PCB DESIGNING

BES202: Fundamentals of Automation Engineering

PREPARED BY
ANMOL SINGH SHEKHAWAT(2018BTechEEE001)
VARDAN SHARMA(2018BTechCSE020)
MADHAV YADAV (2018BTechCSE006)
NIKITA KHOJ (2018BTechCSE122)

FACULTY GUIDE
PROF. JOTHIPRAKASH D. NAIDU

PROF. GUSTAVO SANCHEJ

Dr. DEVIKA KATARIA

Dr. PUSHPENDRA SINGH

Department of Engineering
Institute of Engineering and Technology (IET)
JK Lakshmipat University
January 2019
Abstract
This report is based on the project 1 of Fundamentals of automation
engineering. In this project we studied about DC power supply its
application and construction. We went in chronological order to
understand circuits, components including capacitors, diodes, rectifiers
(construction and working), I.C., transformers (types, construction,
working, uses). The learnings will then be applied in making a powers
supply of desired output rating of 5v, 9v, 12v from input voltage of 230v
by designing a PCB using all the necessary components after decreasing
the voltage using transformer.
Introduction-
The report contains the information of transformer and the devices such as diodes, inductor ,capacitors
etc. voltage regulator used for its designing and constructing with its working. This contain the making of
9V DC supply from 230V main AC supply using a transformer and a filtered current through a rectifier.

Further more it include dc power supply and its application and the result obtained during testing of PCB
on oscillator meter (by tracing the graph) and its readings and thus verifying the step down transformer
on multimeter .

This document is intended for users to brief them about the working a major electronic device
which they use every day but didn’t thought about it. Its aim is to define the terms used,
introduce the different types of power supplies and the technology used to convert them into
another.
This report majorly contains brief information about DC power supply and its application,
transformer, rectifier and its other components like voltage regulators and filters(capacitors),
designing and making the whole PCB by attaching all the above stated parts.

Waveform generated by CRO

We were provided with a task of
making a DC power supply on a PCB board, so we had to design a proper PCB to convert 240V
AC into 9V DC. So our first task was to make a PCB to complete that we first made a rectifier
circuit on a breadboard using four diodes then to reduce the ripples we used capacitor. When
we were sure that the circuit is working we took a copper plate and made a mirror image of the
rectifying circuit containing a voltage regulator and an inductor using a permanent marker.
Then we put the copper plate in ferric chloride solution to remove excess copper from the
plate. After this process we drilled every point where component has to be mounted, then we
put the components at the desired place and soldered them. Then we connected a transformer
in input of the PCB board and we measured output from the PCB board using a CRO to observe
the waveform of the DC current from PCB.
Literature survey

We have by now discovered that the power grid transmits AC current since it is less demanding
to transmit long separations without critical power loss than DC current. So the majority of our
standard wall outlets will give us an AC voltage; in any case, numerous apparatuses require a
DC voltage for legitimate activity. A couple of precedents are TVs, gaming consoles, and PCs.
Along these lines, a circuit known as a rectifier is required to change over the AC voltage from
the outlet to a DC voltage that can be utilized to control numerous family unit machines.

There are two kinds of rectifier circuits, half-wave (utilizes just the positive cycle of the AC flag)
what's more, full-wave (utilizes the two cycles of the AC flag), yet this trial will concentrate on
full-wave since it is all the more generally utilized in certifiable applications. Maybe the least
complex full-wave rectifier circuit is the diode connect rectifier appeared as follows.

The diode connect rectifier utilizes four individual diodes associated in a "connect" design to
deliver the ideal yield. The four diodes marked D1 to D4 are organized in "series pair" with just
two diodes directing current amid every half cycle. Amid the positive half cycle of the supply,
diodes D1 and D2conduct in series while diodes D3 and D4 are off and the current flows
through the load as appeared as follows. Amid the negative half cycle of the supply, diodes D3
and D4 direct in series, however diodes D1 and D2 turn off. The present streaming through the
leap is indistinguishable course from previously. As the present coursing through the load is
unidirectional, the voltage created over the load is likewise unidirectional. The DC yield voltage
over the load is around 0.637Vmax. The last advance in the AC to DC transformation is to
associate a "smoothing" capacitor to the yield which builds the normal DC yield voltage by
wiping out the ripple.
Introduction to DC power supply-
Power is the backbone of any electronic system and the power supply is what feeds the system.
Choosing the right supply can be the critical difference between a device working at optimum
levels and one that may deliver inconsistent results.
The electrical power is almost exclusively generated, transmitted and distributed in the form of
ac because of economical consideration but for operation of most of the electronic devices and
circuits, dc supply is required.
Now a days, almost all electronic equipment includes a circuit that converts ac supply into dc
supply. In general, at the input of the power supply there is a power transformer. It is followed
by a rectifier (a diode circuit) a smoothing filter and then by a voltage regulator circuit.

