PRODUCT DESIGN & DEVELOPMENT LAB

1. Design of converter for solar applications.

2. Construct a transformer.
3. Design a 1 inverter and modify it to a shunt filter.
4. PCB design.
5. Temperature control of a heater using fuzzy.
6. Sensors for voltage and current measurement (Hall sensors).
7. 3D printing based on ORCAD.
8. DSP based control of DC motor.
9. PIC microcontroller based control of 3 Induction Machine.
10. Fuzzy logic based speed control of DC motor.
 Exp No-1-DESIGN OF CONVERTER FOR SOLAR APPLICATION

Aim

To design converter for solar application using MATLAB

Apparatus Required

MATLAB software

THEORY:

A buck converter (step-down converter) is a DC-to-DC power converter which

steps down voltage (while stepping up current) from its input (supply) to its output
(load). It is a class of switched-mode power supply (SMPS) typically containing at
least two semiconductors (a diode and a transistor, although modern buck
converters frequently replace the diode with a second transistor used for
synchronous rectification) and at least one energy storage element, a capacitor,
inductor, or the two in combination. To reduce voltage ripple, filters made of
capacitors (sometimes in combination with inductors) are normally added to such a
converter's output (load-side filter) and input (supply-side filter)

The basic operation of the buck converter has the current in an inductor controlled
by two switches (usually a transistor and a diode). In the idealised converter, all the
components are considered to be perfect. Specifically, the switch and the diode
have zero voltage drop when on and zero current flow when off and the inductor
has zero series resistance. Further, it is assumed that the input and output voltages
do not change over the course of a cycle (this would imply the output capacitance
as being infinite).

Procedure

Open the MATLAB Software

Go file and enter model, then separate page will be open

Then click view- Library browser

After clicking library browser, many mathematical blocks can be viewed.

 Select the appropriate block and drag to the location to connect the

components.

After connecting all specified blocks insert scope in order to view the output

waveform.

Solar photo voltaic system with converter:

 Fig.1. Open loop model of Buck DC-DC Converter

Buck Converter Modeling

Output Waveform:
Result:

Thus converter was designed for solar application using MATLAB

EXP.No:2- DESIGN OF SINGLE PHASE INVERTER

AIM:

To design a single phase inverter using MATLAB simulink

APPARATUS REQUIRED:

MATLAB simulink software

THEORY:

The power circuit of Single Phase Unipolar inverter consists of four

bidirectional IGBT arranged in bridge form. The circuit diagram consists of
four distinct IGBT such that they are connected as the bridge circuit. The
input to the circuit is the 220v DC supply from the rectifier unit.
The IGBT are triggered accordingly such that the AC output voltage is
obtained at the output. The operation of the circuit is as follows.
First the IGBT S1 and S4 are turned on by triggering the gate of the IGBT .
During this time the input supply is 220v DC and at the output the 220v is
applied across the load. The current starts from the supply positive, S1, S2,
load and to the negative of the supply.
During the next phase or the cycle the IGBT S2 and S3 are turned on by
giving trigger pulse to the gate of the IGBT . During this period the input
voltage is applied at the output but in the negative direction. The current
conduction starts from the supply, S2, S3, load and to the negative of the
supply.

PROCEDURE:

Open the MATLAB Software

Go file and enter model, then separate page will be open

Then click view- Library browser

After clicking library browser, many mathematical blocks can be viewed.

Select the appropriate block and drag to the location to connect the

components.

After connecting all specified blocks insert scope in order to view the output

waveform.

CIRCUIT DIAGRAM:
MODEL OUTPUT:

RESULT:

Thus the inverter circuit is designed and the output waveform is viewed in
the output
 Exp No-3- DESIGN OF TRANSFORMER

AIM:

To design and analysis of core type transformer using MagNet software

APPARATUS REQUIRED:

MagNet software version 7.5

ABOUT MagNet software:

It is a powerful simulation tool used to solve complicated structure with non

linear elements

PROCEDURE:

DESIGN OF OUTER CORE :

Select line tool, draw outer layer of length 12mm, breath of 10mm

Select line tool, draw inner layer of length 10mm, breath of 8mm

Select the core with construction line surface tool, apply material CR cold
rolled steel material by model make component in a lineCR cold rolled steel

DESIGN OF CONDUCTORS:

Draw rectangular conductors in the primary and secondary side of length

1mm and breath of 4mm on each sides

Select the conductors with construction line surface tool, apply copper
material by model make component in a linecopper

Select component tool, selecting two copper conductor material to applying

winding by clicking Modelmake simple coil

Apply number of turns and current in coil properties

Select the airgap region, apply air material by model make component in a
lineair
Solver option:

Select solvestatic 2D

Select field flux functionupdate view

Theory:

The basic principle behind working of a transformer is the phenomenon of

mutual induction between two windings linked by common magnetic flux.
Basically a transformer consists of two inductive coils; primary winding and
secondary winding. The coils are electrically separated but magnetically linked to
each other. When, primary winding is connected to a source of alternating voltage,
alternating magnetic flux is produced around the winding.

The core provides magnetic path for the flux, to get linked with the
secondary winding. Most of the flux gets linked with the secondary winding which
is called as 'useful flux' or main 'flux', and the flux which does not get linked with
secondary winding is called as 'leakage flux'. As the flux produced is alternating
(the direction of it is continuously changing), EMF gets induced in the secondary
winding according to Faraday's law of electromagnetic induction. This emf is
called 'mutually induced emf', and the frequency of mutually induced emf is same
as that of supplied emf. If the secondary winding is closed circuit, then mutually
induced current flows through it, and hence the electrical energy is transferred
from one circuit (primary) to another circuit (secondary).

In core type transformer, windings are cylindrical former wound, mounted

on the core limbs as shown in the figure above. The cylindrical coils have
different layers and each layer is insulated from each other. Materials like paper,
cloth or mica can be used for insulation. Low voltage windings are placed nearer to
the core, as they are easier to insulate.
 (a) Solid model of core type transformer

( c) Flux distribution of core type transformer

(D) arrow flow of flux in core type transformer

Result:

Thus core type transformer designed using MagNet software

 Exp No-4- PCB Design

Aim:

To Design PCB using diptrace

Apparatus Required:

Diptrace software

Theory:

A PCB is a printed circuit board, also known as a printed wiring board. It is

used in electronics to build electronic devices. A PCB serves two purposes in the
construction of an electronic device; it is a place to mount the components and it
provides the means of electrical connection between the components.

Holes through a PCB are typically drilled with tiny drill bits made of solid
tungsten carbide. The drilling is performedby automated drilling machines with
placement controlled by a drill tape or drill file. These computer-generated
files are also called numerically controlled drill (NCD) files or "Excellon files".
The drill file describes the location and size of each drilled hole. These holes are
often filled with annular rings (hollow rivets) to create vias. Vias allow the
electrical and thermal connection of conductors on opposite sides of the PCB.Most
common laminate is epoxy filled fiberglass. Drill bit wear is partly due to
embedded glass, which is harder than steel. High drill speed necessary for cost
effective drilling of hundreds of holes per board causes very high temperatures at
the drill bit tip, and high temperatures (400-700 degrees) soften steel and
decompose (oxidize) laminate filler. Copper is softer than epoxy
and interior conductors may suffer.

Areas that should not be soldered may be covered with a polymer solder
resist (solder mask) coating. The solder resist prevents solder from bridging
between conductors and creating short circuits. Solder resist also provides some
protection from the environment. Solder resist is typically 20-30 micrometres thick

Procedure:

Step 1
 1. First open the Schematic from the menu and then draw the schematics of the
respective circuits given to you.
2. Then save the circuit with a name in any location.
3. Now close the schematics
4. Open the PCB Layout software.
5. Click ctrl + ogoto the location where your schematic file has been saved
select the file and open it.
Step 2

1. Lay the board edge.

2. Now check whether all the components have the PCB foot prints.
3. Once you find all the component foot prints go to auto placer, then click on
auto router.
4. Then connect using router option.
5. Check for Design errors.

