PROJECT REPORT

VARIABLE (DC) POWER SUPPLY

GROUP MEMBERS:-
MUHAMMAD AQIB
FA16-EEE-020
TALHA SAEED IRSHAD
FA16-EEE-035

SUBMITTED TO:-
PROF SIR SYED BILAL JAVED

ELECTRIC CIRCUIT ANALYSIS (II)

TABLE OF CONTENTS:-
1)Acknowledgment

2)Abstract

3)Introduction

4)Block Diagram

5)Designing And Calculation Of Each Block

6)Simulation Results

7)Hardware Implementation

8)Packaging
9)Etching

10)Drilling

11)Soldering

12)Problem Faced

13)References

1)ACKNOWLEDGMENT:-‘
We express our deep sense of gratitude to our respected and learned guide Prof Syed Bilal
Javed for their valueable help and guidance,we are thankful to them for the encouragement they
have given us in completing the project.
We are also thankful to the ECA 2 lab staff for their kind co-operation and help.Lastly we would
like to thank our class mates,seniors and our indebtness to our parents for providing us the moral
support,economical support and encouragement.

2)ABSTRACT:-s
1)This project has a huge commercial importance,the regulated power supply is commonly found
in almost all engineering labs and not only there this product is now a days found almost
everywhere and its used by almost everyone for different purposes.

2)The need for designing this project is that to learn the phenomenon of conversion of AC supply
into DC supply and to learn the behavior of voltage after it passes through different components
of the power supply.
3)Tools used in this project are

HARDWARE:-
solder,drill machine,pcb board,acid(ferric chloride),T blocks and all the below mentioned
components.

SOFTWARE:-
Proteus,LTspice and Ares.

3)INTRODUCTION:-
VARIABLE REGULATED POWER SUPPLY:-
As in electronics all the instruments, components work on a particular regulated dc supply ,so a
project which can provide this supply by converting the alternating current into direct current
that too into a range of regulated power keeps its own preferences .As it can produce a range of
1-30V direct current by regulating and converting alternating current has a vast application
too.AC to DC converters generally comprise a rectifier bridge to rectify the AC current of the
input line and a regulating device supplying on output of one or more regulated DC voltages
.Just the simple AC current is supplied and through potentiometer you get the desired regulated
power supply. Our designed power supply has been made by taking ripple factor of 10% as
standard and output current of 1A as standard.
4)BLOCK DIAGRAM OF POWER SUPPLY:-

5)DESIGNING AND CALCULATIONS OF EACH BLOCK:-

1)TRANSFORMER:-
A transformer is an electrical device that transfers electrical energy between two
or more circuits through electromagnetic induction. A varying current in one coil
of the transformer produces a varying magnetic field, which in turn induces
a voltage in a second coil. Power can be transferred between the two coils through
the magnetic field, without a metallic connection between the two
circuits. Faraday's law of induction discovered in 1831 described this effect.
Transformers are used to increase or decrease the alternating voltages in electric
power applications.we have used the transformer in power supply in order to step
down the AC voltage of 220V into the amount of output voltage of that particular
transformer
We have used 12/12 transformerwhich has an output of 24 Volts and 1A
The value of voltage is in rms and it is 24.After converting it into Peak we get
Vpeak=24*1.414
Vpeak=33.94Volts

2)FULL WAVE BRIDGE RECTIFIER:-

Bridge is an electrical device.Bridge rectifier means diodes connected in the form
of bridge.The main of purpose of rectifier is to convert the AC voltage into
DC.That is why we have used this rectifier here because we want smooth DC
voltage in the output.The stepped down voltage will enter the rectifier where it will
further drop 1.4Volts.
Vrectified=Vtrans-1.4V
Vtrans=33.95Volts
Vrectified=32.5Volts

