Design and Implementation of A DC To AC Power Electronics-Based
Design and Implementation of A DC To AC Power Electronics-Based
Mubeezi Conceptar1, Kalyankolo Umaru2, Val Hyginus Udoka Eze1,3*, Okafor O. Wisdom4
1
Department of Electrical, Telecommunication and Computer Engineering, Kampala
International University. Uganda.
2
Department of Electrical Engineering and Automation, Muni University. Uganda.
3
Department of Publication and Extension, Kampala International University.
Uganda.
4
Department of Computer Science and Technology, University of Bedfordshire. Luton,
England.
Article history Abstract: Power inverters play a crucial role in the field of engineering,
05.01.2024 particularly in applications where power stability is imperative. In devices
such as Uninterruptible Power Supplies (UPS), the conversion of raw power
Revised: to DC, subsequent filtering, and inversion to AC are executed through pure
03.02.2024
sine wave inverters. These inverters exhibit remarkable stability, making
Accepted: them ideal for powering sensitive equipment like data switches and Remote
17.02.2024 Terminal Units (RTUs). This study delves into the intricate process of
converting DC power into a pristine sine wave signal. The heart of this
*Corresponding Author: power conversion lies in the utilization of the KA3525A integrated circuit
Val Hyginus Udoka Eze (IC) in conjunction with MOSFETs of the PN55 series, supported by
Email: capacitors and resistors for effective power filtration. The KA3525A, a
[email protected] monolithic IC, encompasses all essential control circuits for a pulse width
modulating regulator. Within this IC, a voltage reference, error amplifier,
This is an open access article,
licensed under: CC–BY-SA
pulse width modulator, oscillator, under-voltage lockout, soft start circuit,
and output driver collaborate seamlessly. The MOSFETs function as
switches, synchronized with the oscillating signal from the KA3525A IC.
This coordination, combined with the filter and other signal conditioning
units, enables the conversion process. The design achieves the conversion of
raw power into a stable pure sine wave signal of 170V AC at the H-bridge
terminals, demonstrating the success of the designed approach.
2024 | International Journal of Recent Technology and Applied Science | Volume. 6 | Issue. 1 | 1-13
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
1. Introduction
In the ever-evolving landscape of engineering innovation, the pursuit of stable and reliable power
solutions stands as a cornerstone for the seamless operation of critical applications. Among the array
of power inverters, the quest for purity in sine wave generation has garnered particular significance,
especially in scenarios where precision and dependability are non-negotiable. This study propels itself
into the forefront of technological advancement, presenting the meticulous design and implementation
of a power inverter that achieves the pinnacle of stability — a stable pure sine waves [1][2][3]. At the
center of this technological endeavor lies the strategic integration of the KA3525A integrated circuit
(IC) and MOSFETs from the esteemed PN55 series. This synergistic pairing, fortified by capacitors
and resistors meticulously chosen for effective power filtration, not only represents a cutting-edge
amalgamation of components but also epitomizes the convergence of sophistication and reliability
[4][5][6]. In the crucible of critical engineering applications, where the resilience of power systems is
paramount, this design seeks to redefine the benchmarks of performance. The KA3525A, a monolithic
IC of unparalleled prowess, emerges as the linchpin in this innovative power inverter design. Within
its silicon confines, an entire ecosystem of control circuits orchestrates the delicate ballet of pulse
width modulation. A voltage reference, error amplifier, pulse width modulator, oscillator, under-
voltage lockout, soft start circuit, and output driver unite seamlessly, their harmonious collaboration
transcending the conventional boundaries of power regulation [7][8].
Complementing this symphony of control, the MOSFETs of the PN55 series step forward as the
virtuoso switches, synchronized in perfect unison with the oscillating signal emanating from the
KA3525A IC. This synchronous dance, coupled with a carefully curated ensemble of filters and signal
conditioning units, forms the backbone of the power transformation process. The result is nothing
short of extraordinary — the conversion of raw power into a stable pure sine wave, resonating at
170V AC at the H-bridge terminals [9][10].
