DFAA Project Assignment

Adithya. S
17QM30006

Product:​ Mobile Phone Charger

Production Rate: ​3 Nos/Hour

Mobile phones are very common these days and so mobile chargers too. Most of us use it in
daily life. In fact they are used to charge the batteries inside the mobiles by providing them a
low level DC voltage and current. There may be different types of chargers used to charge
different mobile phones but the key functions of those all are almost the same.

Product Working:

Latest mobile chargers are kind of power supply units that use the Switched Mode Power
Supply (SMPS) technology. To understand the working phenomenon of a mobile charger,
we need to understand the concept of Power Supply Unit (PSU). PSU is a device that
transfers electrical energy from one end to another by changing its fundamental
characteristics according to the requirements. Example of a PSU is an application that
converts AC mains voltage to regulated DC voltage. PSUs can be of two types depending on
the mode of operation – Linear and Switching.

In these switching mode chargers, energy transfer is done by continuously switching

electrical components (inductor, capacitor, etc) on and off. We can control the output
voltage/current by varying the duty cycle, frequency or the corresponding phase. Using the
SMPS technology makes the chargers smaller and lighter by elimination of low frequency
transformers. It also presents a greater efficiency than the conventional methods which use
bulky transformers.

The AC supply first enters through the line filters in the charger. Line filters are the kind of
electronic filters that are placed between an electronic device and an external line to
alter/attenuate the electromagnetic interference effect. Now filtered signal are made to pass
through the full wave bridge rectifier circuit. Rectifier converts the AC voltage to DC.

Output DC voltage from the rectifier circuit passes through the PFC (Power Factor
Correction) circuit which operates power ​circuits at their maximum efficiency. Further the
voltage signal is transferred to the pulse transformer that is a special type of transformer
optimized to produce rectangular electrical pulses.

Pulse transformers are categorized into two categories – power and signal transformers. The
one used here is a power transformer. It reduces the voltage level of the input power and
gives a low voltage power that is exactly required to charge the battery.

Product Parts:
1. USB Wire/Cable
2. Mobile Charger PCB Board
3. Outer Case (Cuboidal)(With a hole for USB cable at the bottom)
4. Outer strip(Rectangular planar)
5. Plug point pins
Assembly Process:
The assembly process is as follows
1. The PCB board is placed between slids present in the Cuboidal outer case of the
charger.
2. The plug point pins are attached to the PCB board by wiring and soldering.
3. The rectangular strip is pressed into the outer case along with pins thus closing it
completely.
4. The USB Cable is attached to the PCB Board from outside through a small outlet
present in the outer case.

Liaison Diagram:
Assembly Sequence:

Liaison
Matrix
1 2 3 4 5

1 0 1 1 0 0

2 1 0 1 0 1

3 1 1 0 1 0

4 0 0 1 0 1

5 0 1 0 1 0

Part-1 Part-2

1 2

1 3

2 3

2 5

3 4

4 5

2 1

3 1

3 2

5 2

4 3

5 4
Part-1 Part-2 Part-3

1 2 3

1 2 5

1 3 4

1 3 2

2 3 4

2 3 1

2 5 4

3 4 5

4 5 2

2 1 3

3 1 2

3 2 5

3 2 1

5 2 3

5 2 1

4 3 1

4 3 2

5 4 3

Part-1 Part-2 Part-3 Part-4

1 2 3 4

1 2 5 4

1 3 4 5

1 3 2 5

2 3 4 5
 2 5 4 3

3 4 5 2

4 5 2 3

4 5 2 1

2 1 3 4

3 1 2 5

3 2 5 4

5 2 3 4

5 2 3 1

5 2 1 3

4 3 1 2

4 3 2 5

4 3 2 1

5 4 3 1

5 4 3 2

Part-1 Part-2 Part-3 Part-4 Part-5

1 2 3 4 5

1 2 5 4 3

1 3 4 5 2

1 3 2 5 4

2 5 4 3 1

3 2 5 4 1

4 5 2 3 1

4 5 2 1 3
 2 5 3 4 1

3 1 2 5 4

5 2 1 3 4

4 3 1 2 5

5 4 3 1 2

5 4 3 2 1

Precedence
Assembly Operation Precedence
a Inserting the USB Cable to the adaptor c,d,e,f
b Inserting the USB Cable to the adaptor c,d,e,f
Sliding in the PCB Board into the outer
c case
Soldering/Wiring the pins to the PCB
d Board
e Attaching the Strip to the Outer case
f Attaching the Strip to the Outer case

● Note that assembly operations a and b take place simultaneously hence they
should be together in assembly sequence, same goes for assembly
operations e and f.

Considering Precedence only possible sequences are:-

1. 3-2-5-4-1
2. 2-5-3-4-1
Product Sketch: