LM311
to compare voltages of PC power supply capacitor. [3] The LM311 is voltage
comparator that has input currents nearly a thousand times lower than devices like the
LM106 or LM710. It is also designed to operate over a wider range of supply voltages
from standard ±15V op amp supplies down to the single 5V supply used for IC logic.
Its output is compatible with RTL, DTL and TTL as well as MOS circuits. Further, it
can drive lamps or relays, switching voltages up to 50V at currents as high as
50mA.Both the inputs and the outputs of the LM311 can be isolated from system
ground, and the output can drive loads referred to ground, the positive supply or the
negative supply.

Figure 2.2: LM311

2.1.4 Logic gates

We used both NOR gate & AND gate to complete our logic for controller part of our
project. NOR gate gives output logic 1 when it’s both inputs are zero & AND gate
gives output logic 1 when it’s both inputs are 1 else logic 0. [6]

21
2.1.5 FETs

Power FETs are used in switching circuitry. They provide ground on regular intervals
to the primary windings of the transformer by controlling their Gate signals. [2]

Figure 2.3: IRF 3205

2.1.6 SG3525 IC

This IC is the backbone of DC-DC boost converter circuitry. It provides pulses with
desired frequency and sufficient delay to the gates of FETs so that one FET is
conducting in one time. [1] Sg3525 is a voltage mode PWM controller integrated
circuit. It is used in maximum inverters available in market. Even top inverters
manufacture companies also use Sg3525 in dc to dc converter part of the inverter. It is
a 16 pin integrated circuit. It has two PWM outputs both are inversion of each.
Another advantage of SG3525 is that it has built in totem pole base PWM driver.

2.2 Related Projects

The projects that are related to our project work are as follows.

2.2.1 Uninterruptable power supply (UPS) [1]

When UPS was invented in 1950s it was named as “No break power supply”. Its
design was based on two motors, one DC motor and one AC motor. Today the basic
design of UPS is based on battery and rectifier. As the time is passing new
technologies are replacing the previous technologies and the size of UPS is becoming
smaller and becoming more power efficient. The basic working principle of UPS is
that it monitors the voltage fluctuation and spikes of incoming AC power. The safe

22
margin for these fluctuations is ±10% of the actual value. There are three different
types of UPS depending upon their design.
 Offline UPS
 Line instructive UPS
 Online UPS
 Mobile Phone Power Bank
2.2.1.1.Offline UPS
It is also called as Standby UPS and it is the simplest design among the three. It
monitors the voltage fluctuations and when these are significantly higher than the
defined level it gets active and starts providing backup. [1]
2.3.1.1.Line instructive UPS
Line Instructive UPS is similar to Standby UPS but its design consists of a variable
voltage autotransformer which can cover large range of (90V to 120 V). [1] The line-
interactive UPS is similar in operation to a standby UPS, but with the addition of a
multi-tap variable-voltage autotransformer. This is a special type of transformer that
can add or subtract powered coils of wire, thereby increasing or decreasing the
magnetic field and the output voltage of the transformer. This is also known as a
Buck–boost transformer.
This type of UPS is able to tolerate continuous under voltage brownouts and
overvoltage surges without consuming the limited reserve battery power. It instead
compensates by automatically selecting different power taps on the autotransformer.
Depending on the design, changing the autotransformer tap can cause a very brief
output power disruption,[6] which may cause UPSs equipped with a power-loss alarm
to "chirp" for a moment.
This has become popular even in the cheapest UPSs because it takes advantage of
components already included. The main 50/60 Hz transformer used to convert
between line voltage and battery voltage needs to provide two slightly different turns
ratios: One to convert the battery output voltage (typically a multiple of 12 V) to line
voltage, and a second one to convert the line voltage to a slightly higher battery
charging voltage (such as a multiple of 14 V). The difference between the two
voltages is because charging a battery requires a delta voltage (up to 13–14 V for
charging a 12 V battery). Furthermore, it is easier to do the switching on the line-
voltage side of the transformer because of the lower currents on that side.