3)FILTER(CAPACITOR):-
A capacitor is a passive two-terminal electrical component that stores electrical
energy in an electric field.The main reason to use capacitor in our power supply is
that we want a smooth straight DC output and the capacitor here performs the
function of smoothing and removing noise.The purpose of using this capacitor is
that we can provide accurate voltage within a limit to the LM317 voltage regulator
because it only works within a small range of input voltage.
C=(1/f*Vrp-p) *(Vrec/RL)------------------(a)
Vdc=(2/3.14)*Vrec
Vdc=(0.636)*32.5

Vdc=20.7Volts
r=Vrp-p/Vdc
Vrp-p=0.1*20.7
Vrp-p=2.07Volts

RL=Vrec/I
RL=(32.5/1A)rms * 1.414

RL=23ohm

Putting values of Vdc and RL in equation (a)

C=(1/100*2.07)*(32.5/23)

C=6.8mF

We have used a capacitor of 6.8 mili(6800uF) as filter.

RIPPLE FACTOR:-
The wave from we get in the simulations after filter has a upper peak of 32.2V and lower peak
Of 30.49V so
Vdc=Upper+Lower/2
Vdc=32.2+30.49
Vdc=31.35V

Ripple Factor=(Vupp-Vlow/vdc)*100
Ripple Factor=(32.5-30.49/31.358)*100

Ripple Factor=6%
4)VOLTAGE REGULATOR LM317T:-
The LM317 is an adjustable 3−terminal positive voltage regulator capable of supplying in excess
of 1.5 A over an output voltage range of 1.2 V to 37 V. This voltage regulator is exceptionally
easy to use and requires only two external resistors to set the output voltage. Further, it employs
internal current limiting, thermal shutdown and safe area compensation, making it essentially
blow−out proof. The LM317 serves a wide variety of applications including local, on card
regulation. This device can also be used to make a programmable output regulator, or by
connecting a fixed resistor between the adjustment and output, the LM317 can be used as a
precision current regulator.

Features:-
1) Output Current in Excess of 1.5 A
2) Output Adjustable between 1.2 V and 37 V
3)The main purpose of using this in our power supply is that we need 30Volts in the output and
by the help of this regulator we can make our voltage 30Volts.
4)It drops the rectified voltage by 2.5v

Vregulated=Vrect-2.5V
Vregulated=32.5-2.5

Vregulated=30V
5)BREAD BOARD:-
A breadboard is a solderless device for temporary prototype with electronics and test circuit
designs.We have made our power supply initially on breadboard in order to check whether the
circuit is working properly or not.

6)PCB BOARD:-
A printed circuit board (PCB) mechanically supports and electrically connects electronic
components using conductive tracks, pads and other features etched from copper
sheets laminated onto a non-conductive substrate. Components (e.g. capacitors, resistors or
active devices) are generally soldered on the PCB. Advanced PCBs may contain components
embedded in the substrate.
PCBs can be single-sided (one copper layer), double-sided (two copper layers), or multi-layer
(outer and inner layers). Conductors on different layers are connected with vias. Multi-layer
PCBs allow for much higher component density.
We have made the main circuit on pcb board

7)POTENTIOMETER:-
A potentiometer is a three-terminal resistor with a sliding or rotating contact that forms an
adjustable voltage divider. If only two terminals are used, one end and the wiper, it acts as
a variable resistor or rheostat.
The measuring instrument called a potentiometer is essentially a voltage divider used for
measuring electric potential (voltage); the component is an implementation of the same principle,
hence its name.
Potentiometers are commonly used to control electrical devices such as volume controls on audio
equipment.. Potentiometers are rarely used to directly control significant power (more than
a watt), since the power dissipated in the potentiometer would be comparable to the power in the
controlled load.
In our circuit we are using this potentiometer as a variable resistor after the output of
LM317,RL is also used with it in order to vary the output voltage from 0-30V.

The value of resistors used with the LM317 is found by the following formula.
Vout=1.25(1+R2/R1)

R1 is the fixed resistor,R2 is the variable resistor(potentiometer),here Vout is set as 30V (max
value required) and R1 as 220(prefered value).So Variable resistor becomes about 5.6k ohm.

