dics rep

Download as docx, pdf, or txt
Download as docx, pdf, or txt
You are on page 1of 41

CHAPTER 1

COMPANY PROFILE

Fig 1. Company logo

 Digital Instruments and Control Systems (DICS) is an established


exporter and manufacturer in the field of digital instruments and control
systems. Since its inception in 1996, DICS has been dedicated to
providing high-quality products and solutions to meet the evolving needs
of its customers. With a commitment to innovation and customer
satisfaction, DICS offers a comprehensive range of products and services
tailored to various industries.
 Location - # B - 261, 6th Main, 2nd Stage, Peenya Industrial Estate,
Bangalore,Karnataka
 Email - bangalore@dicsglobal.com
 Website - http://www.dicsglobal.com/
Internship Report - Power Electronics 2023-2024

1.1 COMPANY OVERVIEW

Digital Instrumentation and Control System (DICS) is a company established in 1996, has
grown into a venerable entity over its 25+ years of operation in Bangalore, India. With a
dynamic presence spanning the length and breadth of the nation, DICS has solidified its
position as a leading player in the industry. In a strategic move in its founding year, DICS
partnered with the multinational powerhouse, Toshiba, setting up its Chennai office
concurrently. This partnership marked the beginning of a journey characterized by
relentless expansion and innovation.

DICS's commitment to excellence is exemplified by its strategic collaborations with top-


tier names in the automation realm, such as Omron Automation, Fuji Electric, Pro-face,
Autonics, CKD, IDEC, Wohner, and PATLITE. These partnerships have empowered
DICS to offer cutting-edge solutions to its diverse clientele, catering to a myriad of
industry needs.

Expanding its footprint across India, DICS has established a strong presence in key cities
like Chennai, Mumbai, Hyderabad, Coimbatore, Pune, Noida, Lucknow, Vizag, and has
relocated to emerging hubs like Hubli, Mysore, and Pondicherry.

Central to DICS's operations is its headquarters in Bangalore, boasting an owned,


meticulously designed, state-of-the-art manufacturing and testing facility. This facility
serves as a testament to DICS's unwavering dedication to quality, innovation, and
customer satisfaction, setting the stage for continued growth and success in the years to
come.

Quality Policy / Processes


We work with thousands of suppliers to drive innovation across our products and support
mutual and sustainable growth.Accomplish advanced automation challenges through
smart open, industry solutions to reduce complexity and engineering time. We will be fair,
honest, transparent and ethical in our conduct; everything we do must stand the test of
public scrutiny.

Dep of ECE,EWIT Page1


Internship Report - Power Electronics 2023-2024

Our Mission: Increase the efficiency of applications and enabling energy saving by
simplifying the monitoring and control using our smart solutions.

About The Company

Digital Instruments & Control Systems popularly known as DICS, is an Automation


company. Manufacturing panels for different machines including Elevators, hydraulics,
packaging, many more machines.Mostly specialized in OMRON and FUJI components.
Providing professional solution to large & medium enterprise for their Automation needs.

Our Team:

Our teams of highly skilled and experienced professionals help us in the attainment of a
number of the firm’s targets, predefined. The team, for reasons of better and highly
effective management of operations, has been parted into several highly operational units.
These units, in the most effective and efficient manner, boosts the firm’s production
capacity. The division of these professionals is done as per their area of expertise. Further,
regular training sessions are provided, for maximum employee satisfaction.

1.2 Products and Services

1.2.1 Products Overview

1. Aviva Lithium UPS -For Home & Office

Dep of ECE,EWIT Page2


Internship Report - Power Electronics 2023-2024
Fig 1.1 Lithium UPS

Specification of Lithium UPS(Uninterruptable Power Supply)

 Model Name : ASPL UPS.

 Capacity : 1KVA TO 5KVA.

 Usage/Application : Power Backup.

 Battery Type : Lithium Ferro Phosphate based Battery (Li-Fe Po4).

 Phase : Single Phase.

 Operating Temperature : -10 C to +55 C

 Backup Time : Upto 2 hours.

 Form Factor : Tower Model.


 Output Voltage : 220V.

 Frequency : 50Hz.

 Display Type : LCD.

 Certification : BIS.

 Communication : Bluetooth.

 Operating Voltage : 90 V to 300 V.

 Operating Frequency : 50Hz.

 Over Voltage Cuttofff : 270 V.

 Service location : Bengaluru.

 Country : MADE IN INDIA.

Say goodbye to clunky, outdated lead-acid batteries and hello to the future of backup
power: Lithium UPS. These innovative systems are revolutionizing the market with their
increased efficiency, reliability, and lifespan, making them the perfect choice for
demanding applications like data centers, medical facilities, and industrial automation.

Dep of ECE,EWIT Page3


Internship Report - Power Electronics 2023-2024

Imagine lightning-fast recharges after power outages, ensuring minimal downtime for
critical equipment. Picture a sleek, space-saving design that fits even in the tightest
corners. Lithium UPS delivers both, thanks to its lightweight batteries and superior
temperature tolerance. Plus, enjoy worry-free maintenance with a lifespan that dwarfs
traditional lead-acid options.

While the initial cost might be higher, the long-term savings are undeniable. You'll spend
less on replacements, experience fewer disruptions, and benefit from a smaller
environmental footprint. And with an ever-expanding selection across various power
ranges, finding the perfect Lithium UPS for your needs is easier than ever.

So, whether you're protecting sensitive data, ensuring patient safety, or keeping your
industrial processes humming, Lithium UPS offers a powerful and modern solution for
your backup needs. Talk to a power specialist today and discover how Lithium UPS can
revolutionize your power protection strategy.

2. AC-DC Adapter- Aviva ABS Plastic 5V/1A

Fig 1.2 AC-DC Adapter.

Specification of Aviva ABS Plastic 5V/1AAC-DC Adapter

 Voltage : 5 V.

