Power Supply Project

Hongtao Peng

Course Code: CAD 1133

Course Name: CAD for Electronics

Date: April 14, 2015

Submitted to: Professor Louis Bertrand

Letter of transmittal
To: Louis Bertrand
From: Hongtao Peng
Date: April 14,2015
Re: Power supply project report
I am pleased to submit this report in partial fulfillment of the requirements for the CAD 1133 CAD
for Electronics course in the Electro-Mechanical Engineering Technology program at Durham
College. The report details the design, construction and testing of an electronics workbench power
supply.
The attached report is of my own creation. It includes the work of others used by permission and
properly attributed, and I have reviewed its entire contents before submitting it for grading. I
understand what is meant by the terms "academic integrity" and "plagiarism" and guarantee that I am
abiding by Durham College's Academic Integrity Policy #ACAD-101.
Sincerely,
Hongtao Peng

Abstract
This power supply project is built to produce a fixed 5V DC output voltage, positive and negative
variable voltage which is adjust from 0V to +/-15V and stable +/-15V AC voltage. Also, the switch
controls the whole project and LED. It use a fuse to protect the power supply.
At the beginning of this project, it needs a transformer to convert high AC voltage to low AC voltage.
With the low voltage through the four diodes, it will convert to DC voltage. Then, this DC voltage
through different parts in the circuit board, the outputs will become what the project need.
Follow the schematic to build the circuit board and soldering all the components. Then, place board,
panel Meter, buttons, LED, switch, fuse, potentiometer and transformer in the enclosure. Check all the
wires are in good connection and start to test this project.
The output values shows between Multimeter and panel Meter might be different. Make sure those
deviation are in +/-5%. For the safety, the resistance in ground path is less than 1k. Also, check the
potentiometer can control the variable DC output voltage with the range is from 0V to +/-15V.
With all the steps shows in the top done, the power supply project should be finished completely.

Acknowledgements
Thanks for the following people help to finish this project.
Cameron Lunau helped on how to connect the panel Meter.
Thomas Drummond helped on the variable regulator connection in Multisim.
Jiarui Fan helped on the schematic of PCB board in Eagle.
Dean Rauch helped on the wires connection between the board and output buttons.

Any remaining errors or inaccuracies are the responsibility of the author.

Contents
ABSTRACT..................................................................................................................................................III
ACKNOWLEDGEMENTS.........................................................................................................................IV
CONTENTS...................................................................................................................................................V
LIST OF FIGURES....................................................................................................................................VII
1

INTRODUCTION...............................................................................................................................1

1.1

THE POWER SUPPLY PROJECT................................................................................1

1.2

PURPOSE OF A POWER SUPPLY...............................................................................1

1.3

OBJECTIVES OF THE PROJECT.................................................................................1

1.4

LAYOUT OF REPORT...............................................................................................1

DESIGN AND THEORY OF OPERATION.....................................................................................2

2.1

DRAFT SCHEMATIC.................................................................................................2

2.2

CIRCUIT SIMULATION SOFTWARE...........................................................................3

2.3

PRIMARY CIRCUIT AND TRANSFORMER.................................................................4

2.4

RECTIFIERS AND FILTERS.......................................................................................5

2.5

FIXED 5V REGULATOR...........................................................................................6

2.6

VARIABLE POSITIVE REGULATOR...........................................................................6

2.7

TRACKING NEGATIVE REGULATOR..........................................................................7

PRINTED CIRCUIT BOARD...........................................................................................................8

3.1

PCB DESIGN SOFTWARE (EAGLE).........................................................................8

3.2

COMPONENTS AND LIBRARIES...............................................................................8

3.3

SCHEMATIC CAPTURE.............................................................................................9

3.4

PRINTED CIRCUIT BOARD DESIGN.........................................................................9

3.5

PRINTED CIRCUIT BOARD PRODUCTION..............................................................10

POWER SUPPLY ENCLOSURE....................................................................................................12

4.1

ENCLOSURE DESIGN.............................................................................................12

4.2

ENCLOSURE FABRICATION...................................................................................13

FINAL ASSEMBLY AND TESTING..............................................................................................14

5.1

CIRCUIT BOARD ASSEMBLY AND TESTING..........................................................14

5.2

ENCLOSURE ASSEMBLY........................................................................................15

5.3

COMPLETE ASSEMBLY TESTING...........................................................................16

RESULTS AND CONCLUSIONS...................................................................................................17

