CHAPTER THREE

MATERIALS, METHODS AND TECHNIQUE

3.1 COMPONENTS USED

CATEGORY NAME QUANTITY

1 IC SG3524 1

LM358 1
2 CAPACITOR 1µF 3

10µF 4

100µF 6

0.1µF 4

FILTER CAPACITOR 0.1µF/400V 1

10K 4

47K 2

4.7K 5

22K 4

1M 1

100K 4

4 DIODES LED 2

ZENER

4.7V 1

IN4148 9

1
5 TRANSISTORS MOSFET

IRF3205 9

BJT

BC327 3

BC547 1

6 TRANSFORMER STEP UP 1

STEP DOWN 1

Table1; Components used

3.1.1 BASIC BLOCK DIAGRAM OF THE INVERTER WITH CHARGING

This project consists of few semiconductor devices which help in the conversion of the
incoming Dc voltage to AC voltage in the oscillator stage,

Charger

INPUT (AC) TRANSFORMER RECTIFIER CHARGE

24 VOLTS 240 VOLTS

Figure 3.1; Basic block diagram of inverter with the charging system.

The current is amplified by the switching transistors and sent to the transformer for the voltage

to be stepped up to the required range (220-240volts).

3.1.2 BASIC OSCILLATOR BLOCK DIAGRAM

The oscillator stage consists of a resistor-capacitor network connected to a multi-signal IC to

form a multi-vibrator circuit which produces the sinusoidal wave at the output terminals of the

IC. The voltage regulator LM7812 keeps the 24volts input voltage constant at 12volts for the

circuit to oscillate properly.

3
 AC
INPUT (DC) VOLTAGE INTEGRATED
REGULATOR CIRCUIT
24 VOLTS

Figure 3.2; Basic oscillator block diagram

This stage also has a FET driver which charges and discharges the MOSFET gate capacitance

rapidly to ensure high speed switching of the MOSFETs.

The frequency of the oscillator was calculator using F = 1/2ΠRC, where R, C is the resistor and

capacitor respectively.

3.1.3 MOSFET DRIVER

The emitter-feedback circuit comprises of resistor, diode, and a PNP Transistor. R1 determines

the operating point of the driver and also controls the base current (IB). D1 is used to ensure

one-directional flow of current; it also allows only positive pulses to pass through it. While Q1

as it goes on and off, discharges the mosfets gate capacitance and vice versa.

4
3.1.4 LOW VOLTAGE CUT-OFF (INPUT 24V)

This stage involves an operational amplifier LM358 wired as a voltage comparator having a

fixed voltage at the inverting input and a variable voltage at the non-inverting input.
INPUT OP.
(DC) AMP. RELAY
24
VOLTS

Figure 3.4; Block diagram of a low voltage cut-off

At the non-inverting input pin, we have resistors connected in series using the voltage divider

rule to sense the decrease in the battery voltage so as to allow the OP. AMP. Change its state at

the output region. When the output is low, the IC shuts down the Inverter.

Figure 3.5; Low voltage cut-off circuit diagram

5
3.2 THE CHARGING SYSTEM

When the mains input (240v) comes in, the transformer steps down the voltage to about 27volts

and the bridge rectifier converts the ac to dc, then the rectified voltage is sent to the battery

through the charge controller, when the battery is fully charged to about 27.5volts (the batteries

have tolerance of 2(+/-2.5volts) because they are in series, the controller disconnects the

battery from the charger with the help of a relay, thereby keeping the battery cells in a good

charge condition.

3.2.1 FABRICATION PROCEDURE

This design is divided into three sections, the oscillator section, the device/switching section

and the output section

3.2.2 OSCILLATOR SECTION

The IC SG3524 (integrating circuit) is used in the oscillating section of this inverter. This IC is

used to generate the 50Hz frequency required to generate AC supply by the inverter. To start

this process, battery supply is given to the pin-15 of the ICSG3524 through on/off switch

which passes through the normally close contact of the relay. Pin-8 is connected to the negative

terminal of the battery. A voltage regulator LM7812 is connected across the battery through

6
two capacitors connected in parallel and grounded as shown in the circuit below. This regulates

the 12V supply from the battery.

Pin-6 and 7 of the IC are the oscillation section pins. The frequency produced by the IC

depends on the value of the capacitor and resistor connected at these pins. The two capacitors

(each 0.1uf) are connected to pin-7 and decide the 50Hz frequency output by the IC. Pin-6 is

timing resistance pin and helps the oscillator frequency constant. Preset variable resistor is

connected to ground from pin-6 of the IC and used so that the value of the output frequency

can be adjusted to a constant 50Hz. A fixed resistor of 100k is connected in series with the

variable resistor to give a given frequency as shown by the relation:

F=1/ (RTCT)

Where F is the frequency in Hz

RT is the total resistance at pin-6

CT is the total capacitance at pin-7

Therefore, to obtain a frequency of 50Hz

Therefore, RT becomes, RT=1/FCT

Therefore we have that RT must be varied to obtain a frequency of 50Hz.

In my design, I fixed resistor of 100K and a variable resistor of 100k.

This 50Hz frequency alternating signal has an output at pin-11 and 14 of the IC. This

alternating signal may also be known as the MOS drive signal. This MOS drive signal at pin-11

and 14 are between 5-6V. Voltage at these pins should be same, because any variation in the

voltage at these pins could damage the MOSFET at the output. The circuit diagram of the

oscillation section is shown below.

7
Figure 3.6; the circuit diagram of the inverter

8
Figure 3.7; the snapshot of the designed inverter whose circuit diagram is shown in figure 3.6

9
3.2.3 SWITCHING SECTION

The MOS drive signal from the pin-11 and 14 of the IC are given to the base of the transistor

T1 and T2. This results to the MOS drive signal getting separated into two different channels.