(a) LED Driver Circuit

 (b)Simple PCB Design

Result:

Thus the PCB was designed using diptrace

 Exp No-5- DSP based control of DC motor.

Aim:

To control the motor using DSP Processor

Apparatus Required:

TMS320F2812- DSP Processor

Motor Driver Circuit/ MATLAB Simulink

Theory:

Direct current (DC) motors have been widely used in many industrial applications
such as electric vehicles, steel rolling mills, electric cranes, and robotic
manipulators due to precise, wide, simple, and continuous control characteristics.

The speed control methods of a dc motor are simpler and less expensive than other
types of motors and speed control over a large range both below and above rated
speed can be easily achieved. Recently, brush less DC motors, induction motors
and synchronous motors have gained wide spread use in Electrical Traction.
However, there is a persistent effort towards making them behave like dc motors
through innovative designs and control strategies.

DSP processor will take the speed of the motor as the feedback signal and
according to the difference between the set point speed and the present speed
finally it will change the duty cycle of the base drive signal, which is given as the
input to the buck converter.

PROCEDURE:

Open the MATLAB Software

Go file and enter model, then separate page will be open

Then click view- Library browser

 After clicking library browser, many mathematical blocks can be viewed.

Select the appropriate block and drag to the location to connect the

components.

After connecting all specified blocks insert scope in order to view the output

waveform.

Fig: DC Motor Control- Basic block diagram

EVA module for DSP Processor- TMS320F2812

The TMS320F2812 DSP has many special features for the control applications. It
has Event Manager that is specially designed for the motor control and motion
control applications. The general-purpose Timer3 in EVB (Event Manager B) is
used in continuous up/down count mode for the symmetric PWM generation.
Timers have associated compare registers which are used to write the calculated
duty ratio values. These values then get compared with the timer counter value in
order to generate the PWM output

Fig. Block diagram of the EVA module for TMS320F2812.

Result:

Thus motor controlled using DSP Processor

 Experiment No-6-Fuzzy logic based speed control of DC motor.
Aim:
To control the speed of motor using Arduino and MATLAB
Apparatus Required:
MATLAB
Arduino hardware
Theory:
A motor controller is a device or group of devices that serves to govern in some
predetermined manner the performance of an electric motor. A motor controller might include a
manual or automatic means for starting and stopping the motor, selecting forward or reverse
rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting
against overloads and faults.

An electric motor controller can be classified by the type of motor it is to drive such
as permanent magnet, servo, series, separately excited, and current. A motor controller is
connected to a power source such as a battery pack or power supply, and control circuitry in the
form of analog or digital input signals.

Procedure for Arduino:

Test the microcontroller by using one of the preloaded programs, called sketches, in the
Arduino Programmer. Open one of the example sketches, and press the upload button to
load it. The Arduino should begin responding to the program: If you've set it to blink an
LED light, for example, the light should start blinking.
To upload new code to the Arduino, either you'll need to have access to code you can
paste into the programmer, or you'll have to write it yourself, using the Arduino
programming language to create your own sketch. An Arduino sketch usually has five
parts: a header describing the sketch and its author; a section defining variables; a setup
routine that sets the initial conditions of variables and runs preliminary code; a loop
routine, which is where you add the main code that will execute repeatedly until you stop
running the sketch; and a section where you can list other functions that activate during
the setup and loop routines. All sketches must include the setup and loop routines.
 Once you've uploaded the new sketch to your Arduino, disconnect it from your computer
and integrate it into your project as directed.

Simulink Diagram & Output:

Result:
Thus the control of DC Motor done using fuzzy logic technique
 Exp No-7 -PIC microcontroller based control of 3 Induction Machine.

Aim:

To control 3phase Induction motor using PIC Microcontroller

Apparatus Required:

PIC Microcontroller

Theory:

Speed control of three-phase induction motor using pic18 microcontroller article

will help you to design your project. Three phase induction motors are very popular in
industrial, appliances and heavy industry applications. Three phase induction motors are
mostly used in motion based applications. Three phase induction motors are robust and
reliable in motion based applications. Induction motors runs at specific speed when
power is supplied to induction motor. But main problem is control the speed of induction
motor. This technical article help you to design variable speed driver for induction motor
using pic microcontroller.

Recent development in power electronics made speed control of induction motor

very easy. Power electronics made improvement in dynamic and steady state
characteristics of induction motor. For example in home washing machine speed need to
be control at different steps of washing. This is also a domestic application of induction
motor.
Feedback Circuit:
 Exp No-8 Temperature control of a heater using fuzzy.

Aim:

Study of temperature control of a heater using fuzzy

Theory:
Temperature control is to heat the system up todelimitated temperature, afterwardhold it at that
temperature in insured manner. Fuzzy Logic Controller (FLC) is best way in which this type of
precision control can be accomplished by controller. During past twenty yearssignificant amount
of research using fuzzy logichas done in this field of control of non-linear dynamical system.
Here we have developed temperature control system using fuzzy logic. Control theory
techniques are the root from which convention controllers are deducted. The desired response of
the output can be guaranteed by the feedback controller.

Low cost temperature control using fuzzy logic system block diagram shown in the fig. in this
system

set point of the temperature is given by the operator using 4X4 keypad. LM35 temperature
sensor sense the current temperature. Analog to digital converter convert analog value into
digital value and give to the Fuzzy controller.Controller calculates error between set point value
and current value and consider as Input function of fuzzy logic. By fuzzification process
controller calculate it membership. After in rule base and inference system output membership
value calculated. Defuzzification process calculates actual value of PWM for heater and fan
which is output of the

temperature control system.

Block diagram of temperature control System

Working Principle

Temperature control system shown in figure 1 is works on the basic principle of fuzzy logic.The
concept of fuzzy logic conceived processing data by allowing partial set membership rather
than crisp set membership or non membership.

This approach to set theory was not applied to control system until 70s due to insufficient small
computer capability prior to that time. Professor Zedah reasoned

that people do not require precise, numerical information input, and yet they are capable of
highly adaptive control.

A fuzzy logic system (FLS) can be defined as the nonlinear mapping of an input data set to a
scalar output data . A fuzzy logic system consists of four

main parts:

Fuzzifier
Rules
inference engine
defuzzifier.

These components and the general architecture of a

fuzzy logic system are shown

Pulse width modulation technique

 Exp No-9- Sensors for voltage and current measurement (Hall sensors).

Aim:

Study of hall sensors

Theory:

The temperature System has a Heater coil and a Fan. The heater assembly consists
of an iron plate placed at a distance from a nichrome coil. When current passes
through the coil it gets heated and in turn raises the temperature of the iron plate.
We are interested to alter the heat generated by the coil and also the speed at
which the fan is operated. There are many ways to control the amount of power
delivered to the Fan and Heater. We are using the PWM technique. PWM (Pulse
width modulation) is a process in which the duty cycle of the square wave is
modulated.

General features of Hall effect based sensing devices are:

True solid state

Long life (30 billion operations in a continuing keyboard module test program)

High speed operation - over 100 kHz possible

Operates with stationary input (zero speed)

No moving parts

Logic compatible input and output

Broad temperature range (-40 to +150C)

Highly repeatable operation

Fig: General sensors based on hall effect

Principles of Current Measurement

This section looks into some solutions of how to measure electric current. Included
are sections about different shunt measurement solutions as well as the focus
technique of this application note, current sensing using Hall

effect devices.