Block diagram of AC to DC conversion

From the block diagram, the basic power supply is constituted by four elements viz
a transformer, a rectifier, a filter, and a regulator put together. The output of the dc power
supply is used to provide a constant dc voltage across the load. Let us briefly outline the
function of each of the elements of the dc power supply.

Transformer is used to step-up or step-down (usually to step-down) the-supply voltage as per

need of the solid-state electronic devices and circuits to be supplied by the dc power supply. It
can provide isolation from the supply line-an important safety consideration.

Rectifier is a device which converts the sinusoidal ac voltage into either positive or negative
pulsating DC. P-N junction diode, which conducts when forward biased and practically does not
conduct when reverse biased, can be used for rectification i.e. for conversion of ac into dc. The
rectifier typically needs one, two or four diodes. Rectifiers may be either half-wave rectifiers or
full-wave rectifiers type.

The output voltage from a rectifier circuit has a pulsating character i.e., it contains unwanted ac
components (components of supply frequency f and its harmonics) along with dc component.
For most supply purposes, constant direct voltage is required than that furnished by a rectifier.
To reduce ac components from the rectifier output voltage a filter circuit is required.

Thus, filter is a device which passes dc component to the load and blocks I AC components of
the rectifier output. Filter is typically constructed from reactive circuit I elements such as
capacitors and/or inductors and resistors.
So, at the output of a rectifier filter combination a voltage regulator is required, to provide an
almost constant dc voltage at the output of the regulator. The voltage regulator may be
constructed from a Zener diode, and or discrete transistors, and/or integrated circuits (ICs). Its
main function is to maintain a constant dc output voltage. However, it also rejects any ac ripple
voltage that is not removed by the filter.
Applications of DC Power supply:
DC power supply is widely used in low voltage applications such as:
1. Mobile Chargers:
Mobile chargers coverts High voltage AC supply to low Voltage DC supply which is
required by the appliance.

2. Solar cells:
Solar cells also have to be supplied DC current

3. Electrolysis:
During Electrolysis Alternating current can change the terminals therefore DC voltage
supply is required.

4. Laptops and Computers:

For laptops and computers the appliances in that has to be supplied DC voltage.

5. TV Remotes:
Even the TV remotes needs to have DC supply which they get from the Batteries .

“Whenever there is a need of regulated constant current, DC voltage supply is a

must.”
TRANSFORMER:
 A Transformer is an electric device which transforms electrical power from one circuit
to another with the help of a magnetic core using the principle of EMI i.e,
Electromagnetic induction.
 It consists of a primary coil(N1) with Input and Secondary coil (N2) with output.

Energy losses
Transformer energy losses are dominated by winding and core losses. The losses which happen
in core are called iron losses they occur mostly because of flux linked to the core which results
in eddy current. The losses which happen in the winding are called copper losses because
winding wire is made of copper. Copper losses occur because of the resistance possessed by
the windings of the transformer. Transformers' efficiency tends to improve with increasing
transformer capacity. The efficiency of typical distribution transformers is between about 98
and 99 percent.
Types of transformer

Mainly there are two types of transformer:

1. Core type transformer:

The winding surround the core
with two limbs.
2. Shell type transformer:
The core surround the winding
with three limbs.
Rectifiers:
 A circuit which can give DC output from AC input with the help of the arrangement of
diodes in the circuit respectively then it is called a Rectifier.

Rectifiers are of two types :

 Half wave rectifier and Full wave rectifier.

1. Half Wave Rectifier:

 If a circuit with the help of a diode accept only one phase of AC supply and stops the
second phase and giving only half wave output then it is called a half wave rectifier .

2. Full Wave Rectifier:

 If a circuit with the help of a diode accepts the flow of current in both phases but the
direction of flow of current is in one direction and thus giving a full wave as the output
then it is it is called a full wave rectifier.
  Therefore we make a full wave rectified circuit using four diodes in DC voltage supply to
get DC output.

Some Applications of Rectifier Diode

 Rectifying a voltage, such as turning the AC into DC voltages
 Isolating signals from a supply
 Voltage Reference
 Controlling the size of a signal
 Mixing signals
 Detection signals
 Lighting systems
 LASER

HOW DOES A RECTIFIER CHANGE AC TO DC?

