Windmill Based UPS

CHAPTER-1

INTRODUCTION
The Windmill Based UPS, project is an advanced system for generating Uninterruptible Power Supply for feeding the electrical appliances like fan, TV, fridge etc.. This completely hardware based system provides the power supply by converting the wind energy into electrical energy using battery, transformer, controller, rectifier charger circuit, comparator circuit, etc.. Moving air is called wind and it possesses Kinetic energy. In the earlier days, it was utilized by man in winnowing to remove husk from grains, in propelling sail boats in rivers and seas for transport purposes. But nowadays this wind energy is used to produce electricity.

1.1.1 The Principle of Windmill

When the blowing wind strikes across the blades of a windmill, it exerts a force on them due to which the blades of the windmill start rotating. This in turn rotates the shaft of the turbine and generates electricity.

Fig 1.1: Wind Turbine

1.1.2 Working of the Windmill

Wind turbines are used to produce electricity. The machines that generate electricity are the most conventional type with airfoil propeller employing two to three tapered blades. Electricity can be produced by rotating an armature in between the poles of a strong magnet. The shaft of the armature of a generator is connected to the wind turbine by a connecting rod. When the wind rotates the blades of the wind turbine, the shaft rotates, and this in turn rotates the armature, thereby producing electricity.

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1.1.3 Limitations of Wind Energy

Even though wind energy is available in plenty, wind is not available at all times. It is unpredictable and not dependable. Hence to produce maximum amount of energy from wind, wind energy maps are prepared, which give us an idea of the average wind speed throughout the year at different places. The maps give annual average, average for January (a typical low wind month) and an average for July (a typical windy month). The maps also provide information about energy available in one square meter of a wind stream at about 10 m high above the ground level.

For large scale production, a 'wind farm' with a hundred or more wind turbines is needed. The turbines must be sited in windy areas which are often the most attractive parts of the landscape. The energy output of each windmill in a farm is coupled together to get electricity on a commercial scale. The wind power potential of our country is estimated to be about 45,000 MW. At present we are able to generate 380 MW of electricity from the largest wind energy farm established near Kanyakumari in Tamil Nadu. India ranks fifth in harnessing wind energy for the production of electricity.

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CHAPTER-2

BLOCK DIAGRAM & DESCRIPTION

Fig 2.1: Block diagram of windmill based UPS

2.1 BLOCK DIAGRAM DESCRIPTION

2.1.1 DYNAMO It converts mechanical energy into electrical energy. 2.1.2 RECTIFIER It converts AC to pulsating DC output. 2.1.3 REGULATOR It accepts an unregulated supply voltage and produces a stable DC output voltage. 2.1.4 INVERTER An inverter is an electrical device that converts direct current (DC) to alternating current (AC), the converted AC can be at any required voltage and frequency with the use of appropriate transformers, switching, and control circuits.

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Windmill Based UPS 2.1.5 BATTERY Battery is used to store the charge of a particular range. In our project, we use battery of 24V.When the load is running on AC mains, the battery is getting charged simultaneously via the charger unit. 2.1.6 AC DETECTOR The AC voltage detector is a device that uses electric fields to see if there is an electric current in a desired circuit. If there is current in the system, the load will be powered directly from the mains since AC detector will cut-off the battery supply to the PWM unit. 2.1.7 PWM UNIT The Pulse Width Modulating (PWM) unit is used to convert the DC voltage by pulse width modulating the signal. Then the PWM unit will convert this DC voltage to AC voltage by pulse width modulating the signal. The output of the PWM unit is fed to the power driver unit. 2.1.8 POWER DRIVER UNIT The power driver unit contains MOSFET devices having rating 24V, 20-80Amp. It drives the current of different ratings for the different applications. 2.1.9 CHANGEOVER UNIT The changeover unit will switch the load from inverter supply to AC supply or AC supply to inverter supply depending upon the input from the AC detector. When the mains supply fails, the load is shifted to the inverter supply.