2.1 Shunt Resistor Solution

The well known formula of Georg Simon Ohm reads:

where is a shunt resistor through which flows a current , and the difference is the
voltage difference reading on the two terminals of the shunt resistor. This voltage
drop can subsequently be processed in different ways. One possibility is to amplify
the voltage and feed it into an analog to digital converter (ADC). The output of this
configuration is a digital value proportional to the current. We can distinguish
between two possible insertion points of this resistor, the first being as low-side,
the second as high-side shunt.

Low-Side Current Shunt Resistor

As shown in Figure 1, a low-side shunt resistor has one terminal connected to the
battery ground ( ), the other one connected to the load. An opamp setup is used
with two resistors and to amplify the voltage drop accross the shunt resistor. Since
the voltage is slightly higher than the battery ground , the load has to be connected
using two wires and the common ground (e.g. car chassis) cannot be used.

High-Side Shunt Resistor

The use of a high-side shunt simplifies the wiring since now the load can be
connected directly to the common battery ground, which is often available locally,
for example in the form of the car chassis in automotive applications. Accordingly,
one wire can be saved. The measurement circuit however requires additional two
resistors and as voltage dividers. The most critical item of this solution is the offset
adjustment and the relation between the 4 resistors to has to be adjusted carefully.

Although being simple, the shunt solution has several problems:

Voltage drop for measurement: For a good resolution and an acceptable signal-to-
noise ratio (SNR) a voltage drop in the range of 100 mV for full load is
recommended. This is already 2 % in a 5 V application.

Voltage drop at the connectors of the shunt: For higher currents, the shunt resistor
is usually connected with screws. This gives an additional unspecified resistance
added to the shunt value. A solution of this problem is the use of more expensive
four pole resistors - two for the big current and two for the measurement voltage.

Power dissipation in the shunt resistor: A simple example: = 1 m , = 100 A.

Consequently, = 100 mV and the dissipated power is = 10 W!
 Exp No-10-3D printing based on ORCAD.

Aim:
To study on Printing on 3 Dimension using ORCAD
Theory:
3D printing, also known as additive manufacturing (AM), refers to processes used to
create a three-dimensional object in which layers of material are formed under computer
control to create an object. Objects can be of almost any shape or geometry and typically are
produced using digital model data from a 3D model or another electronic data source such as
an Additive Manufacturing File (AMF) file. Stereolithography (STL) is one of the most common
file types that 3D printers can read. Thus, unlike material removed from a stock in the
conventional machining process, 3D printing or AM builds a three-dimensional object from
computer-aided design (CAD) model or AMF file by successively adding material layer by layer.
The term "3D printing" originally referred to a process that deposits a binder material onto a
powder bed with inkjet printer heads layer by layer. More recently, the term is being used in
popular vernacular to encompass a wider variety of additive manufacturing techniques. United
States and global technical standards use the official term additive manufacturing for this broader
sense.
3D printable models may be created with a computer-aided design (CAD) package, via
a 3D scanner, or by a plain digital camera and photogrammetry software. 3D printed models
created with CAD result in reduced errors and can be corrected before printing, allowing
verification in the design of the object before it is printed.

CAD model used for 3D printing

The manual modeling process of preparing geometric data for 3D computer graphics is similar to
plastic arts such as sculpting. 3D scanning is a process of collecting digital data on the shape and
appearance of a real object, creating a digital model

OrCAD:
OrCAD is a proprietary software tool suite used primarily for electronic design
automation (EDA). The software is used mainly by electronic design engineers and electronic
technicians to create electronic schematics and electronic prints for manufacturing printed circuit
boards.
OrCAD PCB Designer is a printed circuit board designer application, and part of the
OrCAD circuit design suite.[25] PCB Designer includes various automation features for PCB
design, board-level analysis and design rule checks (DRC).
The PCB design may be accomplished by manually tracing PCB tracks, or using the
Auto-Router provided. Such designs may include curved PCB tracks, geometric shapes, and
ground planes.
PCB Designer integrates with OrCAD Capture, using the component information system
(CIS) to store information about a certain circuit symbol and its matching PCB footprint.