Dep of ECE,EWIT Page4


Internship Report - Power Electronics 2023-2024
 Current : 1 A.

 Usage/Applications : Electronic Instruments.

 Material : ABS Plastic.

 Power : 10 Watt.

 Type : Adapter.

 Input Volatage : 90-300 V AC.

 Operating Temperature : 0-50 C

 Input Frequency Band : 47 to 63 Hz.

 Efficiency > 85%.


An AC to DC adapter, also known as a power adapter or power supply, is a device that
converts alternating current (AC) electricity from a wall outlet into direct current (DC)
electricity that can be used to power electronic devices. It typically consists of a plug that
connects to the wall outlet, a transformer or converter that converts the AC voltage to the
required DC voltage, and a cable or connector that connects to the electronic device.

The AC to DC adapter is commonly used to power a wide range of devices, such as


laptops, smartphones, routers, and other electronics that require DC power. The adapter
ensures that the device receives the correct voltage and polarity to function properly.

When you plug the AC to DC adapter into a wall outlet, it converts the AC power from
the outlet into the appropriate DC voltage that matches the requirements of the device.
This allows the device to safely and efficiently operate.

It's important to note that different devices may require different DC voltage levels, so it's
essential to use the correct adapter that matches the device's specifications. Using an
incorrect adapter can potentially damage the device or cause it to malfunction.

Versatility: AC to DC adapters come in various shapes and sizes to accommodate


different devices and power requirements. They can be found in the form of wall adapters,
desktop power supplies, or even built-in components in electronic devices.

Voltage Regulation: Some AC to DC adapters have built-in voltage regulation circuits to


ensure a stable and consistent output voltage. This is important for sensitive electronics
that require a precise and steady power supply.
Dep of ECE,EWIT Page5
Internship Report - Power Electronics 2023-2024

Polarity: AC to DC adapters also take into account the polarity of the DC output. The
polarity refers to the positive and negative terminals of the DC voltage. It's crucial to
match the polarity of the adapter with the device to avoid any damage or incorrect
operation.

Efficiency: Modern AC to DC adapters are designed to be energy-efficient, minimizing


power loss during the conversion process. This helps to reduce energy consumption and
heat generation, making them more environmentally friendly.

Safety Features: Many AC to DC adapters incorporate safety features such as overcurrent


protection, over-voltage protection, and short-circuit protection. These features help
safeguard both the adapter and the connected device from potential damage or hazards.

3. Single Axis Solar Tracker

Dep of ECE,EWIT Page6


Internship Report - Power Electronics 2023-2024

Fig.1.3 Single Axis Solar Tracker

Specifications of Single Axis Solar Tracker

 Usage/Applications : Solar Pumping System,Solar Residencials and Solar Roof Tops.

 Capacity : 150 Wattts.

 Type : Solar Powered.

 Axis Type : Single Axis.


 IP Rating : IP67.

 Load Power : 150 W.

 Country : Made in INDIA.

A single-axis solar tracker is a mechanism designed to orient solar panels or photovoltaic


modules along one axis to optimize their exposure to sunlight throughout the day. Unlike
fixed solar arrays, which remain stationary, single-axis trackers automatically adjust the
tilt angle of solar panels to track the sun's apparent motion across the sky.

Typically, single-axis trackers rotate panels along a horizontal axis, allowing them to
follow the sun's east-to-west path from sunrise to sunset. By continuously adjusting the
orientation of solar panels, single-axis trackers can significantly enhance energy
generation compared to fixed installations, maximizing solar energy capture and
improving overall system efficiency.

Single-axis trackers come in various designs, including:


Dep of ECE,EWIT Page7
Internship Report - Power Electronics 2023-2024

 Horizontal Single-Axis Trackers: These trackers rotate panels along a horizontal


axis aligned with the Earth's north-south axis, optimizing sunlight exposure as the sun
moves across the sky.

 Tilted Single-Axis Trackers: In this design, panels are mounted on a tilted axis,
allowing them to track the sun's path while also adjusting their tilt angle throughout
the day to maximize energy capture.

 Polar-Aligned Single-Axis Trackers: These trackers tilt panels along an axis aligned
with the geographic latitude of the installation site, optimizing solar exposure based
on the sun's seasonal variations.

Single-axis solar trackers offer several advantages, including increased energy output,
improved system efficiency, and reduced overall cost per kilowatt-hour of electricity
generated. They are commonly used in utility-scale solar power plants and commercial
installations where maximizing energy production is essential to ensure the economic
viability of the solar project.

While single-axis trackers enhance solar energy capture, they also require additional
mechanical components and maintenance compared to fixed installations. However, the
increased energy output and economic benefits often outweigh these considerations,
making single-axis solar trackers a popular choice for large-scale solar energy projects
aiming to maximize energy production and return on investment.

1.2.2 Services Overview

"The Engineers Design & Develop in Bringing Imagination to reality....."

AVIVA SMART SOLUTIONS’ Engineers ensure the path by applying experience and
ingenuity to your concept, problems and products. They help customers to make sure that
their concept gets to production as soon as possible so that customers can get on to work
with it.

Their Design Service Capabilities Include:

• Conceptualization & implementation of Electronic System Design.

• Mechanical Design for Products & systems from concept to production.

• High level Software Design for the products such as PCB.

Dep of ECE,EWIT Page8


Internship Report - Power Electronics 2023-2024
• Low level & high level Design, Validation & Testing services.

• Custom Prototyping & Production.

• Simplifying the business by solving the problems which in turn increases profitability

and also lead to Customer satisfaction.

