Introductory CDIO Project [Energy Technologies][2020/21]
Topic outline
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Subject data Click here to expand
Subject supervisor and consultations with teacher Click here to expand
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The aim of this course is to make the students familiar with the team work to design, build and test simple electronic circuit. Also, how to write technical and engineering documentation taking in consideration electrical engineering, electronics, CAD and PCB design and computer simulation problems.
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Design of complete prototype of Simple electronic circuit (DC-DC converter) with control based on 555 integrated circuit. The project is divided into the following steps:
- Get familiar with laboratory equipment (oscilloscope, multimeters, DC power supply, assembly and soldering tools)
- DC-DC converter computer simulation,
- Design of control system based on IC timer 555 type (with the option of PWM frequency and duty changing),
- Selection of electronics elements (limitations to the elements accessible in lab),
- Calculations of transistor heat sink,
- Design of magnetic coil using simulation software,
- Draw of mechanical elements for coil winding utilizing 3D CAD software,
- Assembling of control circuit using general, universal board,
- Assembling of whole converter on universal board,
- The initial testing stage of assembled circuit with the possibility to correct connection structure, changing the electronics elements etc.,
- Designing of the printed circuit board PCB utilizing CSD software,
- Manufacturing of PCB board,
- G-code for drilling selected holes in PCB board,
- Assembling the electronic elements on PCB board (soldering and connection tests),
- Starting the operation stage of the assembled electronic circuit,
- Measurements of the assembled circuit (using of multimeters, oscilloscope),
- Making corrections if needed.
- Writing the project documentation (final report),
- Presenting the project with the final results.
Assessment: on base of done laboratory project.
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Class Topic References 1st Introduction and vocabulary 2nd Introduction 3rd Introduction 4th Introduction 5th Theory of buck converter and circuit simulation with LT Spice L15 6th Simulation of magnetic circuits with FEMM (Finite Element Method Magnetics) L1 7th Model of pot core choke L2, L4 8th Printed circuit board design with EAGLE L9 9th CNC Milling machine programming with use of G-code L10 10th Prototype of mechanical elements for the coil winding with use of 3D CAD software and 3D printing technology L11 11th Buck converter prototype - discussion of the project, task assignment and distribution; clarifying the project responsibility; clarifying the future expectations. Project description 12th Buck converter prototype - assessment, assistance and discussion of progress; clarifying the future expectations. Project description 13th Buck converter prototype - assessment, assistance and discussion of progress; feedback from the project implementation activities. Project description 14th Buck converter prototype - assessment, assistance and discussion of progress; providing the laboratory measurement results; guidelines for the project report. Project description 15th Evaluation of the buck converter prototype and project documentation EVALUATION -
- Electropedia: The World's Online Electrotechnical Vocabulary Dictionary
- Glossary of Electrical Engineering Terms - Maxim Integrated Dictionary
- Project description
- Work organization
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- Introduction to Buck Converters: Wikipedia
Buck converter fundamentals
- Circuit Simulation with LT Spice
- Exercise materials: LT-Spice lab
- Exercise materials (Polish): LT-Spice
- LTspice Tutorial - Wilfrid Laurier University Physics Labs LT-Spice Tutorial
- Download link to LT-Spice: http://www.linear.com/designtools/software/
- Details and examples of NE555 use: Wikipedia | Tutorial
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Please download installation file and install LTspiceXVII.exe on your computer.
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Exercise of Axially Symetric Air Coil model in FEMM software
- Lecture materials Exercise description
- Lecture materials (Polish) Lecture slides
- L1 exercise - Axially Symetric Air Coil model in FEMM (in Polish) Exercise description PL | Exercise description ENG
- L2 exercise - Pot core choke part 1 (in Polish) Exercise description PL | Exercise description ENG
- L4 exercise - Pot core choke part 1 (in Polish) Exercise description PL | Exercise description ENG | Data of HKR magnetic materials
- FEMM Software: http://www.femm.info/wiki/HomePage
How to design coil bobbin in 3D CAD and how to manufacture using 3D printer
- How to design a 3D model - requied for the 3D printer Tutorial
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Simulation software for power electronics and electric drives:
Polish installation package: https://cdn.mostwiedzy.pl/e6/36/e1/d3/0_1300203232101181_FME/tcad8portable.zip
English installation package: https://cdn.mostwiedzy.pl/e6/36/e1/d3/0_1300203232101181_FME/tcad8portable.zip
Software is in demo version, saving the files is disabled.
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- Buck converter: Simulation, Design and Prototyping
- Oscilloscope Basics and Training
- Exemplary final report Final report
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- Mosfet driver IR2121
- Integrated circuit NE555
- Diode BYV42
- Transistor MOSFET type AP60T10
- Ferroxcube core E30
- Ferroxcube core E32
- Magnetic material 3C90
- Ferrite cores Polfer Ferroxyd F-1001, F-2001, F-3001
- Ferrite E core from MAGNETICS
- Pot core from Magnetics
- Ferrite cores from Magnetics
- MC34151, MC33151 High Speed Dual Mosfet Driver
- Optocoupler ACPL-W70L
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- Manual of electronic circuits simulation software LT Spice http://www.linear.com/designtools/software/
- LT Spice transistors library including model BC107
- Manual of printed circuit board design software EAGLE Light Edition http://www.cadsoftusa.com/
- David Meeker FiniteElement Method Magnetics. User’s Manual.
- David Meeker FEMM 4.0 Magnetostatic Tutorial.
- Kazimierczuk M.K.: High-frequency magnetic components. John Wiley & Sons, 2009.
- Software FEMM: http://www.femm.info/wiki/HomePage
- ELHAND inductors and transformers: http://www.elhand.pl/
- HaKRon magnetic cores: https://www.hkr.de/home-en.html
- By Chen, Wai-Ka, Electrical Engineering Handbook, Elsevier, 2005.