8)LOAD RESISTOR:-
A resistor is a passive two-terminal electrical component that implements electrical resistance as
a circuit element. In electronic circuits, resistors are used to reduce current flow, adjust signal
Variable resistors can be used to adjust circuit elements (such as a volume control or a lamp
dimmer), or as sensing devices for heat, light, humidity, force, or chemical activity.we have used
A load resistor of 23ohm.
6)SIMULATION RESULTS:-

7)HARDWARE IMPLEMENTATION:-
We have constructed our circuit on a pcb board following is the picture of Pcb without
components
 .

Now the picture with components

Circuit before packing

EXPLANATION:-
Construction:-
In the above circuit,Ac supply is provided to the transformer which is connected to the input
terminals of the bridge rectifier.The positive terminal of the bridge rectifier is connected to the
positive terminal of the capacitor ,the negative terminals of both components are grounded
respectively.The positive terminal of the capacitor is connected to the Input terminal of the
LM317,the resistor is placed between the output and adj terminals of LM317 ,the ouput terminal
of LM317 is further connected with the input terminal of potentiometer and in the a capacitor is
placed which again makes the voltage smooth.

Working:-
AC supply of 230Vrms is provided to the transformer which steps it down to 26Vrms which is

33.94 Vpeak ,then the transformer provides this voltage to the input terminals of the bridge
rectifier,which shifts both the cycles of AC sinosidal wave upwards such as

there is also a voltage drop of 1.4V and the rectified voltage becomes 32.5V.

The input frequency becomes double of its initial value after passing through the rectifier bridge
beacuse the time period T is halves.
Since f=1/T,then f=1/T/2 =>f=2/T.

After it the rectifier passes this voltage into the capacitor which filters it and produces a wave
form such as this
In the end the filtered voltage passes through then the regulator and produces an almost straight
DC output wave

The regulator also drops 2.5V of rectified voltage so the regulated output voltage becomes 30V.

The capacitor placed in the end further make it smooth and we get a complete straight wave at
the end.
8)PACKAGING:-
While designing the PCB Layout on ares we faced some problems in assigning packages to the
components,Some packages were easily available for some components but for some
components there were not available for this we used Tblocks .Packages for
Transformer and potentiometer were not available.Picture of Tblock is shown below

Circuit on proteas

Ares design
9)Etching:-
Different machines and chemicals can be used for etching, which will affect the quality
Two Acid types that can be used for etching are ferric chloride (Eisen-3-Chlorid) and Sodium
Persulfate(Natriumpersulfat–Feinätzkristall).
Although etching can also be done in simple plastic boxes, the quality of the results will improve
dramatically when using a machine that controls temperature and constantly keeps the fluids in
motion. There are small etching tanks with heating and air pump and there are small spray
etching machines which can handle bigger PCBs and even the development and cleaning
processes involved. The sprayer also decreases the etching time and the amount of acid needed.

To get rid of all unwanted copper follow these etching steps:

• Put the board in the acid tank for about 20 minutes until the copper traces are completely
etched. You can tell that it's finished when the board turns from opaque pink to
transparent yellow.
• Move the board into the rinse tank for a few seconds. You can also use an Isopropanol
spray.
3) Dry the board with a cloth.
4)For etching try to use a plastic pot for dipping because steel will react with acid and the
Pcb will not be etched properly.
5)For 100ml solution 40% of ferric chloride is used for etching(in water).

10)DRILLING:-
. PCB drill tools are manufactured in increments of 0.05 mm. We can convert the drill size given
in the drill files or tool lists into milimeters and rount ot hte nearest 0.05 mm.

• Example : Drill size of 31 mil – converted to 0.7874 mm is then rounded to 0.80 mm

A) If possible, provide separate drill files for plated (PTH) and non-plated (NPTH) holes. If this
is not possible, always specify different tools for PTH and NPTH holes and mark clearly which
tools are PTH and which tools are NPTH.