CHAPTER 2

TASKPERFORMED
2.1 INTRODUCTION
Power electronics stands at the forefront of modern engineering, serving as the
pivotal link between electronics and electric power control and conversion. At its core lies
the utilization of semiconductor switching devices like diodes, thyristors, power
MOSFETs, and IGBTs to efficiently manage substantial amounts of electrical energy.
Unlike conventional electronic systems focusing on signal and data transmission, power
electronics deals with the direct manipulation of electrical power. A quintessential
example is the AC/DC converter (rectifier) ubiquitous in numerous consumer electronics,
facilitating the conversion from alternating current to direct current.

The realm of power conversion systems encompasses various classifications based on


input and output power types, including AC to DC, DC to AC, DC to DC, and AC to AC
conversions. Power electronic devices play multifaceted roles as switches or amplifiers,
each tailored to specific applications. Switching devices, mimicking ideal properties of
open or closed circuits, ensure minimal power dissipation, thus enhancing system
efficiency. Conversely, amplifiers regulate current flow continuously, albeit at the expense
of increased power dissipation.

DC to AC converters are instrumental in generating AC waveforms from DC sources,


finding utility in diverse applications such as adjustable speed drives, uninterruptible
power supplies, and photovoltaic inverters. Notably, these converters adopt distinct
topologies categorized as voltage source inverters (VSIs) and current source inverters
(CSIs), each offering precise control over output characteristics.

AC to AC converters empower users to manipulate voltage, frequency, and phase


parameters of AC waveforms, thereby enabling tailored power delivery to loads. These

Dep of ECE,EWIT Page9


Internship Report - Power Electronics 2023-2024

converters span various types, including AC Voltage Controllers, frequency converters,


and specialized variants like cycloconverters and matrix converters.

The pervasive applications of power electronics span a broad spectrum, ranging from
miniature DC/DC converters in handheld devices to gigawatt-scale high voltage DC
transmission systems interconnecting electrical grids. Noteworthy examples include
AC/DC converters facilitating device mains connectivity,

AC/AC converters for voltage and frequency adjustment, and DC/AC inverters crucial for
backup power systems and renewable energy integration.

Among the arsenal of power electronic solutions, switched-mode power supplies (SMPS)
reign supreme, leveraging switching regulators to achieve high efficiency and
compactness. By operating at elevated frequencies, SMPSs ensure minimal transformer
size while mitigating heat generation. Despite their advantages, challenges such as
electromagnetic interference and harmonic distortion necessitate careful design
considerations.

In essence, the evolution of power electronics continues to revolutionize energy


management and distribution, driving advancements across industries and enhancing the
efficiency and reliability of electrical systems worldwide.

2.2 TOOLS USED

2.2.1 SOFTWARE Overview

Dep of ECE,EWIT Page10


Internship Report - Power Electronics 2023-2024

1. ORCAD TOOL

Fig 2.1 Orcad Software Logo.

OrCAD is a comprehensive suite of electronic design automation (EDA) software tools


widely used by engineers and designers for schematic capture, PCB layout, simulation,
and analysis in the field of electrical and electronics engineering. Developed by Cadence
Design Systems, this suite offers a user-friendly interface and powerful features tailored
to meet the needs of both novice and experienced users.

The suite includes various modules such as Capture for schematic design, PCB Editor for
PCB layout, PSpice for circuit simulation, and PCB SI for signal integrity analysis. These
tools seamlessly integrate to provide a cohesive environment for designing and validating
complex electronic systems.

Capture allows users to create schematics and capture electronic designs efficiently,
facilitating collaboration and design exploration. PCB Editor enables precise placement
and routing of components on the PCB, with advanced features for signal integrity
analysis and design rule checking to ensure manufacturability and reliability.

PSpice is a powerful simulation tool that allows users to model and analyze analog,
digital, and mixed-signal circuits. It offers a wide range of simulation options, including
transient analysis, AC analysis, and Monte Carlo analysis, enabling designers to evaluate
circuit performance and verify design specifications before prototyping.

PCB SI focuses on signal integrity analysis, helping designers identify and mitigate issues
such as signal reflections, crosstalk, and timing violations that can affect the performance

Dep of ECE,EWIT Page11


Internship Report - Power Electronics 2023-2024

of high-speed digital designs. By simulating signal behavior in the presence of various


factors, PCB SI assists in optimizing PCB layouts and ensuring signal integrity across the
entire system.

Overall, this suite is a versatile and powerful toolset that streamlines the electronic design
process from concept to production, empowering engineers to create innovative and
reliable electronic products efficiently. Its intuitive interface, extensive feature set, and
robust simulation capabilities make it a preferred choice for professionals in industries
ranging from aerospace and defense to consumer electronics and telecommunications.

Fig 2.2 General Schematics editor in orcad.

Schematics in OrCAD serve as the foundational blueprint for electronic designs,


providing a graphical representation of the circuitry and its components. OrCAD's
schematic capture tool is a crucial component of the OrCAD suite, enabling engineers and
designers to translate their ideas into tangible circuit designs efficiently. Here's a brief
overview of OrCAD schematics:

1 User-Friendly Interface: OrCAD's schematic capture interface is designed to be


intuitive and user-friendly, allowing users to quickly create, modify, and annotate
schematics. The interface provides easy access to a comprehensive library of electronic
components, symbols, and connectors, streamlining the design process.

Dep of ECE,EWIT Page12


Internship Report - Power Electronics 2023-2024

2 Extensive Component Library: OrCAD offers an extensive library of pre-


designed electronic components, covering a wide range of devices, from basic resistors
and capacitors to complex integrated circuits and microcontrollers. Users can easily
search and select components from the library, saving time and ensuring design accuracy.

3 Hierarchical Design: OrCAD supports hierarchical schematic design, allowing


users to organize complex circuits into manageable subcircuits or modules. This
hierarchical approach enhances design clarity and facilitates modular design reuse,
promoting design efficiency and collaboration.

4 Annotation and Documentation: OrCAD enables users to annotate components,


nets, and ports within the schematic, ensuring proper identification and documentation of
the design. Users can add annotations such as reference designators, part numbers, and
descriptions, enhancing the clarity and readability of the schematic.