6.1

SUMMARY OF RESULTS........................................................................................17

6.2

RECOMMENDATIONS.............................................................................................17

REFERENCES/BIBLIOGRAPHY.............................................................................................................18
APPENDICES...............................................................................................................................................19

APPENDIX A: COMPLETE SCHEMATIC...........................................................................19

APPENDIX B: PRINTED CIRCUIT BOARD DRAWING.......................................................21
APPENDIX C: POWER SUPPLY ENCLOSURE DRAWING...................................................23

List of Figures

Figure 1: Draft Schematic design........................................................................................2

Figure 2: Schematic designed in EAGLE............................................................................3
Figure 3: Multisim of different parts...................................................................................4
Figure 4: Shut down transformer and positive rectifier.......................................................4
Figure 5: Full wave of primary AC voltage.........................................................................5
Figure 6: Rectifiers and filters.............................................................................................5
Figure 7: Fixed 5V regulator...............................................................................................6
Figure 8: The variable positive regulator.............................................................................7
Figure 9: Tracking negative regulator.................................................................................7
Figure 10: Components list..................................................................................................8
Figure 11: wire is incorrect connection (from DC connect)................................................9
Figure 12: Board view in Eagle...........................................................................................9
Figure 13: Bottom view of board.......................................................................................10
Figure 14: Complete PCB board........................................................................................11
Figure 15: Components template paste on PCB board......................................................11
Figure 16: The sheet to follow...........................................................................................12
Figure 17: The Enclosure...................................................................................................12
Figure 18: Punch holes......................................................................................................13
Figure 19: Drill holes.........................................................................................................13
Figure 20: Complete circuit board.....................................................................................14
Figure 21: Fixed 5V...........................................................................................................14
7

Figure 22: Variable positive and negative regulator..........................................................15

Figure 23: Primary and secondary AC voltage..................................................................15
Figure 24: Multiple views of enclosure.............................................................................16
Figure 25: The value of AC output voltage.......................................................................16
Figure 26: Hand draft schematic (by Louis Bertrand).......................................................19
Figure 27: Complete schematic in EAGLE.......................................................................20
Figure 28: Screenshot of Eagle PCB design......................................................................21
Figure 29: PCB copper side...............................................................................................22
Figure 30: PCB top side.....................................................................................................22
Figure 31: Power supply assembly drawing of multiview................................................23

Introduction

This report is talked about how to build a power supply project. It use a transformer to convert AC
voltage to DC voltage to through the components on the circuit board. It also can be measured the
positive and negative 0~15 V AC/DC output voltage and fixed 5V DC voltage.

1.1 The Power Supply Project

This project build to get AC voltage and variable DC output voltage and stable 5V DC voltage. In order
to complete this project, it need to learn the knowledge from course in the Electro-Mechanical
Engineering Technology program. In the end of the power supply project, it should get correct values
of each outputs.

1.2 Purpose of a Power Supply

The power supply use a transformer to convert AC voltage to DC voltage, which need to study those
knowledge to know how the transformer works and the wires connection. Also, study of electronics
help to understand how the circuit works in different part. Those knowledge helps to build the power
supply project and fix problems which may happened in the end of testing the whole project.

1.3 Objectives of the Project

The main objectives of this project are:
i.

Test fixed 5V DC

ii.

Test positive 0~15V DC and negative 0~15V DC voltage

iii.

Test 0~15V AC voltage

1.4 Layout of Report

The report is divided into six sections. Section 1 (this section) contains introductory material. Section 2
covers the creation of the schematic diagram. Section 3 is the circuit board design. Section 4 is the
enclosure design. Section 5 is the complete power supply project testing. Finally, Section 6 concludes
the work and suggests areas for future investigations.

Design and Theory of Operation

This section shows the schematic of the power supply works. The key to dealing the power supply
works is to divide the whole circuit in five parts. The five parts are called Positive rectifier, Negative
rectifier, Fixed 5V regulator, Variable positive regulator, and Variable negative regulator.

2.1 Draft Schematic

In figure 1, the first picture shows how the transformer work and it wires connection. In the second
picture of figure 1, it shows the circuit board design. The circuit board can divided into three parts
include fixed 5V, variable positive and negative voltage regulator, and negative rectifier. Those picture
comes from DC connect which designed by Louis Bertrand. After draft schematic by hand, it need to
build the circuit in CAD system. The figure 2 shows the schematic in Eagle.

10

Figure 1: Draft Schematic design

11

Figure 2: Schematic designed in EAGLE

2.2 Circuit Simulation Software

This part will use the screenshot of Multisim to show for different parts shows in figure 3.

12

Figure 3: Multisim of different parts

2.3 Primary Circuit and Transformer

Primary AC Operation and transformer
In figure 4, Multisim is used to simulate the circuit with 120Vrms 60Hz source through transformer T1.
It use seven components which include 120volts 60Hz AC source, 0.5A Fuse, 1S1P switch and 4:3
Transformer. The transformer converts the 120V AC source to 28Vrms AC at secondary voltage. The
full wave of primary AC voltage is shown in Figure 5.

Figure 4: Shut down transformer and positive rectifier

13

Figure 5: Full wave of primary AC voltage

2.4 Rectifiers and Filters

In the figure 6, it is the circuit that have positive and negative rectifier and the DC filtering. Also, the
input will cause the two capacitor keep charge and discharge. The waveform of the capacitor will be a
smoothed.

Figure 6: Rectifiers and filters

14

2.5 Fixed 5V Regulator

In figure 7, shows the fixed 5V regulator circuit designed in Multisim. The input
comes from positive rectifier and across the LM7805. The LM7805 will reduce 5V
and the other voltage will come out across capacitor and diode D3.

Figure 7: Fixed 5V regulator

2.6 Variable positive regulator

In the figure 8, the LM117 and other components are connected as a positive regulator that the output
voltage to a value between 0V and +15V. The potentiometer will control the value of the output
voltage.
This part is similar to the fixed 5V regulator. The positive input goes in the LM117 and reduced some
voltage by LM117.

15

Figure 8: The variable positive regulator

2.7 Tracking negative regulator

The variable negative regulator is the negative output between 0V and 15V. It needs LM337, 741 type
operational amplifier U1 and other components control the output.

Figure 9: Tracking negative regulator

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Printed Circuit Board

This section shows the schematic in Eagle, the PCB design and how to make the circuit board.

3.1 PCB Design Software (Eagle)

The complete PCB designed by Eagle is shown in Figure 1. This software Eagle CAD is different than
AutoCAD. Before to move a component in Eagle, it should click Move first and then select the
component to move it. It is very important to check all the components at correct location. It also needs
to check all the wires all connect well that can zoom in to check the wires are on the components.

3.2 Components and Libraries

Most components are from the cad1133.lbr library. Because the diodes and chips have different type.
The components list is shown in Figure 10.

Figure 10: Components list

3.3 Schematic Capture

First, click Add function

to search and add componets.

17

Second, click right botton of the mice to select a componet nut, then, select property to rename or
change the value of the components.
Third, make sure that wires are actually connect between two components. It shows in figure 11 that
zoom in to check it.

Figure 11: wire is incorrect connection (from DC connect)

3.4 Printed Circuit Board Design

In the figure 12, place all the components in correct location and use DRC to check the board for
problems of insufficient clearances.

Figure 12: Board view in Eagle

3.5 Printed Circuit Board Production

First, after copper pouring, print it out like figure 13.
18

Figure 13: Bottom view of board

Second, use the machine to put the bottom view of board on the real board. Then, put the copper on the
board and remove the copper we do not want. Follow the board and get all holes out. The complete
board shows in figure 14.

19

Figure 14: Complete PCB board

Third, figure 15 shows print the component template out and paste on the PCB board. It easy to place
the components at correct location.

Figure 15: Components template paste on PCB board

20

Power Supply Enclosure

This section includes the enclosure design, notices and how to build the enclosure.

4.1 Enclosure Design

The enclosure is already made by two piece metal board. The enclosure design is to make some holes
that follow the sheet and the holes are enough to put some components on it. In the figure 16, it is the
sheet to follow to make holes. In the figure 17, it is the face and back of the enclosure that are
complete.

Figure 16: The sheet to follow

21

Figure 17: The Enclosure

4.2 Enclosure Fabrication

For the fabrication of the enclosure, it can separate to following steps. First, cut the sheet which shows
in figure 16 and paste on the enclosure. The front face template and rear face template are pasted on the
outside of the enclosure. As for the bottom face template, it pasted on the inside of the enclosure. Then,
start to punch the holes for front face and rear face. Make sure the panel is on the right position and
each holes punched twice to make an oval. It shows in figure 18. Next, start to drill the holes for the
bottom face which shows in figure 19. Last, file all the holes smooth. Those following photos come
from DC connect.

