Power Supply Project

Devin Clarke

Course Code: CAD 3100

Course Name: EDA for Biomedical Engineering Technology

Date: December 6th, 2014

Submitted to: Professor Louis Bertrand

Abstract
The following report details the process from beginning concepts, to final assembly of creating
an operating power supply unit (or PSU). The report begins with a quick introduction outlining the
steps taken in the initial setup of the project, including concept schematics and images depicting the
final layout. Within this section the theory behind the inner workings of the PSU are explained in
technical detail.
This report also covers the process of computer aided manufacturing (or CAM), covering the
steps taken for designing the layout of a printed circuit board (or PCB). This section covers the initial
schematics that were then placed on a circuit board and designed to specifications. This section also
briefly covers the fabrication steps that were taken in manufacturing the final PCB.
Finally this report outlines the process and difficulties that come with final assembly and
troubleshooting of a finished product. Also included in these sections is technical information on the
external case and the steps taken in mounting all the components together to form the finished PSU.

Acknowledgements
I would like to thank several classmates for the help provided during the design and assembly
process of the power supply unit, namely Mark Wanless, and Jake Wilson. Both of these fellow
students provided assistance during the PCB fabrication and design process, as well as advice about the
assembly process for the PSU.
No assistance was provided on the writing of this report, and as such any remaining errors or
inaccuracies are the sole responsibility of the author.

Contents
ABSTRACT...................................................................................................................................................II
ACKNOWLEDGEMENTS........................................................................................................................III
CONTENTS..................................................................................................................................................IV
LIST OF FIGURES.....................................................................................................................................VI
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...............................................................................................2

DESIGN AND THEORY OF OPERATION.....................................................................................3

2.1

INITIAL SCHEMATIC................................................................................................3

2.2

CIRCUIT SIMULATION SOFTWARE...........................................................................5

2.3

PRIMARY CIRCUIT AND TRANSFORMER.................................................................5

2.4

RECTIFIERS AND FILTERS.......................................................................................7

2.5

FIXED 5V REGULATOR...........................................................................................9

2.6

VARIABLE POSITIVE REGULATOR.........................................................................10

PRINTED CIRCUIT BOARD.........................................................................................................12

PCB DESIGN SOFTWARE (EAGLE).................................................................................12

3.1

COMPONENTS AND LIBRARIES.............................................................................12

3.2

SCHEMATIC CAPTURE...........................................................................................13

3.3

PRINTED CIRCUIT BOARD DESIGN.......................................................................14

3.4

PRINTED CIRCUIT BOARD PRODUCTION..............................................................15

POWER SUPPLY ENCLOSURE....................................................................................................16

4.1

ENCLOSURE DESIGN.............................................................................................16
4

4.2
5

ENCLOSURE FABRICATION...................................................................................16

FINAL ASSEMBLY AND TESTING..............................................................................................17

5.1

CIRCUIT BOARD ASSEMBLY AND TESTING..........................................................17

5.2

ENCLOSURE ASSEMBLY........................................................................................17

5.3

COMPLETE ASSEMBLY TESTING...........................................................................19

RESULTS AND CONCLUSIONS...................................................................................................20

6.1

SUMMARY OF RESULTS........................................................................................20

6.2

RECOMMENDATIONS.............................................................................................20

REFERENCES/BIBLIOGRAPHY.............................................................................................................21
APPENDICES...............................................................................................................................................22

APPENDIX A: COMPLETE SCHEMATIC...........................................................................22

APPENDIX B: PRINTED CIRCUIT BOARD DRAWING.......................................................25
APPENDIX C: POWER SUPPLY ENCLOSURE DRAWING...................................................26

List of Figures
Figure 1-A: Schematic diagram of layout of circuits inside PSU.......................................3
Figure 1-B: Schematic diagram of PCB circuit layout........................................................4
Figure 3: Schematic diagram of Primary circuit, transformer, and rectifier circuit............6
Figure 4: Waveform of Vpri (ch-A), and Vsec (ch-B).........................................................6
Figure 5: 4 Diode rectifier circuit example (Storr, 2013)....................................................7
Figure 6: Waveform of Rectifier input, and output. No filter capacitor..............................8
Figure 7: Waveform of Rectifier input (ch-A), and output (ch-B) with Filter capacitor added.

Figure 8: Schematic diagram of 5V regulated circuit with AC input circuit and rectifier attached. 9
Figure 9: Oscilloscope reading of the voltage in (ch-A) to the 5V regulator, and the voltage out (ch-B)
from the regulator. For this reading the load resistor was set to 100......................10
Figure 10: Schematic diagram of Variable 0-15V DC circuit, with added %v regulator, negative
reference, 4 diode rectifier, and AC signal input circuits...........................................11
Figure 11: Schematic capture of final design of PCB components...................................13
Figure 12: Screen capture of the PCB final layout............................................................14
Figure 13(A): CAM output Foil

Figure 13(B): CAM output Top.................................15

Figure 14: Front panel of final assembly PSU...................................................................18

Figure 15: Rear panel of completed PSU..........................................................................18
Figure 16: Internals of completed assembly PSU..............................................................19
Figure 1-A: Schematic diagram of layout of circuits inside PSU.....................................22
Figure 1-B: Schematic diagram of PCB circuit layout......................................................23
Figure 17: Eagle schematic that was the basis for the PCB design...................................24
Figure 12: Screen capture of the PCB final layout............................................................25
Figure 13(A): CAM output Foil.

Figure 13(B): CAM output Top.......................25

6

Figure 18: Template sheet for modifications to case of PSU............................................26

Introduction

1.1 The Power Supply Project

The Power Supply project is undertaken to achieve in depth knowledge on the process behind
the manufacturing and design of electronic equipment. From the initial concepts and schematic design,
to the computer generated circuit board layouts, to the final assembly and troubleshooting. This course
is Computer Automated Design for Biomedical (CAD 3100), and it is a class within the Biomedical
Engineering Technologist program at Durham college in Oshawa, ON.
The final goal of this project is too design and manufacture a power supply unit (or PSU), using
CAD software to design the PCB required, and to use the PCB lab to manufacture the PCB, then finally
assemble the PSU and demonstrate to instructor.

1.2 Purpose of a Power Supply

PSUs are used for many applications in the electronic field. They can be used to output specific
voltages (DC or AC), at fixed or variable amplitudes in order to power an electric circuit. PSUs can
also be incorporated into an electronic device in order to correctly distribute power to its various
modules.
Without a working power supply circuits that require specific values of voltage would not be
able to function. Even if the circuit was connected to a wall socket unless it had an incorporated
transformer and rectifier it would be unable to function (and may cause damage to the components).

1.3 Objectives of the Project

The main objectives of this project are:

To develop an understanding of the overall process involved with the design and manufacturing

of electronic devices.
To familiarize oneself with software associated to PCB design
To attain understanding of the process behind the design and fabrication of PCBs
To practice practical skills (soldering, proper measurements,) of assembling an electronic

device.
To properly understand the process of efficient troubleshooting to expedite delays in a project.

1.4 Layout of Report

The report is divided into six sections. Section 1 contains introductory material. Section 2
covers the creation of the schematic diagram, Section 3 outlines the process of designing and
fabricating the PCB. Section 4 provides information on the fabrication for the case of the PSU. Section
5 depicts the process of the final assembly of the PSU as well as any troubleshooting steps that were
taken to solve any issues. Finally, Section 6 concludes the work and suggests areas for future
investigations.

Design and Theory of Operation

2.1 Initial Schematic

Figure 1-A: Schematic diagram of layout of circuits inside PSU.

10

Figure 1-B: Schematic diagram of PCB circuit layout.

11

Figures 1-(A & B) depict the general layout for the circuitry and components for the final PSU.
The PSU will be comprised of several modules that combined will perform its intended functions. The
device starts with the Primary circuit which will be the AC signal into the PSU, a power switch, a fuse,
and a step down transformer. From there the signal moves into the PCB which will be divided into the
rectifiers, regulators, and outputs which then go to the output leads on the exterior of the PSU. This will
all be accomplished firstly by recreating the schematic in a circuit simulation software (EAGLE &
Multisim), after this the PCB fabrication will begin and final assembly can commence.

2.2 Circuit Simulation Software

The software used to complete this project was mostly done in CadSofts EAGLE PCB design
software. This program is a free program that is used to design and layout circuit boards for practical
use. Design begins with creating a schematic for the desired circuit boards function. After the
schematic is complete the next step is to begin designing the physical circuit boards layout of
components and copper paths. Once the design has been completed and no errors are present, then the
program can output the circuit board into a CAM file. Computer Aided Manufacturing is the image that
will be used to ultimately fabricate the circuit board.

2.3 Primary Circuit and Transformer

Figure 3: depicts a schematic diagram of the AC input and rectifier circuit for the power supply.
The Ac input for this circuit (V1) will be the source voltage into the device (115Vrms). From there the
voltage will pass through the fuse (U1) and a switch (S1). The fuse will sever if the current in the
circuit surpasses 0.5 Amps, to protect the circuit from causing more damage. Then the voltage will pass
through the Transformer (T1), this transformer is a step down transformer that will convert the voltage
down to a more manageable 28Vrms. Diagram 1-A depicts the waveform difference between the
primary and secondary side of the transformer. Figure 4 shows the AC waveforms for the primary and
secondary side of the transformer. The transformer has a turns ratio of 4.1 meaning that every 4V into
the transformer will output 1V.

12

U1
V1 0.5A
115Vrms
60Hz
0

D1
1N4007GP

S1

Key = Space

D2
1N4007GP

C1
2200F

RL
9.2

T1

4.1

Devin Clarke 100509502

CRN: 34836
Assignment 1
2014-09-11

Figure 3: Schematic diagram of Primary circuit, transformer, and rectifier circuit.

Figure 4: Waveform of Vpri (ch-A), and Vsec (ch-B)

13

2.4 Rectifiers and Filters

On the right side of figure 3 at the Secondary side of the Transformer, the Voltage will pass
through the Full wave rectifier (D1 and D2). The diodes force the positive and negative waveforms to
both pass through the load (RL) from the same direction. This causes the voltage on the load to be
positive pulsating voltage only (depicted in 1-B). A capacitor is added to filter the pulsating waveform
into a steadier ripple (as seen in 1-C). The resistance of the load was calculated to limit the amperage in
the primary and secondary sides of the transformer to keep the fuse from breaking.
Calculations:
V (P . P) =V RMS(1.414)=115 V RMS(1.414)=162.6V (P . P )

P(MAX )=V (P . P )I FUSE =162.6 V 0.5 A=81.3 W

N=

V pri 115 V
=
=4.1
V sec 28 V

R L=

V RL (28 V RMS.7 V )2
=
=9.2
P
81.3 W

Figure 6 depicts the waveform of before and after the rectifier circuit, without filtering
capacitors included. Figure 7 Depicts the waveform of the same section after filter capacitors are added
in. In the final version of the PSU a 4 diode rectifier or (Wheatstone bridge) will be used as the
rectifying circuit. This consists of 4 diodes connected to the output of the transformer and provides full
wave rectification (positive and negative cycles). Figure 5 shows the general layout of a 4 diode
rectifier.

Figure 5: 4 Diode rectifier circuit example (Storr, 2013).

14

Figure 6: Waveform of Rectifier input, and output. No filter capacitor.

Figure 7: Waveform of Rectifier input (ch-A), and output (ch-B) with Filter capacitor added.
15

2.5 Fixed 5V Regulator

Figure 8 depicts the power supply circuit with the fixed 5V regulated supply. After the voltage
passes through the rectifier circuit (D1 and D2) and is smoothed out by the filter capacitor (C1) as seen
in figure 5. It then reaches the LM7805 voltage regulator at 17.84V (figure 2). This voltage regulator is
fixed meaning that it takes the input voltage and reduces it to a flat 5V at the output, as seen in figure 9.
An LED will be added to the end of the circuit
This output voltage then goes from the regulator and is filtered again by another capacitor (C2).
From here the output voltage passes by the diode (D3) and goes to the load resistor (R1). The diode D3
is there as a back-feed diode, this means that after the voltage leading into the 7805 is turned off the cap
still retains a charge. This can cause the voltage from the capacitor to flow back into the regulator from
the wrong polarity potentially damaging it. The added diode allows a path for the charge to go that will
not harm the regulator.
Calculations:
PD (U 2)=V I =( 17.94 V )( 1 A )=17.94 W
I out(Max )=( 5 V )( 1 A )=5 W
=

5W
100 =27.9
17.94 W

U2
LM7805CT
LINE
VREG
VOLTAGE

D1
1N4007GP

S1

V1
Key = Space
115Vrms
60Hz
0
U1
0.5A

D2
1N4007GP

COMMON

C1
2200F

C2
10F

D3
1N4007GP

R1
5

T1

4.1

Devin Clarke 100509502

CRN: 34836
Assignment 2
2014-09-12

Figure 8: Schematic diagram of 5V regulated circuit with AC input circuit and rectifier attached.

16

Figure 9: Oscilloscope reading of the voltage in (ch-A) to the 5V regulator, and the voltage out
(ch-B) from the regulator. For this reading the load resistor was set to 100.

2.6 Variable positive regulator

Figure 10 depicts the schematic diagram of the circuit with added variable 0-15V dc supply, and
a negative rectifier and filter. The variable supply (U3) is a voltage regulator that takes an input voltage
and out puts a voltage depending on the input voltage from the adjust pin. R3 is a potentiometer that
controls the voltage going into the adjustment pin and thus controls the output voltage from the variable
regulator.
Also added to this schematic was the negative wave rectifier and the Vneg circuit for the adjust
pin of the LM117. The negative wave rectifier forms a Wheatstone bridge with the positive wave
rectifier to rectify the full wave of the output of the transformer. The Vneg circuit is used to allow the
variable voltage regulator to reach 0V by lowering its reference voltage to a negative voltage.