Pure sine wave inverters generate an output waveform that precisely mimics the sine wave of
conventional electrical sockets. In contrast to modified sine wave inverters, pure sine wave devices
offer a seamless and high-quality power supply, making them suitable for running sensitive
equipment like laser printers, laptop computers, power tools, digital clocks, and medical devices [11].
This type of AC power is especially advantageous as it minimizes the risk of damage to connected
devices. Additionally, pure sine wave inverters contribute to reduced audible noise in appliances such
as fluorescent lights, and they enhance the efficiency and quiet operation of inductive loads like
motors which leads to low harmonic distortion [12][13]. This pursuit of excellence in stable power
inversion for critical engineering applications is not merely an exploration of circuits and components
rather it is a testament to the relentless commitment to pushing the boundaries of what is achievable in
the realm of power systems.
2. Literature Review
Since the initial release of the Application Manual for IGBT and MOSFET power modules, these
components have seen widespread adoption in various new applications. This surge is primarily
fueled by the escalating demand for efficient utilization of fossil fuels, a commitment to reduce
environmental impact, and the resulting surge in the use of renewable energy sources. Evolving
development trends, such as minimizing space requirements, cost considerations, and enhancing
energy efficiency, coupled with the exploration of novel application domains like decentralized setups
in challenging conditions, impose more stringent requirements on devices featuring cutting-edge
power semiconductors [15][16].
Ensuring the consistent performance of devices, circuits, and systems over a designated timeframe
is a crucial consideration in the development of semiconductor technology. Device reliability
encompasses two broad categories: the gradual decline in device performance over time and sudden
failures, both of which are significant for logic, memory, RF, and power devices. The author in [17]
further discuses device reliability based on advancement of electrical or physical characterization
methods, exploration and modeling of specific phenomena, the influence of materials and processes
on reliability, and the creation of technologies that are tolerant to reliability problems.
The researcher in [18] introduced an enhancement to the conventional three-phase diode bridge
rectifier with a DC output capacitor. The circuit aimed to improve the power factor at the AC input
and reduce ripple current stress on the smoothing capacitor. The key innovation involved inserting an
active voltage source between the diode bridge output and the smoothing capacitor, controlled to
2
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
emulate an ideal smoothing inductor. The configuration transforms the high peak amplitudes of diode
bridge input currents into a 120-degree rectangular shape, achieving an ideally improved power factor
of 0.955. The active voltage source is implemented through a low-voltage switch-mode converter of a
small power rating compared to the rectifier's output power [19][20]
The Laser Interferometric Gravitational-Wave Observatory (LIGO) operated two US facilities with
kilometer-scale interferometers to detect gravitational waves caused by violent astronomical events.
LIGO's sensitivity, particularly around 100 Hz, was affected by Brownian noise in reflective coatings.
This noise stemmed from mechanical losses in coatings and was crucial to understand for future
cryogenic detectors. The dissertation focused on constructing a thermal noise test bed at the
University of Florida to explore better coatings and prepare for cryogenic detectors. The work
included a novel frequency stabilization method applicable to LISA and CryoTHOR experiments. The
study adapted LISA technology to assess coating Brownian noise in the LIGO band, with detailed
experimental information and preliminary measurements [21]
The experimental evaluation of a low-voltage Gallium Nitride (GaN) inverter was specifically
created for power steering applications according [22]. It was highlighted that the inverter
incorporates the most recent generation of low-voltage enhancement-mode normally-off GaN Field-
Effect Transistors (FET). The advantages of these devices, such as a high switching frequency
resulting in reduced passive component volume, were discussed. However, the paper also mentioned
challenges in layout and packaging aimed at minimizing parasitic inductances. The benefits and
challenges of employing GaN FETs in two-level Pulse Width Modulation (PWM) motor drive
applications were thoroughly explored, with the paper providing detailed experimental evidence and
design guidelines [22].