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CHAPER-3

HARDWARE DETAILS
3.1 CIRCUIT DIAGRAM & DESCRIPTION

Fig 3.1 Circuit diagram of fixed power supply Power supply circuit consists of 1. 2. 3. 4. Half wave rectifier with capacitor filter Regulator IC7805 Half wave rectifier consists of diodes D1 and D2 as shown in figure Step down transformer

The Power supply section consists of step down transformer of 230V ac primary to 9V/750Ma, 9V/500Ma ac and 12V/1A ac respectively. A center tapped with a capacitor filter. The function of transformer is to avoid shocks from mains and provide isolation. The output of secondary of the transformer is rectified by passing it through center tapped rectifier consisting of two diodes IN4007. The output of the rectifier is a pulsating DC. The pulsating dc is passed through a capacitor filter of 1000F to remove pulsation. The output of capacitor filter is unregulated dc supply. A DC power supply system, which maintains constant voltage irrespective of fluctuations in the main supply or variation in the load, is known as Regulated power supply. The 7805 IC referred to fixed positive voltage regulator, which provides fixed voltage 5 volts. The 7805 regulator is known as fixed voltage regulator.

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Windmill Based UPS Fixed voltage regulator design has been greatly simplified by the introduction of 3 terminal regulator ICs such as the 78XX series of positive regulators and the 79XX series of negative regulators, which incorporate features such as built-in fold back current limiting and thermal protection, etc. these ICs are available with a variety of current and output voltages ratings, as indicated by the xxx suffix; current ratings are indicated by the first part of the suffix and the voltage ratings by the last two parts of the suffix. Thus, a 7805 device gives a 5V positive output at a 1mA rating, and a 79L15 device gives a 15V negative output at a 100mA rating. 3-terminal regulators are very easy to use. The regulators ICs typically give about 60dB of ripple rejection, so 1V of input ripple appears as a mere 1mA of ripple on the regulated output. A rectifier filter and unregulated DC voltage is given to pin of IC regulator. A bypass capacitor is connected between input and ground to bypass the ripples and oscillations. The output capacitor is connected between output and ground to improve transient response. The unregulated input is applied to the IC must be always more than regulated output. The regulation is achieved by using regulator IC LM7805 as shown in the figure. The unregulated supply voltage is given at input (pin 1) (pin 2 is grounded) & regulated supply is taken across the output.

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3.2 CIRCUIT DIAGRAM OF VARIABLE POWER SUPPLY

Fig 4.1 Variable power supply circuit diagram

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3.3 COMPARATOR CIRCUIT

Operational Amplifier: Designed originally for analogue computer and control applications, the operational amplifier has found its way into almost every field of electronics. Todays Integrated Circuit Op-Amps offer many advantages over their discrete component predecessors. Circuit design is greatly simplified with the added bonus that the characteristics of the latest generation of Op-Amps, far exceed those of their predecessors. An Op-amp is a direct coupled high gain amplifier, usually consisting of one or more differential amplifiers and usually followed by a level translator and an output stage. Output stage is generally a push-pull or push-pull complementary symmetry pair. An Op-amp is available as single IC package. The maximum common mode voltage that can be applied to an Op-amp without disturbing its proper function is of the order +13 V or 13 V. The desirable characteristics of an Op-Amps are: the open-loop voltage gain should be very high (ideally infinity); the input resistance should be very high (ideally infinity), the output resistance should be very low (ideally zero); full power bandwidth should be as wide as possible; slew rate and CMRR should be as large as possible; and input offset should be as small as possible. The considerable parameters while choosing any Op-Amps are I/P off-set voltage (Vio) :It is the voltage that must be applied between the two input terminals of an op-amp to verify the output to be null. I/P off-set current (Iio): The algebraic difference between the current into the inverting and non inverting terminal is reffered as input Off-set current.

CMRR(Common Mode Rejection Ratio ):The CMRR is defined as the ratio of differential voltage gain Ad to the common voltage gain Acm , i.e., CMRR = Ad / Acm . The higher the value of CMRR ,better is the matching between two input terminals and smaller is the output common mode voltage .