When AC voltage or AC current is applied across the P-N junction diode, during the positive
half cycle the diode is forward biased and allows electric current through it. ... Thus, the P-N
junction diode acts like a rectifier by converting the AC current into DC current.
The diodes are connected to the two outer taps, and the center tap is used as a common ground
for the rectified DC voltage. The full-wave rectifier converts both halves of the AC sine wave to
positive-voltage direct current. The result is DCvoltage that pulses at twice the frequency of the
input AC voltage.
Filters:

 Electronic filters are circuits which perform signal processing functions, specifically to remove
unwanted frequency components from the signal, to enhance wanted ones, or both. Electronic
filters can be: passive or active analog or digital high-pass, low-pass, band-pass, band-stop, or
all-pass.

Capacitors are used as filters in circuits

Capacitors are used in the circuit to reduce the repulse
of output wave (rectified full wave)

USE OF FILTERS
In signal processing, a filter is a device or process that removes some unwanted components or
features from a signal. Filtering is a class of signal processing, the defining feature
of filters being the complete or partial suppression of some aspect of the signal. ... Filters may
be: linear or non-linear.

WHY FILTER IS USED

Usually a filter is used for signal processing functions such as to attenuate or for
selectively filtering one frequency or range of frequencies out of a mix of different frequencies
in a circuit. ... Depending on the type of requirements, different types of filters can be used, for
either AC or DC circuits.

full wave rectifier with capacitor filter

Capacitor:
A capacitor is made up of two metallic plates.
With a dielectric material in between the
plates.

When you apply a voltage over the two

plates, an electric field is created. Positive
charge will collect on one plate and negative
charge on the other.

And this is what the physicists mean when

they say that “a capacitor works by storing
energy electrostatically in an electric field”.

Role of Capacitor in Filter :

In the rectified full wave, the magnitude of current is propagates from zero to max i.e, it’s not
constant.
During phase 1 the capacitor gets charged.
And during phase 2 when the current in the circuit falls down the capacitor gets discharged and
therefore providing current to the circuit at that time too.
So the repulse of the wave decreases as there is current flowing in the circuit during phase 2
also with the help of capacitor

Inductor:
An inductor, also called a coil, choke, or reactor, is a passive two-terminal electrical component
that stores energy in a magnetic field when electric current flows through it.
An inductor typically consists of an insulated wire wound into a coil around a core.

Role of inductor in Filter:

The current smoothing action of series inductor filter can be combined with capacitor can be used to form a
perfect practical filter circuit.
PCB Design

Step 1

In first step we need a PCB designing software, to convert the circuit schematic diagram into PCB

layout.
Circuit diagram

Step 2

After making layout we need to take the printout of mirror image of the PCB layout. Print should
be taken on Glossy paper/Photo Paper using the Laser Printer.

Step 3

In this step we need a Copper clad Board and we need to cut that copper clad in required size,
according to our PCB layout design.

Step 4

Now rub it by using sand paper or steel wool. It will remove the oxide layer from the board as
well as makes the board rough so that paper can stick properly.

Step 5

In this step, place this copper clad by the side of printed side of photo paper, and fold the
paper.OR put copper board upon the Printed layout, with copper side down towards the printed
layout and plastic side up. Then fold the paper
Step 6

Now take a hot iron and start ironing slowly for 5-10 minutes or tightly
press the hot iron for some time. Heating the paper will transfer the ink
to the copper board. Now allow copper plate to be cool down and open
the folded paper. If paper gets stuck to the plate, use warm water to
remove the paper properly. At some places ink does not get properly
transferred to the copper plate, or gets fainted during the removing of
paper, so use a Black permanent marker and complete the missing lines Copper board with marked circuit
and tracks

[NOTE- for easy circuitry we can directly use permanent marker to draw the circuit but make sure
that the permanent marker should have enough layer so that it doesn’t dissolve in FeCl3]

Step 7

Now we have our circuit layout under the black ink and we only need copper
tracks under these black lines. So, we need to remove all the other copper
except the black lines.
For this we will make Ferric chloride solution (FeCl3), by adding 2-3 tea
spoon of Ferric chloride in some water. This solution is called Etching
Solution. Put the PCB in this solution for approx. half an hour. Now Ferric
Designed PCB in FeCl3
chloride will react and remove the exposed copper and won’t react with
the masked copper under the Black lines. And we get copper track as per
our PCB layout.
Now take out the PCB and check whether all the unwanted copper is removed, if not then put it
back into the solution for some more time. Finally take the PCB out from the solution and wash
it with cold water. This whole process in Step 7 is called the Etching Process. To make the Etching
process faster, you can either stir the solution (with PCB dipped) in every 2-3 minutes or
you can use some warm water to make the solution.

