₦airaland Forum

etching in progress.

PCB art work.

The auxiliary power supply uses a flyback converter to
step down battery voltage from 40-60v to

1. 13v to power mosfet drive stage.
2. Isolated 15v to drive the output IGBT stage.

(note the transformer winding should be reversed as against the schematic's)

Auxillary Power Supply

more to follow soon

System Block diagram.

Objectives.

*** Input
46-60Vdc

***Output
220Vac (+/- 5Vac)
50Hz frequency
2000W

A search on google would provide enough literature review
of inverters.

For this project I built a pure sine wave(PSW) inverter
using a high frequency(HF) design.

In summary input voltage from the battery is stepped up to
350Vdc using PWM (pulse width modulation),
this in turn is chopped using SPWM (sine pulse width modulation)
and filtered to retrieve a 220vac 50Hz output.

Alternative energy sources have become very popular around the globe;
be it in developed nations or otherwise.

Our country Nigeria is no exception.
One of the components of an alternative energy system is an inverter.

Inverter build and design is very extensive and varies from simple to complex designs.

Ok good.

Hope you have some photos for us

Glossy paper is available from those who sell
printing materials... those who sell ordinary stationery
would not know what you are talking about.

@temizeee

hydrogen peroxide in mouth wash is too weak for etching;
and yes i mean car battery seller, the acid usually comes
in a small plastic jerrycan

@temizeee

hydrogen peroxide sold in the chemicals section of most markets (particularly soap makers)
you can buy sulfuric acid from those who sell car batteries (buy the diluted one)

Spot the difference.

the tests show varying ESR values for capacitors that look
similar.
For actual use (especially in a high frequency switching circuit),
the capacitor with the least ESR value is most suitable

the next picture is of the last 8,200uf
capacitor. The meter is clearly on the number 5

Incidentally, the picture above was from testing the 12,000uf capacitor.

below is one of the 8,200uf capacitor.

the meter deflects almost to the middle point between the numbers 2 and 5.

Below is what a normal ESR reading should show on
the meter scale (analogue for now, maybe one day in future I would make it a digital readout)

The meter deflects slightly to the right of the number 2.

Physically they all appear to be ok.
However testing suggest otherwise.

The test is of three capacitors; one 12,000uf and two 8,200uf

I posted photos of three capacitors I was testing for
ESR with the pcb I built earlier in this thread.

Unfortunately, the nairaland bot banned my account/posts.

See a simple pcb design thread below

https://www.nairaland.com/1854486/simple-pcb-design#25422558

Very simple - voltage isolation, the optocoupler maintains the isolation
between the output and input.

@acorntree

chairman, any new developments?

Nice one,

This is encouragement for those interested in electronics design.
Is the copper pour you used for ground continuous?

Sulfuric acid which I use is available from car battery sellers for about =N=700 for a 4litre plastic can.
HCL which might only be available from lab equipment suppliers around you would cost far much more.


Tell those you buy electronic components from that you are interested in buying pcb boards. They
can include it in their next stock, it is a very convenient method I use myself.

@usisky

There are other PCB design software in addition to EagleCAD. Test as many as you can and settle for the
one you are most comfortable with.

Look for complete tutorials on youtube/google. It would do you a lot of good.

PCB boards are sold in Oshodi, Mushin , Alaba.

The top screen and etching solution procedure was covered in a previous post

@usisky

Once you control the the on/off duration of semiconductor switches in a
to influence the output of a power circuit, you have an SMPS (switch mode power supply).

This project involves SMPS technology in two places.

(1) the DC-DC stepdown (48V -12v/5v) flyback converter
(2) buck converter switched at 40khz.

In the not to distant future I will post more detailed SMPS designs.

@usisky

thanks for posting pictures of your work.

some points to note for good pcb design.

(1) keep copper tracks between components as short as possible. This would reduce resistance and stray inductance
(common causes of unwanted results in electronics circuit design)
(2) learn how to use the "ground pour" tool in your PCB design software. It eliminates spaghetti like ground connections in your design
and more importantly it reduces noise due to track resistance and stray inductance.
(3) if you pcb design software is quite popular, you can visit youtube for tutorial videos. You would be designing like a pro in no long time.
PCB price depends on availability. 4ft by 4ft goes for between =N=3,000 to =N=4,000

Once more thanks Jakumo for your comments, hopefully more contributors would help us with details
of projects they have undertaken everyone stands to gain from this.

In addition to All circuits there are other useful sites like diyaudio, diysmps, edaboard, avfreaks among others.