POWER DRIVING CIRCUITS: In many applications, a relay will require some form of interface to the circuit to which it is connected. Often such an interface need consist of nothing more than a single transistor. Almost any n-p-n transistor with a current gain of 50 or more can be used in the circuit. However, it is important to ensure that it is operated within its maximum collector current (IC(max)) rating. The coil resistance of relay and preferred transistors are as follows: 50 ohm to 200 ohm - T1P31 (or equivalent), 200 Ohm to 400 Ohm Department of Instrumentation Technology, PDIT 8

Windmill Based UPS - BC142 (or equivalent), 400 Ohm to 1.2 K Ohm - BC108 (or equivalent). The circuit requires an input current of about 0.5mA when operated from a 5V source. In some applications it may be desirable to increase the sensitivity of the circuit, in which case a Darlington driver stage can be used. A Darlington driver based on two (discrete) n-p-n devices requires a current of only a mere 40A at 5V in order to operate the relay. This circuit can be used with relays having coil resistance as low as about 200 ohm and will also operate reliable with an input current of as little as 40A.

OPTO-COUPLER IC MCT 2E: Buffers does not affect the logical state of a digital signal (i.e. logic 1 input results into logic 1 output where as logic 0 input results into logic 0 output). Buffers are normally used to provide extra current drive at the output are used in interfacing applications. This 6-pin DIL packaged IC MCT 2E acts as Buffer as-well-as Isolator. The input signals may be of 2.5 to 5V digital TTL compatible or DC analogue the IC gives 5V constant signal output. The IC acts as isolator and provides isolation to the main circuit from varying input signals. The working voltage of IC is fed at pin-5 and input to pin-1. The pin-2 is ground and pin-4 is output. Note that pin-3 and pin-4 are not available pins, which must be left free. And the isolated circuit must have its own ground connection. The Opto-coupler IC has a photo diode which illuminates whenever input signal appears at pin-1. A photo transistor, whose Base-lead open, receives the signal from the blinking photo diode and passes it intact to the output pin-4. As this switching action is very fast, in term of micro seconds, the signal transfer is successfully done without any delay and signal loss. As there is any physical contact between photo diode and photo transistor is observed, it is used for isolating two sections of the circuit. Especially the delicate digital circuits or signal sensitive stages whose output is supposed to drive a fluctuating stage or mains operated load. Since the digital outputs of the some circuits cannot sink much current, they are not capable of driving relays directly. So, high-voltage high-current Darlington arrays are added to this opto-coupler IC for interfacing low-level logic circuitry and peripheral power loads. Typical loads include relays, solenoids, stepping motors, magnetic print hammers, multiplexed LED and incandescent displays, and heaters.

4.1 Comparator circuit

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Fig. 4.1 Comparator circuit

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Parts List:
SEMICONDUCTORS IC1 [A1-A2-A3] IC2 RESISTORS R1 to R4 & R13 R5 R6 R7 to R10 R11 R12 R14 R15 P1 & P2 MISCELLANEOUS TR1 D1& D6 D2 to D5 RL1-R L6 BC547 NPN Transistor 1N4148 SIGNAL Diodes Red Indicator LEDs 12 V, 700 Ohm DPDT Reed Relays 6 2 4 6 1 K Ohm, Watt, Carbon Type 10 K Ohm, Watt, Carbon Type 470 Ohm, Watt, Carbon Type 1 Mega Ohm, Watt, Carbon Type 2.7 Mega Ohm, Watt, Carbon Type 100 Ohm, Watt, Carbon Type 33 K Ohm, Watt, Carbon Type 500 K Ohm, Preset 5 2 3 1 1 1 1 2 LM324 Op-Amp MCT 2E Opto-coupler 1 3

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Windmill Based UPS Circuit Description: This simple comparator circuit can be used to compare four resistance ranges applied across its input. Used with care, this instrument also allows testing diodes, LEDs and electrolytic capacitors. The circuit diagram shows that three operational amplifiers compare the drop across the test leads to a fixed voltage and indicate which of the two is highest by switching their output to the positive supply level or ground see the accompanying table. VLO A1 A2 A3 LED Relay 0 0 0 D2 RL1 LO 1 0 0 D3 RL2 HO 1 1 0 D4 RL3 VHO 1 1 1 D5 -------