The researcher highlighted the importance of improving efficiency and power density in power
switching converters for energy conversion, particularly in motor control. It discussed the challenges
with pure silicon switch technologies and introduced Gallium Nitride (GaN) devices, which offered
better static and dynamic characteristics. The paper provided guidelines for the optimal use of GaN
FETs in motor control, emphasizing their advantages and addressing key issues. Experimental
evaluation in low-voltage electrical drives demonstrated GaN FETs' benefits, such as fast switching,
reduced resistance, and decreased power losses. The impact on power loss management, output
waveform quality, input filter capacitor design, and voltage transient slope effect was analyzed
[23][24].
This research delves into the significance of light e-Mobility in transportation and emphasized the
advantages of adopting gallium nitride transistors (GaN FET) in low-voltage motor drive applications.
The benefits of GaN FET technology for electric powertrains were discussed, comparing its features
with silicon-based transistors. Experimental tests on a typical e-powertrain layout with a GaN FET
inverter revealed advantages in inverter output waveforms quality, system efficiency, and power
density. The study also addressed DC-bus filter size and dead-time selection, showcasing
improvements in filters and electrical motor performance. The insights provided were particularly
relevant for understanding GaN FET operations in low-voltage systems, characteristic of light e-
Mobility application [25][26][27].
There are different types of sine wave inverters and they are used in different applications. Square
wave, modified sine wave, and pure sine wave inverters. The different research that was done before,
it was focusing on the production of the modified sine waves using power MOSFETS and 555 timers.
But in this research, the production of a pure sine wave is proposed using Pulse width modulation and
MOSFETS configured in H Bridge [26][27]
The introduction of harmonic-rich waveform by many of the designed inverter possess potential
risk to sensitive equipment such as medical monitors. Conversely, some low-cost inverters generate
square waves or slightly modified versions, maintaining the correct RMS voltage and approximate
frequency but not highly effective.
This drawback formed the bedrock for Design and Implementation of a DC to AC power
electronics-based inverter that produces pure sine wave output for Critical Engineering Applications.
The primary aim of this research paper is to design a DC to AC power electronics-based inverter that
produces pure sine wave output that is cost-effective and reliable without using the transformer-based
approach of designing power inverters with minimal or no switching harmonics.
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
3. Methodology
3.1. Materials Used
Metal Oxide Semiconductor Field-Effect Transistor
Metal Oxide Semiconductor Field-Effect Transistor (MOSFET) is used to switch or amplify voltages
in circuits [28]. It is a current-controlled device that is constructed with 3 terminals known as Source,
Gain and Drain. A sine wave centered on zero volts requires both a positive and negative voltage
across the load for positive and negative parts of the wave respectively. This can be achieved from a
single source through the use of four MOSFET switches arranged in an H-Bridge configuration. To
minimize power loss and utilize higher switching speeds, N¬-Channel MOSFETs will be used as
switches in the bridge. Level translation between PWM signals and voltages required to forward bias
high side N Channel MOSFETS, the IR2110 MOSFET driver integrated circuit was used. Figure 1 is
a typical diagram of a MOSFET.
Figure 1. MOSFET
H-Bridge Configuration
A H-Bridge or a full-bridge converter is a switching configuration composed of four switches in an
arrangement that resembles H [29]. By controlling different switches in the bridge, a positive,
negative, or zero potential voltage can be placed across a load which corresponds to forward, reverse,
and off in motor respectively. Figure 2 is a typical diagram of H-bridge.
The H-Bridge circuit consists of four switches corresponding to high side left, high side right, low
side left, and low side right. Four possible switch positions can be used to obtain voltages across the
load as shown in Table 1.
High Side Left High Side Right Low Side Left Low Side Right Voltage Across the Load
ON OFF OFF ON Positive
OFF ON ON OFF Negative
ON ON OFF OFF Zero potential
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
The switches used to implement an H-Bridge can be mechanical or built from solid-state
transistors. Selection of the proper switches varies greatly. The use of P-Channel MOSFETs on the
high side and N-Channel MOSFETs on the low side is easier, but using all N-Channel MOSFETs and
a FET driver, lower on resistance can be obtained resulting in reduced power loss. The use of all N-
Channel MOSFETs requires a driver, since turning ON a high side N-Channel MOSFET, leads to a
voltage higher than the switching voltage (in the case of a power inverter, 170V). This difficulty is
often overcome by driver circuits capable of charging an external capacitor to create additional
potential.