Transistor T1 and T2 amplify the 50Hz MOS drive signal at their base to a sufficient level and

output them from the emitter while the collector are grounded.

50Hz signal from the emitter of T1 is given to the gate of each MOSFET in the MOSFET

channel, through resistance R4-2K. Each MOSFET gate receives the 50Hz signal through a

resistor (R6-R9).

And also 50Hz signal from the emitter of T2 is given to the gate of each MOSFT in the second

MOSFET channel, through resistance R19-2K. Each MOSFET gate receives the 50Hz signal

through a resistor (R14 –R17). When the first MOSFET channel is switched on, the current

flows through the first half of the inverter transformer winding and when the second MOSFET

channel turns ON, the current flows through the second half of the inverter transformer

winding. This switching on/off of the MOSFET channels will start an alternating current in the

winding of inverter transformer. This AC current in the winding will induce an AC current of

50Hz, in the 220 and 240v tapings of the transformer. The AC voltage output from the

transformer is connected to the normally close of the relay to the output socket.

3.2.4 THE OUTPUT SECTION

The 50Hz alternating MOS drive signal reaches each MOSFET channel separately. This results

in the MOSFET channels being alternating on and off that is when the first channel is ON the

second channel will be OFF, and when the second channel is ON, the first will be OFF. This

on/off switching is repeated 50 times per second. The drain (D) of all the MOSFETs of one

channel is connected together and connected to one end of the inverter transformer’s

winding. Likewise the drain of the MOSFET of the second channel is also connected together

10
and connected to the other end of the inverter transformer’s winding. The position terminal

of the battery is connected to the centre tapping of the winding and results to positive supply

reaching the drain of each MOSFET transistor through each end of the winding. The Source (S)

terminal of each MOSFET is connected to the negative terminal of the battery through a shunt

of low value resistance. This is because polarity of the 50Hz MOS drive signal at pin-11 and 14

are different at a time, only one channel from the output channel remains ON, the other

channel stays OFF.

CHAPTER FOUR

4.1 TEST AND ANALYSIS

Firstly, the battery was tested for polarity and the actual value, which is 24volts also obtained.

If the battery voltage is lower than this value, the inverter would not function.

Secondly, test was carried out on the charging system of the inverter. The multimeter showed

that 27volts was available for charging, below which the battery would not charge.

Thirdly, the no load current which the inverter was drawing from the battery was measured and

0.5A obtained (the load current for this work is in the range of 0-1A, above which the inverter

would automatically turn off)

The inverter output was connected to an oscilloscope to check the output wave form, and a

modified sine wave was produced.

11
 CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

Investigations showed that the inverter with automatic charger was realized and can be applied

to house hold appliances and electrical equipment. The PCB was successfully fabricated. There

was no limitation in the use of an electronic tool or gadget at a fixed location due to power

limitations and unreliable power supply. The invention can make power supply more accessible

to everyone, both those in the remote and rural areas. In other to achieve goals of this project,

two batteries were used to switch the device at 24volts. The batteries recharge automatically in

other to produce continuous power supply to be used. Finally, depending on the availability of

further advanced technologies, this type of power inverter with automatic charger could be

further improved on the efficiency and reduce size by the use of transformer means.

5.2 RECOMMENDATION

This project has successfully been demonstrated by converting a 24VDC to 220VAC with an

automatic charger and it is recommended for medical equipment. Further work on this project

may include:

 the harmonics that were produced using the high frequency switching can be isolated using

a small low-pass filter.

 Better PCB software should be used in other to simulate the circuit diagram before building

the hardware. This will ensure higher efficiency of the inverter.

 Microcontroller can also be used as the voltage comparator to disconnect the batteries from

the inverter and also used in the oscillator. The microcontroller type should be ATMEGA 128.

12
 in other to make the switching of the transistors more efficient, IGBTs should be used

because they handle more power than the mosfets.

REFERENCE

John bird (2000); Electrical and Electronics Principle and Technology, Great; Butterworth

Heinemann Ltd.

Lionel. N. (1998), Electronics and Electrical Engineering Principle and Practice, Macmillan

Press pp.3, 136,211-214,293-294.

Principle of Electronics by V.K Mehta.

Say M.G (1978), Alternating Current Machines, 4th Edition, London; Pitman Publisher (page

92-162).

Theraja B.I. and Theraja A.K. A text book of Electrical technology 24 th ed. S.schand and

company ltd, Ram Nager New Delhi (2008) pp 1069, 1116, 2163, 2188, 2364, 2429, 2567-

2688

King Alexander, Knight William; Uninterruptible power supplies and standby power systems.

Mc Graw – Hill, 2 Penn Plaza, New York. 2003.

Principles of Electronics by V.K. Mehta.

13
Inverters (electrical) retrieved from http://www.wikipedia.inverters (electrical).html, June 16,

2011

Linden D. Handbook of Batteries and Fuel cells.

Belli’s Mary, Stanley Jr. William. Retrieved from

http://www.inverters.about.com/library/inverters/stanley.htm, June 16, 2011.

Power Semiconductor Devices, B. Jayant Baliga, PWS publishing company, Boston.

Bedford B.D.; Hoft R.G. Principles of inverter circuits

Integrated Electronics by Jacob Millman and Christos C. Halkias

Semiconductor Memory Design and Applications by Luecke G., J.P.

Mize and W.N. Carr

Manahar Lotia. Modern Digital Inverter- Introduction, Servicing andTroubleshooting.

Ashutosh Bhatt. Retrieved from http://www.engineersgarage.com/contribution/ambhtt/ir-

remote- switch.

Project on I-R control fan regulator. Retrieved

from /http://www.packsc.org/pk/projects/studensts-project-i

14