5 Netlist Generation: OrCAD generates a netlist based on the schematic, which


serves as the input for downstream processes such as PCB layout and simulation. The
netlist captures the connectivity information of the circuit, including component pin
assignments and interconnections, enabling seamless integration with other tools within
the OrCAD suite.

6 Cross-Probe and Cross-Annotation: OrCAD facilitates cross-probing and


crossannotation between the schematic and other design domains, such as PCB layout and
simulation. This bi-directional communication allows users to quickly navigate between
different views of the design, ensuring consistency and accuracy across the entire design
flow.

7 Simulation Integration: OrCAD's schematic capture tool seamlessly integrates


with OrCAD's simulation tools, such as PSpice, enabling users to perform comprehensive
circuit simulations directly from the schematic. This integration enables designers to
validate their designs and verify performance specifications early in the design process,
reducing the risk of errors and costly redesigns.

Overall, OrCAD schematics provide a powerful and intuitive platform for capturing,
documenting, and validating electronic designs, empowering engineers and designers to
bring their ideas to life efficiently and effectively. With its rich feature set, extensive
component library, and seamless integration with other OrCAD tools, OrCAD schematics
play a pivotal role in the electronic design process, from concept to production.

Dep of ECE,EWIT Page13


Internship Report - Power Electronics 2023-2024

2.2.2 HARDWARE OVERVIEW

1. SURFACE MOUNT RESISTORS

Fig 2.3 SMD

A surface mount resistor is a tiny rectangular ceramic body with silver conductive
edges on either end. Also referred to as surface mount technology, an SMD resistor offers
advantages in saving space on printed circuit boards (PCBs). It features the resistance
value code printed onto it, where there is space. Solder paste is printed onto the mounting
pads of a PCB, and the resistors are placed automatically onto these pads by pick and
place equipment. The whole board is then passed through a reflow oven which melts the
solder into place, making the contacts.

A surface mount resistor provides the same functionality as the more traditional axially
leaded resistors but has a lower power dissipation capacity and oftentimes a lower stray
inductance and capacity. Surface mount resistors can be thick film, which is most
commonly used, thin film, which offers accuracy and stability, metal strip, for current
sensing, or wirewound, which is molded construction as opposed to a flat chip.

Surface mount resistors are used in large quantities and are the preferred resistor for use in
electronics equipment, because of the small size and high reliability. Surface mount
resistors are commonly used in telecommunication, automotive, and medical equipment,
as well as in personal devices, displays, and advanced technology research instruments.

Dep of ECE,EWIT Page14


Internship Report - Power Electronics 2023-2024
2. CERAMIC CAPACITOR

Fig 2.4 Ceramic Capacitor

A ceramic capacitor is a non-polarized fixed capacitor made out of two or more


alternating layers of ceramic and metal in which the ceramic material acts as the dielectric
and the metal acts as the electrodes. The ceramic material is a mixture of finely ground
granules of paraelectric or ferroelectric materials, modified by mixed oxides that are
necessary to achieve the capacitor's desired characteristics. The electrical behavior of the
ceramic material is divided into two stability classes:

 Class 1 ceramic capacitors with high stability and low losses compensating the
influence of temperature in resonant circuit application. Common EIA/IEC code
abbreviations are C0G/NP0, P2G/N150, R2G/N220, U2J/N750 etc.

 Class 2 ceramic capacitors with high volumetric efficiency for buffer, by-pass and
coupling applications Common EIA/IEC code abbreviations are: X7R/2XI, Z5U/E26,
Y5V/2F4, X7S/2C1, etc.

The great plasticity of ceramic raw material works well for many special applications and
enables an enormous diversity of styles, shapes and great dimensional spread of ceramic
capacitors. The smallest discrete capacitor, for instance, is a "01005" chip capacitor with
the dimension of only 0.4 mm × 0.2 mm.

The construction of ceramic multilayer capacitors with mostly alternating layers results in
single capacitors connected in parallel. This configuration increases capacitance and
decreases all losses and parasitic inductances. Ceramic capacitors are well-suited for high
frequencies and high current pulse loads.

Dep of ECE,EWIT Page15


Internship Report - Power Electronics 2023-2024
3. ELECTROLYTIC CAPACITOR

Fig 2.5 Electrolytic Capacitor

Electrolytic capacitors have a metallic anode covered with an oxidized layer used as
dielectric. The second electrode is a non-solid (wet) or solid electrolyte. Electrolytic
capacitors are polarized. Three families are available, categorized according to their
dielectric.

 Aluminum electrolytic capacitors with aluminum oxide as dielectric

 Tantalum electrolytic capacitors with tantalum pentoxide as dielectric

 Niobium electrolytic capacitors with niobium pentoxide as dielectric.

The anode is highly roughened to increase the surface area. This and the relatively high
permittivity of the oxide layer gives these capacitors very high capacitance per unit
volume compared with film- or ceramic capacitors.

The permittivity of tantalum pentoxide is approximately three times higher than


aluminium oxide, producing significantly smaller components. However, permittivity
determines only the dimensions. Electrical parameters, especially conductivity, are
established by the electrolyte's material and composition. Three general types of
electrolytes are used:

 non solid (wet, liquid)—conductivity approximately 10 mS/cm and are the lowest
cost.

 solid manganese oxide—conductivity approximately 100 mS/cm offer high quality


and stability.

Dep of ECE,EWIT Page16


Internship Report - Power Electronics 2023-2024

 solid conductive polymer (Polypyrrole or PEDOT:PSS)—conductivity approximately


100...500 S/cm,[20][21] offer ESR values as low as <10 mΩ

Internal losses of electrolytic capacitors, prevailing used for decoupling and buffering
applications, are determined by the kind of electrolyte.