Battery
Battery was used to supply input voltage and power [31], since the voltage need to be inverted from
DC to AC. A 7AH, 12VDC battery as shown in figure 3 was used to supply power to the system.
Capacitors
A capacitor or condenser is a passive electronic component consisting of a pair of conductors
separated by a dielectric. Capacitors in filter networks was used for smoothening the output of power
supplies and are also used for blocking direct current while allowing alternating current to pass
[32][33]. The typical diagram of capacitor is shown in Figure 4.
KA3525A
KA3525A is a monolithic integrated circuit that includes all of the control circuits necessary for a
pulse width modulating regulator. There is a voltage reference, an error amplifier, a pulse width
modulator, an oscillator, an under-voltage lockout, a soft start circuit, and the output driver in the
chip. The block diagram in Figure 5 shows the external and the internal components of the KA3525A
IC that produces PWM signal.
Resistors
A resistor is a two-terminal electronic component designed to oppose an electric current by producing
a voltage drop between the terminals in proportion to the current as opined by Ohm's law (V = IR).
Where; V is applied voltage across the terminals of a resistor, I is current and R is the resistance
[32][33]. The typical diagram of resistor is as shown in figure 6.
5
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
Zener Diode
The Zener Diode is a voltage regulator device that ensures a constant voltage output regardless of the
fluctuations that may occur in the circuit [34]. In this research project the Zener diode was connected
in parallel with an 82 Ohms resistor to the MOSFET terminal to ensure and regulate the signal to the
gate of the MOSFET. Figure 7 is the diagram of Zener diode
3.2. Methods
The first step taken in this research design is creating an accurate pulse width modulation signal using
analog circuitry as shown in Figure 8, to ensure an accurate representation of the signal that is to be
duplicated. In the case of a pure sine wave inverter, the 50 Hz sine wave output is required.
Therefore, an oscillator will be used to produce a stable 50 Hz. The KA3525a IC produces a signal
from its output pins of 12 and 14 as shown in Figure 5 that act as the inputs for the MOSFETs to
generate AC signal at the source terminal of the MOSFET.
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
An internationally recognized pure sine wave driver in conjunction with MOSFETs to generate
170VAC power from a 12V DC power source was employed in this research. The inclusion of an N
coefficient temperature sensor facilitates the detection of heated components thereby triggering the
fan ON to effectively cool the system. To streamline this research construction, it was organized into
distinct sectors: DC to AC inversion for converting battery power (DC) to electricity (AC), a
temperature sensing system to regulate internal component heat, and a feedback monitoring system
[19][20]. This monitoring system assesses the inverter output, ensuring its correctness. In cases where
the output deviates from the design specifications, the control circuit adjusts settings to achieve a
sinusoidal waveform for the output feedback voltage Root Mean Square (RMS).
A MOSFET drive integrated circuit and a low pass filter were used to generate a 60Hz, 240V AC
sine wave across a load in this research paper. The block diagram shown in Figure 9 shows the
control circuit which comprised of three basic blocks known as the voltage reference, sine wave
generator, and triangle wave generator blocks. When these three blocks are implemented with
comparators and other small analog circuitry, they control the Pulse Width Modulation (PWM)
signals that the two MOSFET drivers send. The PWM signals is being fed into these MOSFET
drivers that perform level translation to drive four N-¬Channel MOSFETs in an H¬-Bridge
7
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
configuration. From here the signal is sent through a low¬ pass (LC) filter so that the output delivers a
pure sine wave.