B) When no PTH/NPTH info is given we use the following rules to determine PTH/NPTH:

1) For 0-layer and 1-layer boards: ALL holes are considered as NPTH by default.

• For 2-layer and multilayer boards: ALL holes are considered PTH except the following
cases which are considered NPTH:
• Non-connected holes without copper pads.
• Non-connected holes where the copper pad size is equal to or smaller than the
drill TOOLSIZE (the copper pad will be removed in single image preparation)
• Connected holes with a copper pad on 1 side (outer), no connection on any other
layer (outer or inner) and no copper pad on the other side (outer).

NOTE: The above mentioned process is a standard way of drilling for complex circuits,but
sinse out circuit was comparatively simple and only had a few components and due to shortage
of time we printed the pcb design on A4 paper and confirmed the size between legs of
components,and thus printed the circuit on butter paper accordingly with correct zoom
percentage.After that firstly we drilled holes on first pcb by a solder iron due to unavailability of
small drill but the final circuit was drilled by a small drill.
11)SOLDERING:-

To solder through-hole components on a PCB starts by placing the part in its hole. Bend the
leads of the part so that it stays in its place.

Put the tip of the iron on the pad so that it heats both the lead of the part and the pad of the circuit
board. Heat them for a second or so before you apply solder. Remove the iron and the solder
wire and inspect your solder joint to see if it looks okay.

SOLDERING PASTE:-

A solder paste is essentially powder metal solder suspended in a thick medium called flux. Flux
is added to act as a temporary adhesive, holding the components until the soldering process
melts the solder and makes a stronger physical connection. The paste is a gray, putty-like
material.

USE:-

When solder paste is used in mass PCB assembly as well as prototype PCB assembly there are a
number of stages that are undertaken. First solder paste is applied to the printed circuit boards.
The solder paste is only applied to the areas where solder is required. This is achieved using a
solder paste stencil that only allows the solder paste through in certain areas. (Further
information is available on another page in this section of the website).
Once the solder paste has been applied to the printed circuit board, it is then passed into the pick
and place machine where the components are added. The solder paste has sufficient tension that
it holds the components in place. However care should be taken not to knock the board at this
stage otherwise the components may move of fall off. Additionally the board should be soldered
within a few hours of being placed, otherwise the solder paste may deteriorate.

Solder paste is widely used in PCB assembly - both in mass production and also for prototype
PCB assembly. When used with care it enables very high quality soldered joints to be produced,
however very careful control of the process is required if this is to be maintained. It is necessary
to apply the correct amount, and in the correct place. Additionally the solder paste must be
within its "use by" date.

12)SOLDERING WIRE:-

Solder is basically metal wire with a "low" melting point, where low for our purposes means
low enough to be melted with a soldering iron. For electronics, it is traditionally a mix of tin and
lead. Tin has a lower melting point than Lead, so more Tin means a lower melting p

12)PROBLEMS FACED:-
`1)First of all,the major problem we faced in this was the we couldn’t get the desired
components(of accurate voltage ratings,capacitance and resistance values) which we calculated
because most of them were not available in the market so that’s why we used components of
values near the calculated values which obviously affected the output in the end.

2)Another problem we faced was during soldering because in over pcb layout the wires were
very close to each other so it was quite difficult to solder.
3)Pasting the circuit layout on pcb was also very difficult,we did it 3 or 4 times and still we
couldn’t get the proper design due to which we had to change 3,4 pcb boards.

4)When we were testing our circuit on breadboard ,whenever we tried to measure the current the
load resistance exploded everytime it was because of the Low power rating of resistor.

5)The last and the main problem we were facing was that we couldn’t understand that which
transformer we should use to get desired output,whether we should use 12/12 or 18/18 and rms
and peak values were also creating a lot of confusion.
13)REFERENCES :-
[1] Electronic Devices 9th Edition,by Floyd
[2] Introductory Circuit analysis 9th Edition by Robert Boylsted