4. SMD CAPACITOR

Fig 2.6 SMD Capacitors

SMD capacitor is nothing but a capacitor with compact size and no long lead. It is
developed in such a way that it offers an advantage for mass production of electronic
devices and equipment, along with some technical advantage in the operation of
highfrequency devices.

Dep of ECE,EWIT Page17


Internship Report - Power Electronics 2023-2024
5. LED (LIGHT EMITTING DIODE)

Fig 2.7 LED

Early LEDs were often used as indicator lamps, replacing small incandescent
bulbs, and in seven-segment displays. Later developments produced LEDs available in
visible, ultraviolet (UV), and infrared wavelengths with high, low, or intermediate light
output, for instance, white LEDs suitable for room and outdoor lighting. LEDs have also
given rise to new types of displays and sensors, while their high switching rates are useful
in advanced communications technology with applications as diverse as aviation lighting,
fairy lights, strip lights, automotive headlamps, advertising, general lighting, traffic
signals, camera flashes, lighted wallpaper, horticultural grow lights, and medical devices.
[8]

LEDs have many advantages over incandescent light sources, including lower power
consumption, a longer lifetime, improved physical robustness, smaller sizes, and faster
switching. In exchange for these generally favorable attributes, disadvantages of LEDs
include electrical limitations to low voltage and generally to DC (not AC) power, the
inability to provide steady illumination from a pulsing DC or an AC electrical supply
source, and a lesser maximum operating temperature and storage temperature.

LEDs are transducers of electricity into light. They operate in reverse of photodiodes,
which convert light into electricity.

Dep of ECE,EWIT Page18


Internship Report - Power Electronics 2023-2024
6. DIODE

Fig 2.8 Diode

A diode is a two-terminal electronic component that conducts current primarily in


one direction (asymmetric conductance). It has low (ideally zero) resistance in one
direction and high (ideally infinite) resistance in the other.

A semiconductor diode, the most commonly used type today, is a crystalline piece of
semiconductor material with a p–n junction connected to two electrical terminals.[4] It
has an exponential current–voltage characteristic. Semiconductor diodes were the first
semiconductor electronic devices. The discovery of asymmetric electrical conduction
across the contact between a crystalline mineral and a metal was made by German
physicist Ferdinand Braun in 1874. Today, most diodes are made of silicon, but other
semiconducting materials such as gallium arsenide and germanium are also used.The
obsolete thermionic diode is a vacuum tube with two electrodes, a heated cathode and a
plate, in which electrons can flow in only one direction, from cathode to plate.

Among many uses, diodes are found in rectifiers to convert alternating current (AC)
power to direct current (DC), demodulation in radio receivers, and can even be used for
logic or as temperature sensors. A common variant of a diode is a light-emitting diode,
which is used as electric lighting and status indicators on electronic devices.

Dep of ECE,EWIT Page19


Internship Report - Power Electronics 2023-2024
7. DK1203

Fig 2.9 DK1203

DK1203 is a secondary feedback flyback AC-DC offline switching power supply control
chip. The chip adopts highly integrated CMOS circuit design, with output short circuit,
secondary open circuit, over temperature, over voltage and other protection functions. The
chip has built-in high-voltage power tubes and self-powered circuits, with few external
components and simple transformer design (the transformer for the isolated output circuit
only needs two windings).

Features

 Input voltage : 8 5V~265V full voltage

 Output power : 12W

 Output voltage : 5V

 Output current : 2.4A

 Efficiency Rate : 7 6.51%

Dep of ECE,EWIT Page20


Internship Report - Power Electronics 2023-2024
8. THERMISTER

Fig 2.10 Thermister

A thermistor is a semiconductor type of resistor whose resistance is strongly


dependent on temperature, more so than in standard resistors. The word thermistor is a
portmanteau of thermal and resistor.

Thermistors are categorized based on their conduction models. Negative-


temperaturecoefficient (NTC) thermistors have less resistance at higher temperatures,
while positivetemperature-coefficient (PTC) thermistors have more resistance at higher
temperatures.[1]

NTC thermistors are widely used as inrush-current limiters and temperature sensors,
while PTC thermistors are used as self-resetting overcurrent protectors and self-regulating
heating elements. An operational temperature range of a thermistor is dependent on the
probe type and is typically between −100 °C and 300 °C (−148 °F and 572 °F).

Dep of ECE,EWIT Page21


Internship Report - Power Electronics 2023-2024
9. PC817

Fig 2.11 PC817

PC817 is a 4pin DIP General Purpose Photocoupler/Optocoupler. PC817 contains an


IRED optically coupled to a phototransistor.It is packaged in a 4pin DIP. Input-output
isolation voltage(rms) is 5.0kV. Collector-emitter voltage is 80V and CTR is 50% to
600% at input current of 5mA.

Features of PC817 Optocoupler

 4 pin DIP package

 Double transfer mold package (Ideal for Flow Soldering)

 High collector-emitter voltage (VCEO:80V)

 Current transfer ratio (CTR : MIN. 50% at IF=5 mA,VCE=5V)

 Several CTR ranks available

 High isolation voltage between input and output(Viso(rms) : 5.0 kV)

 Lead-free and RoHS directive compliant

Dep of ECE,EWIT Page22


Internship Report - Power Electronics 2023-2024
10. LM431

Fig 2.12 LM431

LM431 is a regulator IC featured with adjustable output voltage. It is a 3-terminal shunt


regulator with guaranteed temperature stability over the entire temperature range of
operation. The output voltage may be set at any level greater than 2.5V (VREF) up to 36V
merely by selecting two external resistors that act as a voltage divided network. Due to
the sharp turn-on characteristics this device is an excellent replacement for many zener
diode applications.