23
2.2.1.3. Online UPS
In an online UPS, the batteries are always connected to the inverter, so that no power
transfer switches are necessary. When power loss occurs, the rectifier simply drops
out of the circuit and the batteries keep the power steady and unchanged. When power
is restored, the rectifier resumes carrying most of the load and begins charging the
batteries, though the charging current may be limited to prevent the high-power
rectifier from overheating the batteries and boiling off the electrolyte. The main
advantage of an on-line UPS is its ability to provide an "electrical firewall" between
the incoming utility power and sensitive electronic equipment.
The online UPS is ideal for environments where electrical isolation is necessary or for
equipment that is very sensitive to power fluctuations. Although it was at one time
reserved for very large installations of 10 kW or more, advances in technology have
now permitted it to be available as a common consumer device, supplying 500 W or
less. The initial cost of the online UPS may be higher, but its total cost of ownership
is generally lower due to longer battery life. The online UPS may be necessary when
the power environment is "noisy", when utility power sags, outages and other
anomalies are frequent, when protection of sensitive IT equipment loads is required,
or when operation from an extended-run backup generator is necessary.
2.3.1.3. Mobile phone power bank
Power banks are popular for charging smart phones and mobile tablet devices. A
power bank is a portable device that can supply power from its built-in batteries
through a USB port. They usually recharge with USB power supply. Technically, a
power bank consists of rechargeable Lithium-ion or Lithium-Polymer batteries
installed in a protective casing, guided by a printed circuit board (PCB) which ensures
provides various protective and safety measures. Due to its general purpose power
banks are also gaining popularity as a branding and promotional tool. Different brands
and promotional companies use it as a promotional tool and provide a customized
product.

2.3 Related Studies

Various studies and research had been carried out in field of power supplies, UPS and
inverters and DC-DC converters. All of them are purely based on power electronics

24
devices. These devices become larger in size as we increase the power rating of our
design.

2.3.1 Power Supply

A power supply is an electronic device that supplies electric energy to an electrical

load. The primary function of a power supply is to convert one form of electrical
energy to another and, as a result, power supplies are sometimes referred to as electric
power converters. Some power supplies are discrete, stand-alone devices, whereas
others are built into larger devices along with their loads. Examples of the power
supplies include power supplies found in desktop computers and consumer electronics
devices.

2.3.2 DC-DC converters

A DC-to-DC converter is an electronic circuit or electromechanical device that

converts a source of direct current (DC) from one voltage level to another. It is a type
of electric power converter. Power levels range from very low (small batteries) to
very high (high-voltage power transmission).

2.4 Limitations of Earlier Work

All the researches discussed in sections 2.2 and 2.3 have some limitations. Some of
them are given below:

 A UPS do not deliver power intelligently and efficiently. It delivers power

whether our PC is shutdown or working.
 It is bulky in size and costly as well.
 Power electronics devices generate harmonics in the circuits which are not
favorable.

2.5 Summary
In this chapter we have discussed related technologies and related projects.
Limitations of earlier work is also discussed. Details of the components that can be
used in design of our project and different options available is also discussed. Pros
and cons of different technologies, and components is also discussed.

25
Chapter 3

PROJECT DESIGN AND IMPLEMENTATION

In this chapter, the design of the project and the methods of implementation will be
discussed. In this chapter each and every step of our mathematical calculations, our
practical design and fabrication will be explained. This chapter will show a path
which we followed and achieved our goals. There will also be a section which will tell
that what were the areas where we got struck and how we tackle those problems.

3.1 Design of the Project Hardware

Our project consists of three basic parts. Controller part, Intelligent Battery charger
and dc-dc boost converter.

3.1.1 Project Block Diagram & Description

Figure 3.1: Block Diagram of our Design

26
In above block diagram, there is direct input to main switch of main power source
(WAPDA) after which PC is connected. IPBB checks the condition of main switch
whether it is ON or OFF and at the same time it also confirms that whether the PC is
working or shutdown. It also constantly monitors the WAPDA power failure. In case
if the PC is working and there is power interruption then Backup gets active starts to
provide power to PC without reboot. In any other case IPBB remains idol.

3.1.2 Design of controller part

As the requirement of our project IPBB will only provide power if and only if the PC
is working in any other case IPBB will remain silent. To add this intelligence to our
project we compared the voltages before switch and after the switch by stepping down
to 5V and rectifying using transformer less power supply circuit. We are using
capacitor instead of transformer. It directly steps down the input 220V to 7V. After
then we rectified these 7V and compared both outputs e.g. after switch and before
switch using logic gate NOR. It gives output logic 1 when both the inputs to gate are
zero. It means that when switch is on there is power interruption. Up till this point we
detected the power interruption when the switch is on. Our next step was to detect
whether the PC is shutdown or working. For this purpose, we first inserted current
transformer in power supply cable to check whether the current was flowing through
the circuit or not. If the current was flowing, then we could decide that PC was
working. But CT stores energy for a bit long time which was not desired because if
the PC was shutdown there were still some voltages across the secondary terminals of
the Current Transformer(CT). [1] So, it was not feasible to use CT for this purpose.
Then we decided to check the voltages at capacitors of PC power supply. We rectified
220V and supplied this to PC power supply and used capacitive power supply in
parallel to the PC power supply capacitors and stored the voltages using RC circuit
and used LM311 to compare these voltages with reference 5V. This logic gave us
output logic 0 when PC is working and logic 1 when PC is shutdown or powered off.
We inverted this output. Then we compared this output and output of previous stage
by using AND gate. AND gave us logic 1 when PC is working and there is power
interruption. This output is made input to relay for switching to secondary backup.