8
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
MATLAB was used to model the switching losses in the MOSFETs, based on their capacitance and
switching rise times (which depends on the frequency), as well as their resistive losses (independent
of frequency). Figure11 is the IR210 MOSFET characteristic curve which considered the resistive
losses in the filter inductor (dependent on the inductor value/size) which is dependent on the
frequency.
Figure 12 shows the frequency losses of 3 different MOSFETs and 2 different inductors. The
IRFb20n is an International Rectifier MOSFET with lower resistance than C740 and the IRC630, but
has a higher capacitance. This is why the losses for this switch was significantly lower but rise
drastically at higher frequencies. The curve with the 'notch' around 40 kHz shows the loss curve using
the IRFb20n added to the resistive losses in the filter inductors. The notch occurs at the frequency
where the required inductance value dropped. Based on the curve of figure 12, 50 kHz switching
generates little extra loss over 20kHz, but have drastically improved output accuracy (less voltage
ripple). This obvious observation made us to switch to 50 kHz, 2mH inductor.
All components are assembled on the breadboard as shown in Figure 13, and the concept and
functionality of this research work tested before transferring the components to a Printed Circuit
Board (PCB). After this test the components were placed on a PCB and soldered with the aid of a
soldering gun and lead.
A continuity test was carried out to check if there was current flow in the project circuitry and was
aimed at finding electrical open paths in the circuitry after completing soldering and configuration. A
multimeter was used to perform a continuity test on the electric circuit by measuring electric current
flow as shown in Figure 14.
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
Figure 14. Testing and Implementation of the Designed a DC to AC Power Electronics Based
Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications
Power on test was performed to check whether the voltage at different terminals is according to
required or designed specifications. A multimeter was switched to voltage mode, the voltage across
the source terminals of the MOSFETs was checked and measured at 170V AC voltage. The voltage
across the Gate terminal measured at 0.00VAC value as shown in Figure 14.
The results obtained after tests were approximately the same as designed. Table 2 is the validation
test results showing the designed data accuracy with the expected data
The results in Table 2 were obtained after the final implementation of the research work. Due to
minimize losses in the circuit, the final output that was expected out of the project was affected
because some key components that were supposed to be used could not be found on the market for
example EGS002 board for the production of a pure sine wave that is more efficient was replaced by
KA3525a IC which can do comparably the same function with fewer effects.
5. Conclusion
In conclusion, this study focused on the conversion process of raw power to a pristine sine wave
signal, crucial for powering sensitive equipment such as data switches and Remote Terminal Units
(RTUs). The study utilizes the KA3525A integrated circuit (IC) in conjunction with MOSFETs of the
10
Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
PN55 series, supported by capacitors and resistors for effective power filtration. The KA3525A IC
serves as a monolithic solution encompassing essential control circuits for a pulse width modulating
regulator. Its components include a voltage reference, error amplifier, pulse width modulator,
oscillator, under-voltage lockout, soft start circuit, and output driver, all working seamlessly together.
The MOSFETs act as switches synchronized with the oscillating signal from the KA3525A IC. This
coordinated action, combined with filters and other signal conditioning units, enables the conversion
process. The outcome of the study is the successful conversion of raw power into a stable pure sine
wave signal of 170V AC at the H-bridge terminals. In conclusion, the approach involving the
KA3525A IC, MOSFETs, and associated components proves effective in achieving the desired power
conversion for applications demanding high stability. This research recommends for further
improvement by using more MOSFETS for during design for higher power outputs as well as voltage
regulator to improve the precision capacity in terms of comparing the input and the output data.
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[11] R. Redl, & N. O. Sokal. Current-mode control, five different types, used with the three
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
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Mubeezi Conceptar, Kalyankolo Umaru, Val Hyginus Udoka Eze, Okafor O. Wisdom.
Design and Implementation of a DC to AC Power Electronics-Based Inverter that Produces Pure Sine Wave Output for Critical Engineering Applications.
International Journal of Recent Technology and Applied Science, vol 6, no. 1, pp. 1-13, March 2024. DOI: 10.36079/lamintang.ijortas-0601.615
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