Features and Electrical Characteristics

 Programmable output voltage

 Fast turn-ON response

 Low output noise

 Temperature compensated for operation over the full temperature range

 Average temperature coefficient 50 ppm/°C

 Low-dynamic output impedance

 Available in space saving SOIC-8, SOT-23 and TO-92 packages

 Maximum cathode voltage: 37V


 Maximum reference voltage: -0.5V

 Maximum continuous cathode current: 150mA


Dep of ECE,EWIT Page23
Internship Report - Power Electronics 2023-2024
 Maximum reference input current: 10mA

 Operating temperature range: 0ºC to 70ºC

 Maximum power dissipation: 0.78W

11. SCHOTTKY DIODE

Fig 2.13 Schottky Diode

The Schottky diode (named after the German physicist Walter H. Schottky), also known
as Schottky barrier diode or hot-carrier diode, is a semiconductor diode formed by the
junction of a semiconductor with a metal. It has a low forward voltage drop and a very
fast switching action. The cat's-whisker detectors used in the early days of wireless and
metal rectifiers used in early power applications can be considered primitive Schottky
diodes.

When sufficient forward voltage is applied, a current flows in the forward direction. A
silicon p–n diode has a typical forward voltage of 600–700 mV, while the Schottky's
forward voltage is 150–450 mV. This lower forward voltage requirement allows higher
switching speeds and better system efficiency.

The most evident limitations of Schottky diodes are their relatively low reverse voltage
ratings, and their relatively high reverse leakage current. For silicon-metal Schottky
diodes, the reverse voltage is typically 50 V or less. Some higher-voltage designs are
available (200 V is considered a high reverse voltage). Reverse leakage current, since it

Dep of ECE,EWIT Page24


Internship Report - Power Electronics 2023-2024

increases with temperature, leads to a thermal instability issue. This often limits the useful
reverse voltage to well below the actual rating.

While higher reverse voltages are achievable, they would present a higher forward
voltage, comparable to other types of standard diodes. Such Schottky diodes would have
no advantage unless great switching speed is required.

12. TRANSFORMERS

Fig 2.14 Transformer

A transformer is a passive component that transfers electrical energy from one


electrical circuit to another circuit, or multiple circuits. A varying current in any coil of the
transformer produces a varying magnetic flux in the transformer's core, which induces a
varying electromotive force (EMF) across any other coils wound around the same core.
Electrical energy can be transferred between separate coils without a metallic (conductive)
connection between the two circuits. Faraday's law of induction, discovered in 1831,
describes the induced voltage effect in any coil due to a changing magnetic flux encircled
by the coil.

Transformers are used to change AC voltage levels, such transformers being termed
stepup or step-down type to increase or decrease voltage level, respectively. Transformers
can also be used to provide galvanic isolation between circuits as well as to couple stages
of signal-processing circuits. Since the invention of the first constant-potential
transformer in 1885, transformers have become essential for the transmission,
distribution, and utilization of alternating current electric power. A wide range of
Dep of ECE,EWIT Page25
Internship Report - Power Electronics 2023-2024

transformer designs is encountered in electronic and electric power applications.


Transformers range in size from RF transformers less than a cubic centimeter in volume,
to units weighing hundreds of tons used to interconnect the power grid.

A varying current in the transformer's primary winding creates a varying magnetic flux in
the transformer core, which is also encircled by the secondary winding. This varying flux
at the secondary winding induces a varying electromotive force or voltage in the
secondary winding. This electromagnetic induction phenomenon is the basis of
transformer action and, in accordance with Lenz's law, the secondary current so produced
creates a flux equal and opposite to that produced by the primary winding.

The windings are wound around a core of infinitely high magnetic permeability so that all
of the magnetic flux passes through both the primary and secondary windings. With a
voltage source connected to the primary winding and a load connected to the secondary
winding, the transformer currents flow in the indicated directions and the core
magnetomotive force cancels to zero.

According to Faraday's law, since the same magnetic flux passes through both the primary
and secondary windings in an ideal transformer, a voltage is induced in each winding
proportional to its number of turns. The transformer winding voltage ratio is equal to the
winding turns ratio.

An ideal transformer is a reasonable approximation for a typical commercial transformer,


with voltage ratio and winding turns ratio both being inversely proportional to the
corresponding current ratio.

The load impedance referred to the primary circuit is equal to the turns ratio squared times
the secondary circuit load impedance.

Dep of ECE,EWIT Page26


Internship Report - Power Electronics 2023-2024
13. HEAT SINKS

Fig 2.15 Heat Sinks

A heat exchanger is a system used to transfer heat between a source and a working fluid.
Heat exchangers are used in both cooling and heating processes. The fluids may be
separated by a solid wall to prevent mixing or they may be in direct contact.They are
widely used in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing, and sewage
treatment. The classic example of a heat exchanger is found in an internal combustion
engine in which a circulating fluid known as engine coolant flows through radiator coils
and air flows past the coils, which cools the coolant and heats the incoming air. Another
example is the heat sink, which is a passive heat exchanger that transfers the heat
generated by an electronic or a mechanical device to a fluid medium, often air or a liquid
coolant.

Heat sinks are important components used to dissipate heat generated by electronic
devices, such as CPUs, GPUs, and power transistors. They are designed to absorb and
transfer heat away from the device, helping to prevent overheating and maintain optimal
performance.Heat sinks are typically made of materials with high thermal conductivity,
such as aluminum or copper. They have fins or other structures that increase the surface
area, allowing for more efficient heat dissipation. The increased surface area helps to
transfer heat to the surrounding air through convection.

Dep of ECE,EWIT Page27


Internship Report - Power Electronics 2023-2024

Heat sinks are often attached to the device using thermal interface materials, such as
thermal paste or pads, to ensure good thermal contact and minimize any air gaps that
could hinder heat transfer.

In addition to their primary function of heat dissipation, heat sinks can also provide
mechanical support and protection to the electronic components.

Heat sinks work based on the principles of thermal conductivity and convection. When an
electronic device, like a CPU or a power transistor, generates heat during operation, the
heat sink helps to transfer that heat away from the device.