27
3.1.3 Battery rating selection

We measured current and voltage for working PC. [1]

I= 0.47A

V=234V (AC)

Then we calculated power factor of PC using following relation:

PF=

Direct Current (DC) voltage is measured using oscilloscope with 100x attenuation
probe. Due to ramp of 90V dc the average DC voltage was 254.2V and the current
was 0.47A.

PF= 0.786=0.8(approx.)

Power= 100W (approx.)

We needed a backup of at least 7min. So considering the above requirements, we

selected 1.2AH and 4 V batteries. We will use four batteries and to make 12 v and
boost this to 250 volts. There was also an option of using bulk of batteries to make
250 V directly and it was easy as well but it was feasible because it becomes costly
and bulky in size as well.

Figure 3.2: Rechargeable battery

3.1.4 DC-DC Boost converter Design

It was the most important, difficult and backbone part of our project. We first
designed the inductor mathematically. We designed Pot-G core with 50µH inductor.
The upper peak value of current was of 6A and lower was 4A. As a result, our ripple
current was 2A with 50% duty cycle and 40 KHz frequency. But the core we designed
was not available in the market. Then we selected SB 14.2 isolation transformer
28
which easily available in the market and relatively cheap also. After then we selected
a power FET with minimum drain to source resistance and desired power rating. We
selected IRF 3205 which has 8mΩ drain to source resistance and high power rating.
Then our next and major task was to generate two clock pulses with some delay for
switching the FETs. We firstly used 555 timer IC and 74HC14N Hex-inverter IC. We
successfully generated the pulses but when we applied these pulses at the gate
terminal of FETs the waveform was distorted and changed into triangular waveform
because of input capacitance of FETs and low current supply by IC as we were using
CMOS. Another issue was that at low frequency transformer core got saturated very
early and our circuit heat up in no time. We increased 555 timer frequency up to 285
KHz but again same was the problem waveform was totally deformed due to low
input current to the gate. Then we searched for alternate solution and consulted our
project supervisor. He advised to use SG3525 IC instead of 555 and 74HC14N. We
implemented the circuit of SG3525 we obtained desired output waveform at
frequency of 55 KHz. This IC has built in property that it does not allow two FETs to
switch ON at one time. It controls the duty cycle as well though feedback. After
implementing this circuitry, we got our desired results.

3.2 Analysis Procedure

We connected the controller circuit with PC and assumed another supply as backup
and it was perfectly working with rebooting if we turn off the main input i.e. power
interruption.
Then we separately checked the output of DC-DC converter which was above then
200V and it was desired. After then we integrated the complete circuit.

3.3 Implementation Procedure

We have implemented the controller part of IPBB that is the detection of the
condition on which the backup system will get active. We have implemented this part
by using discrete electronic components like capacitors resistors, diodes, op-amps and
logic gates. We designed DC-DC converter by using isolation transformer and power
FETs. We rectified the output and filtered it by deploying 450V capacitor at the
output side of DC-DC converter. We used SMPS of 19V and 2.1A to charge our
batteries.

29
3.4 Details about hardware
Plastic film capacitors are used to step down the 220V. Electrolytic capacitors are
used to filter the rippled DC voltage. LM311 is used as voltage comparator. Relay is
used for switching purpose and bridge rectifiers are used to rectify AC to DC.
SG3525 is used to generate clock pulses with delay. SB14.2 isolation transformer is
used to step up the 16V to 200V [18]. FETs are used for switching purpose.

3.5 Details of final working prototype

After the implementation, project is working very efficiently. Our target is achieved in
an efficient and easy way. Following is schematic of controller part.

Figure 3.3: Proteus Schematic of controller part

Before converting our project on hardware we simulated the project on proteus

software in which we assumed motor as a load (PC) in above configuration. It was
working perfectly. Then we fabricated the controller part of our project separately and
the DC-DC converter separately and at the end we integrated them into one box.