Step 8
Now rub the PCB with the steel wool or fine sand paper to remove the black ink, or you can use
thinner (Acetone) on a piece of cotton to remove Black ink. Now you can see the shiny copper
tracks clearly as per our printer PCB layout

Step 9

In this step take a hand drill machine for holing. And drill the holes according to the components
placement. And cut the IR sensors part from it

COMPONENT MOUNTING ON PCB

Following components were mounted in PCB:
1) Capacitors
2) Voltage regulators
3) Diodes
4) Inductors

1) Capacitors:
In our PCB we used two capacitors of 47 and 100 micro farads . Both the capacitors were in
a parallel connection. In power supply reservoir capacitors are used for smoothing the
output of a full or half wave rectifiers.

2) Voltage Regulator
A voltage Regulator is used for stabilizing DC power supply. Usually we call it ‘IC’, here we
have used a 7805 IC which provides a constant 5 volts output.

3) Diodes
It is a semiconductor device which allows flow of current in one direction only . The silver
side of a diode is it’s negative terminal. In our PCB there are four diodes.

4) Inductor
It is a device which is used for storing energy in a magnetic field when the current flows
through it.
All these components are mounted on a PCB as described
in following steps:
1) Check the continuity with the help of a multimeter.
2) Insert the legs of components in the drilled holes.
3) Solder them with the help of soldering machine.
4) Cut the remaining part of the leg.

DC Power Supply testing

 First we made a circuit of ac to required dc output
on a breadboard and then test the continuity,
input and output reading with the help of multi
meter.
 After that we connect the breadboard circuit
output (load) with CRO (Cathode Ray
Oscilloscope) and trace the waveform of the
output (load).
 Then we sketch the giving PCB circuit on the
copper clad laminate with the help of permanent marker and put the designed PCB in
ferric chloride solution.
 Then we put on the components on the circuit after it is taken out of solution and solder
them out on the designed PCB.
 Again, with the help of multi meter we check
the continuity of the circuit and connections
and also check the terminals.
 At last, with multi meter we calculate the ac
input from transformer and dc output from
the load.
 Also we check the dc output from the drawn
PCB with CRO machine for the perfect
=waveform we want as result.
 Supply voltage=230V
 Ac output from transformer = 14.2V
 Dc output = 8.89V
COST ANALYSIS

S NO. PART DISCRIPTION QUANTITY COST (₹)

1. Transformer 1 60
2. Diode 4 16
3. Capacitor 2 4
4. Inductor 1 5
5. Voltage regulator 1 15
6. Wires 4 10
7. PCB 1 35
8. Two pin 1 15
9 Box 1 40
TOTAL 200

The PCB cost total of ₹200 . The total time of construction of it takes about 6-7 hrs.
CONCLUSION AND DISCUSSION

Transformers are capable of either increasing or decreasing the voltage and current levels of their
supply, without modifying its frequency, or the amount of electrical power being transferred
from one winding to another via the magnetic circuit.
So here we made a step down shell type transformer which decrease down 230V to 9V by
increasing the current using rectifier, filter, voltage regulator etc and noting down the wave form
from oscilloscope and verifying it.
There is some loss of power between input and output coil and output voltage depend on the no
of turns in secondary coil wrt primary coil.

1. We first discuss about each and every component of circuit and tested it on multimeter
and understood the working of circuit and the role of each and every component attached
to it.
2. Then the applications of transformer and its working.
3. Error Analysis and Result: The possible causes of this error might be that when the
external voltage had very significant change and connection might get loose somewhere.
4. Connecting positive and negative terminal of diodes properly along with capacitor and
inductor, else they will fuse and will not work.

As mentioned above we successfully converted alternating current into direct current and
used it to run a DC motor , which will be used in other projects such as conveyer belt etc.

The output voltage that we converted was 9 volts and it was direct, that is it was constant
with time.

Voutput = 9 volts
Vsupply = 230 volts(rms value)
Vsecondary = 12 volts(from transformer)

LEARNING FORM DC POWER SUPPLY

 understand construction and operating principle of DC machines and transformers
 acquire knowledge on characteristics of DC machines and transformers for different operating
conditions
 test and calculate performance parameters of DC machines and transformers
 select DC machines and transformers for specific application
 working of different components for various purpose
 types of transformer base on voltage supply and winding of coil on limb
 soldering and making connection
 error possibility and how to correct it
 connecting positive and negative terminal properly
 all the connecting on PCB should be neat and proper