Universal Power Variator

This project is a continuous variator of supplied power for power tools, lights or
heating. Works universally for AC or DC power supplies.

Beginner
Full instructions provided
20 hours
4,190
Universal Power Variator
Things used in this project
Hardware components
male main power plug
× 1
female main power plug
× 1
600V CoolMos C7 Gold
× 2
Arduino UNO
Arduino UNO
× 1
Story
This project is a continuous variator of supplied power for 220V/110V power tools,
lights or heating. It works for AC as well as for DC power supply, that is why it
is named Universal. Compared to existing built-in speed variator if the power tool
has one, our solution using 600V CoolMos C7 makes less EMI and noise. Moreover, it
works for controlling AC or DC power supply with the same hardware. It is useful
because of you can add new functionaliies to low-end electrical equipment.

To vary the supplied power, two 600V CoolMos C7 are tied back-to-back, then
together are put in series with the load. The pack of two CoolMos C7 controls the
supplied power by controlling the supplied current. The pack in turn is controlled
by an Arduino which PWM modulates the supply current passing through the two
CoolMos C7.

The circuit and components are not galvanic isolated. Using a Wireless shield this
power variator can be remotely controlled.

One use case is to vary the speed of low-end power tools such as drills, saws, and
which don't have speed variation. Many times, we would need the tool to run at
lower speed to avoid damaging the part we are working on, or sometimes just to
reduce the noise for neighbors.

Another use case is to fine tune the electrical heater's temperature, and
automatically switch it on/off depending on the ambient temperature.

Another use case is to control a fan's speed and stop it as a function of ambient
temperature.

Schematics
How to switch DC ON
Principle for switching DC ON

coolMos pinout
The pin-out is referenced in electronics schematics

schematics of power variator

overall schematics of the project

How to switch AC ON - positive half-cycle

principle of conduction during AC positive half-cycle

How to switch AC ON - negative half-cycle

principle of conduction during AC negative half-cycle

zero crossing detection

principle of zero crossing detection on AC

Code
Varying DC power supply
Varying AC power supply
Varying DC power supplyArduino
This code periodically and endlessly increase then decrease the supplied DC power.
When used on AC power, only half of the cycle is passed, consequently the max power
is only half of the max of supplied power.

int G1 = 9; // the PWM pin connected to gate of CoolMos-1

int G2 = 6; // the PWM pin connected to gate of CoolMos-2
int S = 7; // the digital out of '0' connected to the Driver Source of
both CoolMos-1,2
int brightness = 0; // how much power on the load (e.g. lamp)
int increase = 5; // how many points to increase the power by

// the setup routine runs once when you press reset:

void setup() {
// declare pin 9/6/7 to be an output:
pinMode(G1, OUTPUT);
pinMode(G2, OUTPUT);
pinMode(S, OUTPUT);
}

// the loop routine runs over and over again forever:

void loop() {
G2 = 0;
S=0;

// set the brightness of pin 9:

analogWrite(G1, brightness);

// change the brightness for next time through the loop:

brightness = brightness + increase;

// reverse the direction of the fading at the ends of the fade:

if (brightness <= 0 || brightness >= 255) {
increase = -increase;
}
// wait for 30 milliseconds to see the dimming effect
delay(30);
}