The heat sink is made of a material with high thermal conductivity, such as aluminum or
copper. These materials are excellent at conducting heat. The heat generated by the
electronic device is transferred to the base of the heat sink through direct contact.

The heat sink is designed with fins or other structures that increase its surface area. This
larger surface area allows for more efficient heat transfer. As the heat is conducted
through the base of the heat sink, it spreads out across the fins.

Once the heat reaches the fins, it can be dissipated into the surrounding air through a
process called convection. The larger surface area of the heat sink enables more contact
with the air, allowing the heat to be transferred and carried away.

To enhance the heat transfer process, thermal interface materials, such as thermal paste or
pads, are often used between the electronic device and the heat sink. These materials help
to improve the thermal contact and minimize any air gaps that could hinder heat transfer.

Overall, heat sinks play a crucial role in keeping electronic devices cool and preventing
overheating. They provide an efficient pathway for heat to escape, ensuring optimal
performance and longevity of the devices.

2.3 TASK ASSIGNED AND TASK PERFORMED

2.3.1 TASK ASSIGNED

To manufacture SMPS to the given specifications as below


Voltage : 9V
500 m
Current :
A
Color : Black
Electronic Instruments : Usage/Application
Material : ABS Plastic
Dep of ECE,EWIT Page28
Internship Report - Power Electronics 2023-2024

Power : 10 watt

Type : Adaptor

Port Type : Type D

Brand : Aviva

Input Voltage : 90-300 V AC


ASPL 24 W -
Part Number : 5W
Operating Temperature : 0-50 Degree C

Input Frequency Range : 47 to 63 Hz

Efficiency : >85%

Product Capacity : 10000

2.3.2 TASK PERFORMED

 PCB Assembly

 Quality check

 Testing

 Packing
2.3.2.1. PCB ASSEMBLY

Fig 2.16 PCB of SMPS

Component placement: Properly placing the components on the PCB is crucial for
ensuring optimal functionality and efficient use of space. It's important to follow the

Dep of ECE,EWIT Page29


Internship Report - Power Electronics 2023-2024

design guidelines and consider factors like component orientation, clearance, and signal
integrity.

Soldering: Soldering is the process of attaching the components to the PCB using solder.
It's important to ensure that the solder joints are strong, reliable, and free from defects like
cold solder joints or solder bridges.

Soldering is a crucial step in PCB assembly where electronic components are securely
attached to the printed circuit board using solder. Here's a simplified explanation of the
soldering process:

1. Preparation: Before soldering, it's important to prepare the PCB and components.
This involves cleaning the PCB to remove any dirt or contaminants that could affect the
soldering quality. The components should also be inspected for any defects or damage.

2. Flux application: Flux is applied to the solder pads and component leads. Flux
helps remove oxidation from the surfaces and promotes good solder wetting, ensuring a
strong and reliable solder joint.

3. Component placement: Once the flux is applied, the components are carefully
placed on their corresponding solder pads. This step follows the component placement
process we discussed earlier.

4. Solder application: Solder is applied to the joint area where the component lead
meets the solder pad. This can be done using various methods, such as soldering irons,
soldering stations, or reflow ovens, depending on the manufacturing process.

5. Heat application: Heat is applied to the solder joint, melting the solder and
creating a bond between the component lead and the solder pad. The heat source can be a
soldering iron or a reflow oven, depending on the soldering method used.

6. Cooling and solidification: After the solder melts and forms a bond, the joint is
allowed to cool and solidify. This ensures that the solder joint becomes stable and secure.

7. Inspection: Once the soldering is complete, the PCB is inspected to ensure the
quality of the solder joints. This involves checking for proper wetting, fillet formation,
and the absence of solder bridges or cold joints.

It's important to note that different soldering techniques, such as through-hole soldering or
surface mount technology, may have slight variations in the process. Additionally,

Dep of ECE,EWIT Page30


Internship Report - Power Electronics 2023-2024

soldering requires skill and precision to ensure reliable connections and avoid damage to
the components or PCB.

Accurate and detailed documentation is essential for PCB assembly. This includes
component placement diagrams, bill of materials (BOM), assembly instructions, and other
relevant documentation to ensure consistency and ease of future repairs or modifications.

Fig 2.17 Soldering

Fig 2.18 Fully Assembled PCB of a SMPS

Dep of ECE,EWIT Page31


Internship Report - Power Electronics 2023-2024
2.3.2.2. QUALITY CHECK

PCB assembly involves rigorous quality control measures to ensure that the final product
meets the required standards. This includes visual inspection, functional testing, and other
quality checks to identify any defects or issues before the PCB is finalized.

A visual inspection is conducted to check for any visible defects, such as solder bridges,
misaligned components, or damaged traces. This is usually done by trained technicians
who carefully examine each solder joint and component.

It aims to ensure that products meet the required quality standards and are free from any
visible defects or abnormalities. It helps identify issues that may affect the functionality,
appearance, or safety of the product.

Visual inspection involves carefully examining the product or component using the naked
eye, magnifying glasses, or specialized tools. Inspectors look for various types of defects,
such as scratches, dents, cracks, discoloration, misalignment or missing parts.

The criteria for visual inspection are typically defined by quality standards or specific
requirements set by the manufacturer or industry. Inspectors compare the observed
characteristics of the product with the specified criteria to determine if it meets the
required standards.

Can be performed at different stages of the manufacturing process, including incoming


inspection, in-process inspection, and final inspection. Each stage focuses on specific
aspects of the product to ensure quality at different checkpoints.

Visual inspection findings are often documented, either manually or digitally, to track the
inspection results, identify trends, and provide evidence of quality control efforts. This
documentation helps in identifying recurring issues, implementing corrective actions, and
maintaining quality records.