17

U2
LM7805CT
LINE
VREG
VOLTAGE

C2
10F

COMMON

D1
1N4007GP

D2
1N4007GP

C1
2200F

U3
LM117HVH

S1

Vin

Vout
ADJ

V1
Key = Space
115Vrms
60Hz
0
U1
0.5A

D3
1N4007GP

R2
120

D6
1N4007GP

C3
10F

RL
30

T1
D7
1N4007GP
4.1

D4
1N4007GP

D5
1N4007GP C4
2200F

D8
R3
1N4007GP
1.5k
R4

Devin Clarke 100509502

CRN: 34836
Assignment 3
2014-25-12

1k

Figure 10: Schematic diagram of Variable 0-15V DC circuit, with added %v regulator, negative
reference, 4 diode rectifier, and AC signal input circuits.

In the final design a negative tracking regulator (LM317), will be added after the Vneg area of
the circuit. This circuits purpose is to regulate the negative side voltage for the variable 0-15V DC
output.

18

Printed Circuit Board

This chapter will mostly outline the process of creating the printed circuit board (or PCB), that is to
house the rectifier circuit, the fixed 5V DC voltage regulator, and the Variable 0-15V DC circuit. The
process begins with schematic concepts, then moves into a design software for circuit board layout and
design. Finally after the PCB is ready to be made, it moves into the fabrication stage where the physical
board is created.

PCB Design Software (Eagle)

The software used to complete this project was mostly done in CadSofts EAGLE PCB design
software. This program is a free program that is used to design and layout circuit boards for practical
use. Design begins with creating a schematic for the desired circuit boards function. After the
schematic is complete the next step is to begin designing the physical circuit boards layout of
components and copper paths. Once the design has been completed and no errors are present, then the
program can output the circuit board into a CAM file. Computer Aided Manufacturing is the image that
will be used to ultimately fabricate the circuit board.

3.1 Components and Libraries

For this project the components have to be carefully chosen to ensure they will be correctly
fabricated in the final design.
This is where the libraries of components are described. What goes into a component: schematic
symbol and PCB footprint? How are those components organized? Briefly explain about the
cad1133.lbr library of components: what makes those components special?
Suggested illustrations/screenshots: Compare the schematic symbol with the PCB footprint for a typical
component.

19

3.2 Schematic Capture

Figure 11 shows the final schematic capture for the PCB components layout. Test points
and test links were added. Each Component must be selected from its specific library before
being placed into the schematic. Some components such as the resistors must have their values
changed to reflect the desired values (for clarity during assembly). Nets are added to anywhere
multiple wires conjoin to ensure the paths are all connecting. Once the full schematic is fully
lain out, then the error rule checker (or ERC) is used to verify that all connections are present
and there are no major issues with the final design.

Figure 11: Schematic capture of final design of PCB components.

20

3.3 Printed Circuit Board Design

Using the Schematic diagram figure 11, the circuit was then taken into the board design phase. Layout
of the board is shown in figure 12, the design was placed on board and properly lain out until no
clearance errors were present. The voltage regulators required an on board heat sink to vent all of the
heat that would be generated, this area is in the top right of the board design and had a restriction
placed over it to prevent components from being placed there. All isolated islands (with connection to
power), were opened either by using jumpers or reworking the paths around them until the islands were
connected. Design Rule Checker (DRC) was used to ensure no errors were present in the final product
before going out for fabrication.

Figure 12: Screen capture of the PCB final layout.

Before Fabrication the final step of the design process of a PCB is the CAM images. These
images figures 13 and 14, display the final layout of the circuit board and what it should look like after
fabrication. Figure 3 is the Foil or what the bottom of the board will look like and depicts what the
copper paths layout will look like. Figure 4 depicts what the top of the board will look like, mainly the
21

top only consists of the electrical components that comprise the boards functions. After the CAM files
were completed then the images were converted into PDF files to make them compatible with the
software that would create the photo tool that is used in the circuit boards fabrication.