Our final project prototype has only one input and one output.

30
Following are the details of our final working prototype:

 Output voltage =280 V DC

 Backup time= 5 mins (approx.)

 Switching time= less than 10 ms

There was a fluctuation ± 15V at the output of IPBB which was acceptable because
we already had a safe side of 20V more than the required voltages.

3.6 Summary
. In this chapter the complete implementation and design procedure of the project is
discussed in detail with final prototype working details. We simulated each and every
step on software before going to hardware for the confirmation of our design. To
make this device was not such a big deal but the methods to make it accurate proved
to be difficult. We finally achieved maximum of the accuracy with the methods
discussed above.

31
Chapter 4

TOOLS AND TECHNIQUES

This chapter is about the discussion of the Hardware that is used by us. It will be
further discussing the use of our hardware with the technical specifications and the
Software(s), the simulation tool(s) used.

4.1 Function Generator

We used function Generator to check the input and output of the transformer. In other
words, we wanted to check the gain of the transformer by providing small signal at
input. [8]

Figure 4.1: Function Generator

4.2 Digital Oscilloscope

We used digital oscilloscope to analyze different signals related to our project. [9]

Figure 4.2: Digital Oscilloscope

32
4.3 Power supply
We used power supply to provide input to DC-DC converter with controlled input
voltage and current for testing purpose. [12]

Figure 4.6: Power supply

4.4 Software(s), simulation tool(s) used

4.4.1 Proteus professional

We used proteus professional as a simulation software for our design simulation. It

provides all the components that are used in any electronic circuit design.

Figure 4.10: Proteus professional

33
4.4.2 PCB Wizard

We used this software to design PCB schematic of our circuit. [13]

Figure 4.11: PCB Wizard

4.5 Summary
This chapter includes the detailed discussion about all the tools and techniques used in
the project design. Function generator and oscilloscope play an important part in any
electronic project design; especially they are used when we want to analyze the design
output on different input frequencies and waveforms. Proteus professional is the best
software tool which provides a vast variety of electronic components and their
simulations. PCB wizard is PCB design software in which it automatically generates
the PCB design when we provide a circuit to it.

34
Chapter 5

PROJECT RESULTS AND EVALUATION

5.1 Presentation of the findings

Our project consists of hardware and discrete electronic components. Our project goal
for was to Design IPBB for PC. We have successfully performed this task and we are
getting very efficient results. We have used discrete electronic components for this
purpose.

5.2 Hardware results and problems

As per requirement of our project our controller should indicate a signal to turn on the
backup. We have tried to make our logic as simple as possible. After fabrication our
controller is working very efficiently. It gives output logic 1 if and only if switch is on
and PC is working and there is power interruption. Relay switching time is less than
10 milli seconds which is enough to avoid PC to reboot. Our DC-DC converter is also
working properly.
We observed the core saturation of transformer by analyzing following output at drain
terminal of FETs.

Figure 5.1: Transformer core saturation

35
The output of SG3525 is below:

Figure5.2: 3525Output

5.3 Results with scenarios

Table 4: Different scenarios with different DC levels

Scenario IPBB DC output

PC shutdown and power interruption zero
Main switch is OFF and power interruption zero
PC is working and power interruption 250V
PC shutdown and switch is OFF and power zero
Interruption

5.4 Comparison of Initial Targets and Achievements

Table 5: Comparison of Targets and Achievements

Initial targets Achievements

Provide backup up to 10 minutes We achieved 7 minutes Backup
Backup Power rating should be 110W We achieved 80W
Avoid PC to reboot Achieved
Design should be cheap Our design is in less than 2000 Rs

36
5.5 Limitations
The limitations for proposed project solution are:
 It is useful in those places where electricity generator is used as secondary electric
source. IPBB will work as a bridge between WAPDA and generator.
 It provides backup for short span of maximum 10 minutes.

5.6 Summary

In this chapter the results of the project and the evaluation of the project is discussed.
Our project results are near to the designed values. Our project is working very
efficiently and our goal is achieved that we have successfully detected the required
information and result is according to requirement that was to provide backup to PC
only when it is working state and there is power interruption and avoid PC reboot.

37
Chapter 6

CONCLUSION & FUTURE WORK

We have successfully designed an efficient and small intelligent power backup box
for personal computers (PC’s). Boost DC_DC converter has been designed for the
design prototype. To reduce the output ripple of the converter other technique have
been used. Majority of project specifications have been achieved. DC-DC converter
used in the design converts input 16V to 280V backup time of 5 minutes approx.
Detection circuit is working efficiently and have switching time less than 10ms which
is more than enough to avoid PC reboot.

