GUJARAT TECHNOLOGICAL

UNIVERSITY
(GTU)

Vishwakarma
Government
Engineering
College
affiliated with GTU

A
Project Report on

Power Supply Unit

prepared as a part of the requirements for the subject of

DESIGN ENGINEERING II B
B. E. III, Semester VI
(Power Electronics Branch)
Submitted By :Group: 12

Sr. No.
1.
2.
3.
4.

Name of students

Enrolment no.

LINSON LAZAR
MEET PIYUSHBHAI PATEL
RISHABH AGARWAL
SOUMENDU S CHATTERJEE

130170124030
130170124031
130170124052
130170124056

Anwarul M. Haque
(Faculty Guide)

Vipul G Patel
Head of the Department
Academic year

(2016-2017)

CERTIFICATE
This is to certify that the Design Engineering 2B (2160001) report
entitled Power Supply Unit submitted by Linson Lazar (030), Meet
Patel (031), Rishabh Agarwal (052) & Soumendu Chatterjee (056)
towards the partial fulfillment in Design Engineering 2B (Power
Electronics Engineering) of Gujarat Technological University is the
record of the work carried out by him under our supervision and
guidance. The work submitted has in our opinion reached a level
required for being accepted for examination. The results embodied
in this Project Work to the best of our knowledge have not been
submitted to any other university or diploma.
Date: 13/04/2016

Guided by:
Prof. Anwarul M. Haque
Assistant Professor
Department of Power Electronics Engineering
Vishwakarma Government Engineering College,
Chandkheda - 382424

Head of Department
Prof. Vipul G. Patel
Department of Power Electronics Engineering
Vishwakarma Government Engineering
College,
Chandkheda 382424

1. Introduction to concept/ idea

About team members:In our team four persons (1) Linson Lazar (2) Meet Patel (3) Rishabh Agarwal (4)
Soumendu Chatterjee
Guide and Mentors :-

Prof Anwarul M. Haque

He received his B.E (Power Electronics) from Lukhdhirji Engineering College, Morbi, Gujarat,
India in 1989 and M. Tech (Electrical) from Manav Bharti University, Solan, Himanchal Pradesh
(HP) in 2012. He is pursuing his PhD (Electrical Engineering & Technology) from Jodhpur
National University, Jodhpur, Rajasthan since July 2012. He is involved in design engineering since
last two years and presently guide all the students of power electronics for DE-1A, 1B, 2A & 2B.

Initial Idea about Design Thinking:

Design thinking is a problem solving methodology that helps students, faculty members
and innovators to approach todays problems from a new perspective and methodology.
This multi-disciplinary process involves the involvement of users at an early stage and
rapidly leads towards the prototype. This thinking process will provide practical experience
in approaching problems with this innovative methodology. Students will learn key Design
Thinking concepts and then get to apply these concepts working with companies on real
examples.

As discussed among team member after having introductory session on Design Thinking,
we team members, after a long discussion, decided to choose a domain for design process.
The domain is Power Supply Unit by which we can solve certain Power Electronics sector
problems.

Relation of Design Thinking according to academic Point of view

Think out of the box

Design thinking process is interesting

Team work

Find the problems technologically

Solutions keeping Energy Conservation in mind.

Phase 1
Evaluation of Idea
Observation Record sheets (AEIOU Framework)
AEIOU stands for
A Activity
Activity means the users specific activity that user performs on day-to-day or daily basis. Our
project have users that are interested in our project and have their wishes fulfilled through our
product.
E Environment
Environment means the situation surrounding our product that may or may not affect
directly/indirectly our project. Humid conditions are always not reliable for electrical and
electronics products and results in failure of product, and results in reduced lifetime.
I Interaction
Interaction means the users interaction with our product, validate it and give feedback to us.
O Observation
Observation means the summary or overview of the product that we are going to launch.
Analyzing it from every angle and from users point of view is necessary.
U User
Users are the prime concern. Without them, our product will be useless.

Empathy Mapping /framework

Domain area or pre requisite we start with empathy campus is Power Electronics.

Deciding Users (including Selected User) and stakeholders

-

Power Electronics Design Engineer (Selected User)

Power Electronics Based Factories
Test and Measurement Based Factories
Mobile/Smartphone Industry techies

Activities of the user and stakeholder

Test the product before bulk production and suggest different methods to improve the
damages caused while production

Re-testing the product till no damages found and then suggesting the production team for
a bulk production of the product

Checking for damages in the machine used during the product production and repairing
them before starting a bulk production

Planning different designs and discussing them with the management team for launching a
new product

Report latest technologies and new methods used in the product development to the
product planning team and implement them to improve the product

Check the product quality after first round of test production and bulk production

Maintain a shift register of the team and report the team members of their weekly shifts.

Stories
Sad Story 1 :Once we were making project on BCD counter using IC4510 and the rated supply voltage was 9V.
But due to certain conditions it was not enough for the circuit to run and we were trying different
configurations, but they didnt work too and submissions got delayed. The power supply was not
reliable. And we ended up buying the components again which increased the cost of our project.
Happy Story 1 :We used power supply unit as a backup for speed control of small dc motor. Everything was
running fine until the power supply got cut off. But luckily we had our power supply unit which
gave constant supply to our small dc motor till the supply was resumed.