Visual inspection of Quality check is a cost-effective and efficient method for detecting
visible defects. However, it may have limitations in identifying defects that are not visible
to the naked eye or require specialized testing equipment. In such cases, additional testing
methods like automated inspection or functional testing may be necessary.

In the given figure there is a example of a PCB undergoing a Quality Check, where a IC is
not assembled in there so the will be returned to the department with the error note which
specifies the exact error.

Dep of ECE,EWIT Page32


Internship Report - Power Electronics 2023-2024

Fig 2.19 Quality check of SMP

2.3.2.3. TESTING

Fig 2.20 Testing of a SMPS

Once the PCB assembly is complete, thorough testing and validation should be conducted
to verify the functionality and performance of the assembled PCB. This may involve
functional tests, electrical tests, and other validation procedures.

Testing has various methods, as per the company the followed method is as below

To begin, you will need a dipper, which is essentially a variable resistor that can be used
to create different load conditions. Connect the dipper in series with a resistive load, such
as a power resistor, to the output of the SMPS.

Dep of ECE,EWIT Page33


Internship Report - Power Electronics 2023-2024

Start by setting the dipper to its minimum resistance value, which creates a high load on
the SMPS. Gradually increase the resistance of the dipper while monitoring the current
and voltage. You can measure the current by connecting a multimeter in series with the
resistive load, and measure the voltage across the resistive load using the multimeter or an
oscilloscope.

As you increase the resistance, the load on the SMPS decreases, and you will observe a
decrease in current and voltage. Continue adjusting the dipper until you reach the desired
load condition for testing. Make sure to take note of the current and voltage readings at
each resistance setting.

By varying the resistance and monitoring the current and voltage, you can assess how the
SMPS performs under different load conditions. This can help you determine if the SMPS
is providing stable and regulated output voltages, and if it can handle varying loads
effectively.

Remember to always exercise caution when working with electrical circuits and ensure
that you are following proper safety procedures. If you are unsure or uncomfortable with
performing these tests, it's best to seek assistance from a qualified professional.

2.3.2.4. PACKING

Dep of ECE,EWIT Page34


Internship Report - Power Electronics 2023-2024
Fig 2.21 Packing a SMPS
SMPS units are typically packed in various ways depending on the manufacturer and the
specific model. They are usually packed in sturdy cardboard boxes or plastic packaging to
protect them during shipping and handling.

After all the processes, packing an SMPS involves carefully securing and protecting the
components. It typically includes placing the SMPS in an appropriate packaging material,
such as a box or anti-static bag, to prevent damage during transportation. Additionally,
foam inserts or padding may be used to provide extra cushioning. The packaging should
be sturdy enough to withstand handling and shipping while ensuring the SMPS remains
safe and intact. Proper packing ensures that the SMPS reaches its destination in optimal
condition.

Inside the packaging, you will find the SMPS unit itself, along with any necessary
accessories such as power cords or mounting brackets. The SMPS unit is often encased in
a metal or plastic housing to provide protection and to contain any potential
electromagnetic interference.

Additionally, the packaging may include user manuals, warranty information, and
sometimes even cable ties or screws for installation purposes.

It's important to handle the packaging with care and follow any instructions provided by
the manufacturer when unpacking the SMPS unit to ensure its safe and proper
installation.

If you have any specific concerns or questions about a particular SMPS unit or its
packaging, it's always a good idea to refer to the manufacturer's documentation or contact
their customer support for further assistance.

CHAPTER 3

REFLECTIONNOTES
3.1 INTERNSHIP EXPERIENCE
This internship has provided a opportunity to connect the classroom theory with the
industrial challenges and provide a exposure to the latest technology. Opportunities to
converse and interact with a large pool of talented experienced department members has
provided a deeper insight to the overall operation and valuable pool of resource to assist

Dep of ECE,EWIT Page35


Internship Report - Power Electronics 2023-2024

in completion of internship practical skills. I have acquired practical experience to


complement the theoretical content of my studies.

This internship was a useful experience for me personally. I gained knowledge, enhanced
my skills and also met many new people. The internship program helped me by providing
a lot of clarity on my strengths, weakness and interests.

This experience increased my professional confidence and also my communication skills.


I got an opportunity to understand the business processes and various job functions of the
organization. The Internship was a very constructive way of implementing theory to
practicality and measure myself with the outcomes. I personally enjoyed my association
with Aviva Smart solution and more so the team which was involved in conceiving,
planning and executing the entire project. The experience of working together as a group
was also been a good experience. Our project helped me in learning about the PCB
designing, PCB Assembly.

3.2 TECHNICAL OUTCOME


During internship I had to conduct research on the different components used in the

project, it was useful to understand to the dept of its working and characteristics concepts.

 We learnt about PCB board and PCB designing using Orcad tool.

 Learnt about components such as its limitation, advantages, types, characteristics


used in the industries.

 Learnt about the PCB Assembly .


 Learnt to read the BOM which is useful for the Assembly .

 Learnt the test of the products using corresponding methods.

 Learnt about the Quality check .

 Understanding Power Conversion: learnt how SMPS converts the input AC or DC


power into the desired output voltage and current levels efficiently.

 Exposed to industrial need in todays technology.

 Applying theoretical concepts to practical projects,such as designing a power supply


or motor control system.

Dep of ECE,EWIT Page36


Internship Report - Power Electronics 2023-2024

3.3 NON - TECHNICAL OUTCOME


 Enhancing communication and teamwork skills through collaboration with
colleagues.

 Gaining project management skills by organizing and prioritizing tasks.

 Improve time management skills by meeting project deadline .

 Increase knowledge of industry standards .

 Enhancing adaptability and flexibility by working in dynamic and fast paced


environment .

 Improving presentation and communication skills by sharing project updates.

 Building professional network and connection in power electronic industry.

 Gaining deep understanding of workplace ethics and professionalism.

Dep of ECE,EWIT Page37

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy