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Multiple-output, Variable-output DC Power Supply May03-22

Multiple-output, Variable-output DC Power Supply May03-22. Team Members: Erik Johnson Joel Jorgensen Peter Holm Philip Schulz Clients – Prof. Patterson, Prof. Lamont Faculty Advisor – Dr. Allan Potter April 30 th , 2003. Presentation Overview. Problem statement and solutions

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Multiple-output, Variable-output DC Power Supply May03-22

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  1. Multiple-output, Variable-output DC Power SupplyMay03-22 Team Members: Erik Johnson Joel Jorgensen Peter Holm Philip Schulz Clients – Prof. Patterson, Prof. Lamont Faculty Advisor – Dr. Allan Potter April 30th, 2003

  2. Presentation Overview • Problem statement and solutions • Summary of activities • Resource requirements • Summary of progress • Questions

  3. General Problem Statement • Develop a power supply with the following voltages: +1.5V,  3.0V, +3.2V, +4.5V,  5.0V, +6.0V, +7.5V, +9.0V,  12.0V, +15.0V, +18.0V, +24.0V • Output 2 + voltage outputs and 2 + voltage outputs simultaneously • Produce for a low cost (~$150) • Allow a maximum current of 1A through each set of terminals

  4. Solution Approach • Develop general design • Simulate and test on CAD program • Order parts • Assemble • Test • Modify and re-test if necessary

  5. Operating Environment • Standard laboratory conditions • Indoors • Approximately 24 degrees Celsius • Standard 120V, 60 Hz wall output

  6. End Users and Uses • Users • Research and design students • Faculty • Uses • Power and test design projects • Produce a small current at many voltages • Provide several voltages simultaneously

  7. Assumptions and Limitations • Assumptions • All four outputs will be used simultaneously • Power supply will be used indoors at room temp • Power supply will be powered by 120V, 60 Hz • Limitations • Output current limited to 1A max per output • Total cost must be below $150 • Input must be 120V at 60 Hz

  8. End Product Description • 4 selectable output voltage terminal sets • Maximum current of 1A per output • Output voltage selected by rotary knobs • Digital readout of voltage, current and wattage • Fuses for power supply protection

  9. End Product

  10. Present Accomplishments • Schematic simulated and successful • Successfully implemented transformer and bridge rectifiers on circuit board • Successfully implemented +/- voltages on circuit board • Examined methods of implementing positive only voltages

  11. Approaches to the Design • Recycle/modify/incorporate existing insufficient power supplies • Create and design an original power supply • Use store-bought voltage converters • Design and create voltage converters • Flyback converter • Buck converters • LM317T/LM337T voltage regulators

  12. Project Definition Activities • The power supply specs were expanded from the original to include the following: • +3.2V, +7.5V, +15V, and +18V • 2 + voltage outputs and 2 + voltage outputs • Ammeter and voltmeter

  13. Research Activities • The need for more voltage outputs was researched. • It was found that the additional voltages of +3.2V, +7.5V, +15V, and +18V would be useful for small home electronics • Also researched various power supply designs for ideas to implement in the final product.

  14. LM317T/LM337T Voltage Regulators • Adjustable output down to +1.2v • Adjustable current limiting feature • Line regulation typically .01%/V • Load regulation typically .1% • 80 dB ripple rejection

  15. TL494 PWM Control Circuit • Up to 200 kHz oscillator frequency • Feedback allows voltage and current regulation

  16. Design Activities • Different implementation schematics tested • Because the LM317T/LM337T voltage regulators are not in the Workbench/Pspice libraries, the circuits were physically tested

  17. Team Members Paper Work Research Design Construction Totals Est. Act. Est Act. Est. Act. Est. Act. Est. Act. Erik Johnson 8 10 21 14  32  25 12 13 73 58  Joel Jorgensen 5 27 25 13 34 26 13 14 77  76 Peter Holm 9 25 15 7 25 22 14 8 63 58 Philip Schulz 7 10 18 8 28 27 12 12 65 53 Totals 27 72 79  42 119 100 51 47 278 265  Personnel Effort Budget

  18. Item Original Estimated Cost Cost to Date Poster $50.00 $50.00 Case $14.99 $0.00 Transformers $35.53 $21.94 Resistors/capacitors/diodes $26.80 $21.18 Cooling fan $9.99 $8.99 Switches, dials, and terminals $25.00 $6.21 Meters ($10.25 each) $30.75 $0.00 Variable voltage regulator $4.00 $3.90 Total $197.07 $112.22 Financial Budget

  19. Project Schedule

  20. Project Schedule, cont.

  21. Project Evaluation • Done on a scale of: incomplete = 0%, to complete = 100% • Milestones: • Overall Status: Prototype

  22. Commercialization • Estimated cost to produce: $100 - $200 • Estimated sales price: $400 - $1000 • It is anticipated that this product would have a very large market • Versatile • Financially viable

  23. Recommendations forAdditional Work • Finish original implementation • Develop a commercial version • Add power factor correction • Make each set of terminals fully isolated • Make current limitation adjustable

  24. Lessons Learned • What worked • Team worked well at brainstorming, designing • Advisor was helpful when we got stuck • Regular, scheduled meeting • What did not work • Collaborating on reports and poster • Weekly status reports • Ordering parts • Gaining the necessary knowledge • Advisor absence for extended period of time

  25. Lessons Learned (cont) • Technical knowledge gained • How power supplies work • How DC-DC converters work • How transformers work • How to use Workbench • Things to do differently • Put more time into research early on

  26. Risks and Risk Management • Illness • Follow good health practices • Take on some of the sick member’s workload among the other members • Accidents such as electrocution or fire • Follow high voltage safety procedures when assembling • Cut power, use First Aid, call 911, put out fire • Losing a team member • Be such a good team that nobody wants to leave • Divide the work among the remaining members, seek assistance from colleagues

  27. Summary • Problem: Replace the current power supplies with a single versatile tool • Approach: Consider several different alternatives by which multiple voltages can be provided simultaneously by a single power supply • Solution: Provide two plus/ground terminals and two plus/minus/ground terminals whose voltage can be set independently of the others. Also provide meters to display the voltage, current, and wattage of the selected set of terminals

  28. What questions do you have?

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