The Comparator compares the inputted resistance value with the reference value set by the user using presets P1 & P2. According to the result, whether inputted resistance is low or high, respective LED glows. The Comparator output is fed to Opto-coupler stage, which is used where the main circuit is supposed to isolate itself from the mains operated loads. The control signal is applied at input pin-1 and at pin-4 output is observed. Thus the Comparator circuit is isolated from this load driver circuit. But this signal level is not strong enough to drive the low impedance relay. So, Darlington driver is created using two NPN transistors and boost the signal level. The output signal from the Darlington driver stage is strong enough to actuate relays [RL1, RL2 & RL3]. These relays can be used to switch ON/OFF any mains operated load. The red LEDs [D2, D3 & D4] indicates the relay position, whether load is ON or OFF. The resistors R13, R14 and R15 are current limiting resistors. The ranges of indicator LEDs D1 and D2 are adjusted with P1 and P2. Clip the test leads to a 5 resistor, and adjust P1 so that D1 just goes out and D2 just lights. Similarly, use a 100k resistor for adjusting P2 until D3 and D4 just go out and light respectively. NOTE: It is recommended to decouple R11 with a 22F electrolytic capacitor when the supply voltage is relatively low.

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Windmill Based UPS

3.4 PWM GENERATOR & DRIVER

PULSE WIDTH MODUALTOR IC SG3524N: The SG3524 is an industry standard regulating pulse width modulator that contains all the functions required for the construction of regulating power supplies, inverters or switching regulators in single ended or push/pull applications. It is Dual-In-Line Packaged, 16-pin IC with Vcc at pin-16 and ground at pin-8. The maximum supply voltage tolerable is up to 40 Volts with maximum operating frequency limit of 300 Kilo Hertz. It consumes only 8mA of current during the standby mode.

PWM Generator & Driver: Whereas most electronic equipment may contain its own regulated dc power supply, many industrial electric generators require voltage regulators; likewise the speed of dc motors may be regulated by electronic controls. The speed of a dc motor is controlled through a wide range by changing both the armature voltage and the field voltage. When the armature is connected across the largest voltage that the motor is designed to receive continuously (called its rate voltage) and the field current is also at its largest or rated amount, the fully loaded motor runs at a medium speed, called its base speed. Instead of operating from a d.c. generator, a variable-speed dc motor may receive power from an a.c. feeder or d.c. generator and driver; these are arranged so as to change the alternating voltage into a direct voltage suitable for the d.c. motor. A dc generator produces electric power if it is driven by some engine or motor [instead of using electric power and driving a load, as in ac generator]. When the generator is being driven at the required speed, it produces no voltage or electric power unless direct current flows in its filed winding. When there is filed current and the generator forces current through a load, much greater power is required from the driving engine. The produced voltage increases when the generator is driven faster and also increase when the field current is increased.

3.4.1Circuit Diagram of PWM Generator and Driver

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Windmill Based UPS

Fig 3.4.1 PWM generator and driver circuit

PARTS LIST

SEMICONDUCTORS IC1 R1,R2 & R8,R9 R3 R4 TO R7 P1 P2 SG 3524 2.2 K Ohm Watt 120 K Ohm Watt 4.7 K Ohm Watt 10 K Ohm Preset 47 K Ohm Preset 1 4 1 4 1 1

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Windmill Based UPS Circuit Description: This circuit is specially meant for producing control signals for the stepper motors. The heart of this circuit is SG 3524 industry standard pulse width modulator and generator IC. The IC is configured for the required pulse width using proper valued resistors and capacitors across the pins. The working voltage +Vcc is connected at pin-15 and grounded at pin-8. The biased voltage present at input pin-2[internally Non-inverting input of Error Amp] is adjusted to get the error free pulses at the output pins 11 and 14. These two outputs are usually given to push-pull circuit designed by two transistors with a step-up transformer. The output of the transformer secondary is given to the stepper motor whose speed or direction is to be changed. The width of the pulses generated by this design is varying by adjusting the value of preset P1 connected at pin-6 [internally RT time-period pin of Oscillator] with the capacitor connected at pin-7 [internally CT pin of Oscillator]. It is not necessary that all pins of this IC1 should be used to design the desired circuit. So not-required pins are either pulled-up to high or make it ground.