Conclusion
From this canvas we concluded the following things
-

The domain power electronics have variety of applications.

Empathy is understanding users feelings, their needs, their requirements and come out
to solve the problems they face in uniform manner.
Without users and stakeholders our project is of no use. If there is no user, nobody will
use our product which will result in loss of our profit and work.

Ideation Canvas /framework

Deciding People :- This section is for the people with whom we are going to test our product
and we will note their experience and will try to analyze and evaluate afterwards.
-

Power Electronics Design Engineers

Power Control Manager
Commodity Purchase Manager
Product Manager
System Test Engineer

Activities
System Test Engineer/Power Control Manager

Test the product before bulk production and suggest different methods to improve the
damages caused while production

Re-testing the product till no damages found and then suggesting the production team for
a bulk production of the product

Checking for damages in the machine used during the product production and repairing
them before starting a bulk production

Check the product quality after first round of test production and bulk production

Power Electronics Design Engineer/Product Manager/Commodity purchase Manager

Planning different designs and discussing them with the management team for launching a
new product

Report latest technologies and new methods used in the product development to the
product planning team and implement them to improve the product

Situation locations and contexts

Defining situation/context/location in ideation canvas. The users are to be relate with the in what
situation and at what
location they are working. This will relate more to the users activities. We got some ideas about
the situations the users are related.
-

Voltage level fluctuation conditions of product

Hot and Humid Conditions under which product has to operate
Time to Market and NRE cost considerations
Moulding the Product according to latest technology
Using Test and measurement machines having higher bandwidth
Pressure of creating bulk products of good quality

Props :- Finding the props of the users working in such situation at certain locations will be
clicking to some possible solutions those are existing or want some technological changes.
-

Integrated Circuits
Connectors
Basic circuit elements like resistors, capacitors, inductors
Printed Circuit Board
Indicators
Semiconductor Switches

Iterations
Various Iterations have been tried with various users and the situations under which they have to
work.
Example
1) A design Engineer while designing has to incorporate changes to nullify hot and humid
conditions

2) While Designing, Product has to be capable of handling various voltage fluctuations, either
due to faulty supply to product or due to changes in load side.
3) Design engineers has to continuously kept evolving the product to reduce the power losses
and keeping in pace with market innovations and latest technologies.
4) Test Engineers have to use high bandwidth machines while testing and they have to keep
track of range of frequencies a product can produce, otherwise their test results wont be
applicable and will be faulty.
5) Test Managers also have to maintain the quality of product for bulk production while
reducing the time to produce, otherwise the company wont be able to completely harness
the market potential.
Based on these iterations following problems have been identified
1)
2)
3)
4)

Humidity and environmental conditions greatly affect the design of product.

Environmental conditions causes design cost to increase and delays the product launch.
Faulty distribution lines available with the user can cause product to fail.
In absence of basic template available designers have to redesign the product after
every few months.
5) To reduce the power losses designers rethink the product after few months.
6) High Bandwidth machines are required for testing.
7) Products range of highest order harmonics have to be taken care of, otherwise it will be
difficult to test and new machines have to be bought.
8) While bulk production, unit cost has to be kept low while balancing other factors, to
have competitive edge.
9) Quality of bulk product is important and it has to be taken care of.
10)
Continuous testing of all machines is required at various stages of production and
designing, from planning to bulk production, so high quality T&M equipments are
required

Product Development Canvas /framework

Purpose :- It states the purpose of our project. That is, what we are actually meant to do and
what we will be capable of providing features to customers. The major purposes of this project are
-

To provide uninterruptible power supply with various voltage levels.

Reduce heating effects
Reducing losses
Power Factor improvement
24x7 support

People :- People are required to use our product, test it and give feedback to us. For our project
we decided to let these people have our products first hand experience.
-

Power Electronics Design Engineers

Computer Users
Power Electronics Based Factories
Test and Measurement Based Factories

Product Experience :- It means that what experience users will have once the product launches
into the market. It includes
-

User Friendly Support

Comfortability and Convenience
Low Power Consumption
Automatic Control

Product Features :- The features that are being provided in Power Supply Unit. They are

Mobility
Compactness
Different Indications
Short Circuit Protection
Overload Protection
Closed Loop Control with filters

Product Functions :- Functions states the functions to be performed by Power Supply Unit in
order to achieve maximum reliability and ease of use. The Product Functions are as follows
-

It will warn about any incoming warnings through indicators

It will try to reduce the power consumption as low as possible
It may have digital data display system

Components :- The components used in Power Supply Unit are listed here. They are as follows
-

DPA424 IC
Zener Diode TL430
HPCL817A optocoupler
Basic circuit elements (resistors, capacitors and inductors)

Customer Revalidation :Customers are our prime concern. They will use our product only if it satisfies all their needs and
requirements. We need to cover all the customers interests in order to sell our product efficiently
and effectively. One of our customers was happy with our product as it fulfilled most of his
requirements. He required this for domestic/general use. We continued to validate our product
with him and h reported certain negligible instability in our product. When tested with
oscilloscope it was giving irregular (but negligible) waveshapes at certain period. We looked into
that matter and found that disturbing element that was causing this instability. We replaced that
component with appropriate value and the system started to work normally again.
Reject, Redesign, Retain :Redesign-

Digital filters should be used

Digital Display should be included

Retain-

Closed loop Control

Overload Protection
Short circuit Protection
Different Voltage Level Outputs
Isolation Between Input and Output Side
Various Test Points in PCB

Customer Validation with customer

Customers are our prime concern. They will use our product only if it satisfies all their needs and
requirements. We need to cover all the customers interests in order to sell our product efficiently
and effectively. One of our customers was happy with our product as it fulfilled most of his
requirements. He required this for domestic/general use. We continued to validate our product
with him and h reported certain negligible instability in our product. When tested with
oscilloscope it was giving irregular (but negligible) waveshapes at certain period. We looked into
that matter and found that disturbing element that was causing this instability. We replaced that
component with appropriate value and the system started to work normally again.

Product solution with its functions, features and components.

We analyzed our product from every angle and included features and functions that customer
demanded. Weve included the warning system about any incoming warnings through indicators.
Weve tried to reduce the power consumption by using quality components and design has also
been taken care of. Including digital display is nowadays required to have accurate control over
device.
-

Mobility
Compactness
Different Indications
Short Circuit Protection
Overload Protection
Closed Loop Control with filters

Redesigned features and components

Digital filters - A digital filter is a system that performs mathematical operations on a sampled,
discrete-time signal to reduce or enhance certain aspects of that signal. A digital filter system
usually consists of an analog-to-digital converter to sample the input signal, followed by a
microprocessor and some peripheral components such as memory to store data and filter
coefficients etc.
Digital Display - A display device is an output device for presentation of information in visual or tactile form.
Examples of digital displays are LCD, Plasma, Segment displays, etc

Final product solution

The final product solution includes the appropriate value of circuit elements and providing
accurate closed loop control with proper feedback system which will result in reliable and
optimized system (Power Supply Unit).

Phase: 2
1) Material Requirement

Printed Circuit Board with FR4 masking. Size= 2 x 3

DPA424 switch
HCPL317 optocoupler ic
TL431 zener diode
Capacitors, resistors, diodes and LEDs

2) Manufacturing Process-

The power supply unit can be thought of as to be divided into four sections. These
sections are shown as blocks in the above generalized block diagram of power supply
unit. The input filter, the power modulator & isolation, the output filter and control section
are the four sections that form the main structure of power supply unit.
The input filter filters out the AC components from input supply and fulfills transient
requirements of power supply. The power switch and isolation circuit chops the DC
voltage
according to control signal generated by control circuit and transfers the energy at the
secondary of transformer. Output available from transformer is rectified, filtered and
made available as output to load circuit. The output filter also sends a feedback to the
control section of the unit which can either be a microcontroller or arduino controller etc
by means of an optocoupler.

3) Design Specifications

Input Voltage= 24V DC 20%

Output Voltage= +15V/-12V or 12V or 9V (As required)
Efficiency 80%
Regulation (Line and Load)= 5%
Overload capacity= 20%

4) Future Advancements

Gate Driver unit For Thyristors

Frequency Measurement Unit

5) Learning Needs Matrix

PSU is based on theory of closed loop control of output voltage and thus provides
stable load voltage.
Various Mathematical requirements are there for this product like Transfer Function
solution and state matrix.
Multisim Ultiboard is required for simulation of schematic and pcb designing.
Various Applications of this product are1) Motor Speed Control
2) Measurement Devices/Oscilloscope
3) Other Common Applications

6) Challenges faced while implementing the unit

Electrical faults
Overload demands

Bottom Layer

Top Layer

Schematic Diagram
Component Values
C2
C3
Co3
Cin
CSF1
Ccross
C1
Co2
Co5
C1A
C4
C5
C6
C7
Co1
Co4

0.1u
0.1u
0.1u
0.1u
0.1u
0.1u
10u
10u
10u
10u
470p
100p
2.7n
220n
220u
220u

Cf
Cf1
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11

1u/50V
47u
Shorted
250k

Rl1
Rl2

2.2k
2.2k

Pot

5k

Din
D1
D2
D4
D5

1N4007
Fr104/106
Fr104/106
Fr104/106
Fr104/106

TVS1

MCV681K05DS

LED1
LED2

Red
Green

Opto

HCPL817A

ZENER

TL431ILPR

DPA SWITCH

DPA 424

Connectors

Screw Terminals

22e
100/110
62.3
5.9
1k
51k
15k

Conclusion :
The final product solution includes the appropriate value of circuit elements and providing
accurate closed loop control with proper feedback system which will result in reliable and
optimized system (Power Supply Unit).