DC-AC Power Inverter

Design II, Spring 2004 Midterm Presentation

Team Members

Daniel Martin

Min-Chiat Wee
Team Leader

Faculty Advisor Dr. Yaroslav Koshka Dustin Bailey

Industrial Advisor: Dr. Mark Kinsler

Jason Horner

Abstract
Design a switch-mode power supply that converts 12 VDC to 120 VAC Pure sinusoidal waveform with 60 Hz frequency 300 W continuous output

Problem Statement
Problems:
Inexpensive inverters are very inefficient due to a high harmonic content of the output signal Pure sine wave inverters have a high cost per watt ratio

Solution:
An inexpensive inverter that produces a near perfect sine wave output

Design Constraints
Name
Voltage Power Efficiency Waveform Total Harmonic Distortion Physical Dimensions Cost

Description
Convert 12VDC to 120 VAC Provide 300 W continuous > 90% efficiency Pure 60 Hz sinusoidal < 5% THD 8 x 4.75 x 2.5 $175.00

Main Components
12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

PWM Control Circuit

12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

PWM Controller
Produces two complementary pulses to control half-bridge transistors Problem:
Voltage dropped less than 170VDC when the input voltage was decreased

Solution:
A feedback network was added for voltage regulation

PWM Oscilloscope Waveform

Prototype Device as Built

Half-bridge Converter
12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

Half-bridge Converter
Chops the 12 VDC to produce a 12 V, 100 kHz, square pulse Problem:
IRF740A MOSFETs has an Rds(on) = 0.55, resulting in high power losses.

Solution:
Chose IRF530 MOSFETs with an Rds(on) = 0.16

Half-bridge Oscilloscope Readings

Prototype
Device As Built

Transformer
12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

Step Up Transformer
Steps up voltage from 12 VAC to 340 VAC Problem:
Initial transformer had high internal capacitance leading to failure of device

Solution:
Custom ordered a transformer to fit our design constraints

DC-DC Converter Schematic

DC-DC Converter Testing

Simulation Device As Built

Sinusoidal PWM Controller

12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

Sinusoidal PWM Circuit

Last Semester:
PIC18F452 too many unused ports Insufficient dead-time in PIC program caused crossconduction in full-bridge inverter

This Semester:
Chose PIC18F252 fewer unused ports Programmed 500ns between each control pulse

Software Flow Diagram

Initialize all variables no Count0 = 300 (300 duty cycles) Output 1 = high, Output 2 = low Read duty cycle table (increment pointer) Duty cycle and sampling period timer no no Output 1 = low, Output 2 = high Decrement Count0 by 1 yes 300 duty cycle values? yes

Has duty cycle been reached?

yes

One Sampling Period?

Sinusoidal PWM Drive Pulses

Simulation Device As Built

Full-bridge Inverter
12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

Full-bridge Inverter
Converts 170 VDC to a 120 Vrms, 60 Hz, sine wave

IRF740A MOSFETs
Vdss = 400 V Id = 10 A Rds(on) = 0.55

Simulation vs. Actual (unfiltered)

Simulation Device As Built

Frequency Spectrum Before Filtering

Simulation
60 Hz 18 kHz

Device As Built
60 Hz

18 kHz

Low-pass Filter
12 VDC Input (from vehicle battery)

PWM Control Circuit

Half-bridge Converter

Transformer

Low-pass Filter
120 VAC, 60 Hz, 300 W Output

Full-bridge Inverter

Sinusoidal PWM Controller

Low-pass Filter
2nd order L-C filter
Filters to retain a 60 Hz fundamental frequency Few components Handle current Wind inductor (fine tune)

DC-AC Full-bridge Inverter Schematic

Final Output Testing

Simulation Prototype

Frequency Spectrum After Filtering

Simulation Device As Built

Component Costs
Item
PIC18F252 transformer driver inductor capacitor inductor MC34025 MOSFET capacitor MOSFET 40 MHz oscillator diode capacitor capacitor Misc. capacitor resistor diode

Quantity
1 1 2 1 1 1 1 2 1 2 1 5 2 5 x 2 1 1

(per unit 10,000)

$2.66 $2.20 $1.80 $1.71 $1.59 $1.59 $1.40 $1.17 $1.17 $0.79 $0.70 $0.33 $0.20 $0.11 $17.81 $0.10 $0.02 $0.02

Price
$2.66 $2.20 $3.60 $1.71 $1.59 $1.59 $1.40 $2.34 $1.17 $1.58 $0.70 $1.65 $0.40 $0.55 $17.81 $0.20 $0.02 $0.02

Total

$41.19

PCB Layout

Dimensions: 7.5 x 6.5 x 2.5

Packaging

Status and Goals

Continue working with PCB Fine tune filter Improve packaged appearance Attempt to further reduce costs

Acknowledgements
Dr. Yaraslov Koshka Dr. Mark Kinsler Dr. Mike Mazzola Dr. Raymond Winton Dr. Herb Ginn Jim Gafford Robin Kelley Len Cox Jessie Thomas

Any Questions?

???