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Windmill Based UPS

3.5 HIGH-LOW VOLTAGE CUTOUT CIRCUIT

The power supply available everywhere is subjected to variations such as black-out, brown-out, surges, spikes, harmonic distortions and frequency variations. Voltage variations and power cuts adversely affect various equipments such as inductive loads [such as fan, motors etc], TV, VCR, music system and refrigerators. To protect the costly equipment from high as well as low voltages and the voltage surges (when power resumes) there is need for cut-out circuit. Although there are Un-interrupted Power-supplys for voltage fluctuations and inverters for black-out are available in the market. But the equipments like TV, VCR, Music systems seldom need such costly equipments to guard them. So the simple circuits were designed which take care of high and low voltage variations in the mains supply. Such circuits basically have three sections: power supply section which supplies working voltage to the circuit, sensing section senses the voltage variations [here zener diodes with suitable voltage rating are used] and alerts the switching stage. The switching section switches the load by energizing relay. Separate relays are employed for under voltage and Over voltage cut-off. The relays output are connected to the load such that is should cut-off itself whenever any one of the two states is detected [i.e., either under / Over voltage].

3.5.1 Circuit Diagram of High-Low Voltage Cutout

Fig 3.5.1 High-Low voltage cutout circuit diagram

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Windmill Based UPS SEMICONDUCTORS TR1 & Tr2 Z1 to Z2 D1 D2 & D3 R1 & R2 P1 & P2 C1 MISCELLANEOUS RL1 & RL2 X1 450 Ohm, 12 V DPDT Relay 230V AC Pri,0 -24V 1Amp Sec Transformer 2 1 SL100 NPN TRANSISTOR 15 Volts Zener Diode BY 127 Rectifier Diode 1N4148 Signal Diode 4.7 K Ohm Watt 10 K Ohm Preset 470 f/25V Electrolytic 2 2 1 2 2 1 1

Circuit Description: The working function of this Under/Over voltage cutout circuit is very simple. X1 is a step-down transformer, primary of which is connected to 220 Volts AC supply. Its secondary is connected to half-wave rectifier comprising diode D1, and the voltage is then smoothed by C1. Next to power supply is a cut-off relay circuit. When the supply voltage is within limits, transistor TR2 is conducting, and TR1 is in cut-off state. Hence relay stays energized. When the voltage is too low, zener Z2 will not break down, and TR2 will not conduct, causing the relay RL2 to de-energize. This adjustment is done by preset P2. When there is a high voltage, zener Z1 breaks down, transistor TR1 conducts, and the relay RL1 energized. This adjustment is done through preset P1. Whenever the voltage moves to abnormal state and presetted limit relays energizes and switch OFF the load. The signal diodes across the relays prevent the back e.m.f produced during the switching action. Note: While connecting the diodes and electrolytic capacitors the polarities must be taken into consideration. The transformers primary winding deals with 230V AC, care should be taken with it.

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Windmill Based UPS

3.6 OPTO-COUPLER
OPTO-COUPLER IC MCT 2E: Buffers does not affect the logical state of a digital signal (i.e. logic 1 input results into logic 1 output where as logic 0 input results into logic 0 output). Buffers are normally used to provide extra current drive at the output are used in interfacing applications. This 6-pin DIL packaged IC MCT 2E acts as Buffer as-well-as Isolator. The input signals may be of 2.5 to 5V digital TTL compatible or DC analogue the IC gives 5V constant signal output. The IC acts as isolator and provides isolation to the main circuit from varying input signals. The working voltage of IC is fed at pin-5 and input to pin-1. The pin-2 is ground and pin-4 is output. Note that pin-3 and pin-4 are not available pins, which must be left free. And the isolated circuit must have its own ground connection. The Opto-coupler IC has a photo diode which illuminates whenever input signal appears at pin-1. A photo transistor, whose Base-lead open, receives the signal from the blinking photo diode and passes it intact to the output pin-4. As this switching action is very fast, in term of micro seconds, the signal transfer is successfully done without any delay and signal loss. As there is any physical contact between photo diode and photo transistor is observed, it is used for isolating two sections of the circuit. Especially the delicate digital circuits or signal sensitive stages whose output is supposed to drive a fluctuating stage or mains operated load. Since the digital outputs of the some circuits cannot sink much current, they are not capable of driving relays directly. So, high-voltage high-current Darlington arrays are added to this opto-coupler IC for interfacing low-level logic circuitry and peripheral power loads. Typical loads include relays, solenoids, stepping motors, magnetic print hammers, multiplexed LED and incandescent displays, and heaters.