Final design prototype is a cost-effective solution, easily repairable and easy to install
in work environment and offices. Proposed design is purely based on discrete
electronic components and can be extended as an industrial product in the future.

38
 References
[1] Sezi, Tevfik, and B. K. Duncan. "New intelligent electronic devices change the structure of
power distribution systems." Industry Applications Conference, Thirty-Fourth IAS Annual
Meeting. Conference Record of the 1999 IEEE. Vol. 2. IEEE, 1999.

[2] Shimamoto, Hajime, and Yasuhiro Ishida. "Intelligent power supply system for a portable
computer." U.S. Patent No. 5,300,874. 5 Apr. 1994.

[3] Voegeli, Derick, et al. "Intelligent power supply control for electronic systems requiring
multiple voltages." U.S. Patent No. 6,396,169. 28 May 2002.

[4] Allen, Robert, and William Bain. "Intelligent power supply for information processing system."
U.S. Patent Application No. 10/741,400.

[5] Anderson, Robin L., Ronald J. Perholtz, and Dennis Hawkins. "System and method for
accessing and operating personal computers remotely." U.S. Patent No. 6,633,905. 14 Oct.
2003.

[6] "Circuit Wizward Software", New Wave Concepts [Online]. Available: http://www.new-wave-
concepts.com/pr/cw_files.html. [Accessed April, 2016].

[7] Santos Filho, Rubens M. "Comparison of three single-phase PLL algorithms for UPS
applications." IEEE Transactions on Industrial Electronics pp. 2923-2932, 2008

[8] "DC UPS user manual" Centralion [Online]. Available:

http://www.centralion.com/download/UM-DC%20UPS.pdf. [Accessed Jan, 2016].

[9] “Hackers Toolbox: Function Generator”, MoHacks [Online]. Available:

http://mohacks.com/hackers-toolbox-function-generator [Accessed 12-4-2016].

[10] “Pulse-Width-Modulator Control Circuit”, On Semiconductors [Online]. Available:

http://www.onsemi.com/pub_link/Collateral/SG3525A-D.pdf [Accessed 23-5-2016].

[11] da Silva, SA Oliveira, "A line-interactive UPS system implementation with series-parallel
active power-line conditioning for three-phase, four-wire systems." International Journal of
electrical power & energy systems pp. 399-411, 2004

[12] Su, Haihua, et al. "Full chip leakage estimation considering power supply and temperature
variations." Proceedings of the 2003 international symposium on Low power electronics and
design. ACM, pp. 221-224, 2003.

[13] Weldon, L. A. "Voltage-Variable Capacitor Guide for Communications Circuit

Designers." Semiconductor Products and Solid State Technology pp. 34-35, 1994.

39
[14] Lanni, Luigia "500 bipolar integrated OR/NOR gate in 4H-SiC." IEEE Electron Device Letters
pp. 1091-1093, 2013

[15] Wilk, Glen D., Robert M. Wallace, and J. M. Anthony. "High-κ gate dielectrics: Status and
materials properties considerations." Journal of applied physics-pp. 5243-5275, 2001

[16] Jewett, Douglas E., Phil Webster, Dave Aldridge, Peter C. Norwood, and Nikhil A. Mehta.
"Fault-tolerant computer system with auto-restart after power-fall." U.S. Patent 5,317,752,
May 31, 1994.

[17] Li, Yunwei, D. Mahinda Vilathgamuwa, and Poh Chiang Loh. "Design, analysis, and real-time
testing of a controller for multibus microgrid system." IEEE Transactions on Power Electronics
pp. 1195-1204, 2004

[18] Mustafa, Mazin A., and Craig L. Chaiken. "Computer system with power loss protection
mechanism." U.S. Patent No. 6,243,831. 5 Jun. 2001.

[19] Silva, Sérgio Augusto Oliveira da "A line-interactive UPS system implementation with series-
parallel active power-line conditioning for three-phase, four-wire systems." Sba: Controle &
Automação Sociedade Brasileira de Automatica, pp. 200-210, 2005

[20] Cromer, Daryl C. "Method and system for providing protection against theft and loss of a
portable computer system." U.S. Patent No. 6,954,147, 11 Oct, 2005.

40
 Appendices
Appendix A

Pin configuration of LM311[1]

Pin configuration of Relay

41
Pin configuration of LOGIC GATE 7402

Pin configuration of LOGIC GATE 7408

42
Appendix B

43
44