Figure 18: Punch holes

22

Figure 19: Drill holes

23

Final Assembly and Testing

This section is for the testing the circuit board with it outputs are all correct and in the right range error.
Also, it needs to test the enclosure for the holes it big enough to fit the components.

5.1 Circuit Board Assembly and Testing

The input of this circuit board is around 28V AC, then it through the four diodes and converts to DC
voltage. Next, this DC voltage will through different parts and it can test the output voltage to
identified those parts are worked. The complete circuit board is shown in figure 20.

Figure 20: Complete circuit board

The first testing part is fixed 5V, the details information is already talked in section 2. The secondary
AC voltage comes into the blue component which shows in figure 20 at the left top corner. After the
DC voltage through the 7805chip, the output of this part is around 5V which shows in figure 21.

Figure 21: Fixed 5V

24

Second, it is testing the positive and negative variable DC voltage. It should connect the DMM to the
output of the +0/15V or -0/15V button and the GND button. The potentiometer should turn to the
maximum voltage and compare the values shows in the Multimeter and the panel Meter. The positive
and negative values are shown in figure 22.

Figure 22: Variable positive and negative regulator

Figure 23: Primary and secondary AC voltage

5.2 Enclosure Assembly

The purpose of testing the enclosure is to know the transformer, switch, fuse, binding posts, LED, panel
Meter and circuit board are in right location and the holes are fit for those components. The multiple
views of the complete power supply project are shown in figure 24.

25

Figure 24: Multiple views of enclosure

5.3 Complete Assembly Testing

The complete power supply project testing include testing all the things that in the first and second part.
It also need to test the LED is working and the values of the AC output. The testing progress is shown
in figure 25.
26

Figure 25: The value of AC output voltage

27

Results and Conclusions

6.1 Summary of Results

For this power supply project, the whole project is done very well.
First, the circuit board design which already shows in section 3. All the components are placed at good
location. While soldering the components on the circuit board, it should follow the board view on
EAGLE to distinguish the positive and negative. Before soldering the next part, it need to test current
part should be worked. After all the soldering work are done, clearing the back of the circuit board to
remove the extra silver and make it as a good look.
Second, the fabrication of the enclosure should make all the holes is larger enough to suit the
components. Glue the template before punch holes and each holes punched twice to make an oval.
Place the transformer on the bottom to note two holes and then drill it. After all the holes are done, use
the file to make all the holes smooth.
Final, the output of fixed 5V of this project is 5.02V, which is a good number. The output of the
variable positive and negative DC voltage, the maximum voltage should be 15V. The panel Meter
shows 14.77V on the screen, however, the Multimeter shows 14.80V and -14.48V. Those values are
almost close to 15V and the output of 0V to negative 15V is a little bit lower. It should be figure out. As
for the AC output, the Multimeter shows 15.57V which means those values are a little bit high than
15V.

6.2 Recommendations
For the circuit board design, try to avoid use jumpers and leave enough space between each
components. After the board paste cupper, compare the real board and board view on EAGLE to make
sure the extra cupper is all removed.
The PCB fabrication, the enclosure is too thick that is hard to punch holes. Pay more attention and
careful on drill holes.
While soldering the panel Meter, it must read the introduction to solder correct location.

28

References/Bibliography
Mehta, V.K. (2008). Principles of Electronics. New Delhi: Ram Nagar.
DC Connect. (n.d. ). Retrieved April 13, 2015, from
https://durhamcollege.desire2learn.com/d2l/le/content/114699/Home

29

Appendices
Appendix A: Complete Schematic

Figure 26: Hand draft schematic (by Louis Bertrand)

30

Figure 27: Complete schematic in EAGLE

The schematic in EAGLE is followed the hand draft schematic and is more details that the draft
schematic. The schematic in EAGLE shows all the components and values.

31

Appendix B: Printed Circuit Board Drawing

Figure 28: Screenshot of Eagle PCB design

32

Figure 29: PCB copper side

Figure 30: PCB top side

The figure 28 shows the complete schematic in Eagle with all the components are correct connection
and place the cupper already. The figure 29 and 30 are the bottom view and top view of the circuit
board.

33

Appendix C: Power Supply Enclosure Drawing

Figure 31: Power supply assembly drawing of multiview

This is the multiview of the enclosure that used AutoCAD to draw. This scale is 1:2 for the enclosure.

34