3.6.1 Circuit diagram of Opto coupler

Fig 3.6.1 Opto coupler circuit diagram

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Parts List:
SEMICONDUCTORS IC1 RESISTORS R0 & R1 R2 R3 MISCELLANEOUS D1 TR1 & TR2 RL1 Red Indicator LED BC547 NPN Silicon Transistors 12 V, 700 Ohm DPDT Relay 1 2 1 33 K Ohm, Watt Carbon Type 100 Ohm, Watt Carbon Type 1 K Ohm, Watt Carbon Type 1 1 1 MCT 2E OPTO-ISOLATOR IC 1

Circuit Description: This module is used where the main circuit is supposed to isolate itself from the mains operated loads. The control signal is applied at input pin-1 and at pin-4 output is observed. Thus the signal supplying circuit is isolated from this load driver circuit. But this signal level is not strong enough to drive the low impedance relay. So, Darlington driver is created using two NPN transistors and boost the signal level. The output signal from the Darlington driver stage is strong enough to actuate relay RL1. This relay can be used to switch ON/OFF any mains operated load. The red LED D1 indicates the relay position, whether load is ON or OFF. The resistors R1, R2, R3 and R4 are current limiting resistors.

NOTE: If the load is inductive add a diode across the relay to prevent the back e.m.f produced by quick switching action.

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APPENDIX 1. PRINTED CIRCUIT BOARD:

A printed circuit board is used to avoid most as all disadvantages of conventional breadboards. They are small in size, efficient in performance. The only disadvantage is that once the board is prepared no more changes are possible. It gives all the information on the board. This involves the clear conception and details of the circuit before the actual layout can be alone.

TYPES OF BOARD: The two most popular boards are 1. Single sided boards & 2. Double sided board. The single sided printed circuit boards are widely used for general-purpose application where the cost is to be high and the layout is simple. However the circuit performance is also to be considered in selecting the appropriate board. To jump over a conducting tracks jumper wires are used. If the number of jumper wires the board is more than the double-sided printed circuit boards are preferred. Even in the board the minimum for are liability the cost of double sided printed circuit board without plated through holes is considered through contact are made by soldering the component lead on both side.

PREPERATION OF PRINTED CIRCUIT BOARD: The drawing or art work as is the 1st steps on the preparation of printed circuit board. A perfect drawing overcomes problem like inaccurate registration, broken annual rings and critical spacing. A good method of artwork tabs is of the smallest details. The pads are available in two varieties the self-adhesive and transfer type. Self adhesive pads are supplied sticking on a backing paper .The pad is pulled from the backing pad paper and positioned where required and then slightly pressed. If the position of the pads is to be shifted it can be pulled off again placed in the position required and prepared firmly again. The term transfer pads are pointed on a thin adhesive film. The thin film is mounted on the carrier strip on to the art work by rubbing with a wooden stick on the carrier strip while the pad is exactly positioned on the art work case. The carrier strip can there after be lifted from the art work leaving behind pad.

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Windmill Based UPS To prepare Printed Circuit Board following apparatus are required. 1. Copper Board. 2. Ferric Chloride. 3. Attaching stickers. 4. Drill machine, etc.

To design a Printed circuit board, we have to proceed as follows: Draw the component layouts on a graph paper systematically i.e., for I.C base, place the IC on graph paper and mark it. If more ICs are present draw the other too keeping an adequate gap between the two ICs. Gap should be selected taking into the account of the other components, which also have to be connected. The layout should be such that there must not be jumpers, similarly positive and negative power supply lines should be kept apart sufficient otherwise the two may create capacitance. Also the width of negative line should be thick depending upon the current flowing through it. After completion of drawing layout on graph paper the same drawing should be attached on copper plate by attaching stickers. Then the copper plate should be dropped into ferric chloride solution, till a required copper portion is dissolved. Now ferric chloride becomes greenish from bluish color. If even more time required the plate should be allowed to be in the solution. Now the PCB will be in trace with the attached stickers, now deep the copper plate in the fresh water so that all the impurities left over copper plate are washed out. Now dry the copper plate, wipe with the help of blotting paper and not with cloth. Then remove stickers with help of spirit petrol or nail polish remover. Now we will get the desired layout of the circuit on the printed circuit board, further drilling should be done to provide inspiration of components having more than 5000 rpm. The result will be the printed circuit board ready for connecting circuit.

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