Figure 13(A): CAM output Foil

Figure 13(B): CAM output Top

3.4 Printed Circuit Board Production

The fabrication process for PCB creation begins with imaging, a photo tool is created from the
image in figure 13. This is put under a UV light with the circuit board for a period of time. The areas
under the dark area of the photo tool remain untouched, while the areas that were exposed become
darker. Darker areas are resistant to the next step of the process, Etching. After the UV exposure the
photo tool is removed and the circuit board is placed in a tank with a chemical, this chemical clears all
of the unprotected (light) areas on the board down to the base of the board. This prepares the board for
the developing. Since the traces of the board are now cleared developing of the board can begin, the
board is placed into another tank with a different chemical housed within. This chemical develops the
etched out areas with a new trace of copper. These traces are what form the electrical paths of the PCB.
Once developing is complete the board is ready to be drilled and have the desired components installed.

22

Power Supply Enclosure

The information in this chapter will outline details about the Case that will enclose the completed PSU.

4.1 Enclosure Design

The metallic case that the PSU will be installed in begins as a standard 2 piece case with a base
that forms: the front panel, the bottom, and the rear panel of the case. The second piece fits overtop the
base and includes the top and sides of the case. A series of templates is available in the appendix that
details the changes that will be made to the case.

4.2 Enclosure Fabrication

Using a combination of drills and metal punches, sections were taken from the front, bottom, and rear
panel of the case to fit components. Using the templates available In the appendix measurements were
made to ensure accuracy of placements, before any sections were removed. There was a slight
modification to the rear panel, to accommodate the changes that were present in the heat sink used.
Figure 14 shows the front panel after assembly.

23

Final Assembly and Testing

This section contains information on the process of the final assembly and the steps taken to ensure the
PSU was working as intended.

5.1 Circuit Board Assembly and Testing

The final version of the PSU was a complete success. Despite several safety issues with the
final design (that was easily rectified after assessment), the PSU passed all inspections with flying
colors.
Assembly began with attaching the heat sink to the board followed by soldering of the 3
regulators. After the heat sink was installed the rest of the components were soldered into place
beginning with the rectifier circuit.
Illustrations:

5.2 Enclosure Assembly

The assembly of the enclosure began with stripping and installing the power cord into the rear
of the case. From there the fuse and switch were attached with stripped wires and soldered onto their
respective leads. After the switch was installed the transformer was installed into the base of the case,
and the primary leads were connected to the open lead on the switch and the open wire in the power
cord. All leads were insulated using electrical tape and heat shrink.
From there the Heatsink and PCB was installed into the rear panel of the case. The secondary
leads from the transformer were connected to the PCBs 3 input leads and bound together. Then the
potentiometer had stripped wires attached to its leads, and the wiper connected to the negative lead of
the potentiometer. The potentiometer was then installed into the front panel of the case.
The output leads were then each installed separately into the front panel of the case, and wires
were ran from each into their respective areas. AC output leads were soldered to the stripped wires that
ran to the inputs of the PCB, Variable DC and the fixed 5V DC were each ran from the output pins of
the PCB to their respective outputs on the front panel using wires stripped on both ends and solder.
The LED used to show the PSU is on was installed connected to a branch from the 5V fixed DC
Output in the PCB.
24

The Front display screen was then configured and installed into the PSU. The screen was
configured by soldering together the desired pads (20V and DC). The screen was then attached to the
Front panel and paths were soldered from the fixed and variable DC outputs. Figures 14 15 and 16
show multiple views of the final PSU.

Figure 14: Front panel of final assembly PSU.

Figure 15: Rear panel of completed PSU

25

Figure 16: Internals of completed assembly PSU.

5.3 Complete Assembly Testing

Describe how the completed power supply is tested (switch, outputs at binding posts, including the low
voltage AC outputs). The results can be summarized into a table of expected vs. measured values, or a
checklist of features to be tested and the test result for each point.

26

Results and Conclusions

6.1 Summary of Results

In conclusion all objectives of this project were achieved. Significant knowledge was gained in
the process behind the designing and fabrication behind electronic devices. Overall the design and
assembly process went smoothly with virtually no issues.
The design did include the maximum allowed jumpers which could have been improved given
more time put into design. The overall design of the PCB proved to work fairly well no glaring faults
were made apparent during assembly.

6.2 Recommendations
No major issues in the structure of this project have been a problem for the completion of this project.

27

References/Bibliography

Floyd, T. L. (2010). Principles of Electric Circuits: Conventional Current Version (9th ed.).
Upper Saddle River, New Jersey: Prentice Hall.
Robertson, C. T. (2004). Printed Circuit Board: Designers Reference Basics. Upper Saddle
River, NJ: Prentice Hall.
Durhamcollege.desire2learn.com,. (2014). SA3-DRG-R4. Retrieved 5 December 2014, from
https://durhamcollege.desire2learn.com/d2l/le/content/82188/viewContent/1439694/View
Texas Instruments Inc. (2013, February). LM317: 3-Terminal Adjustable Regulator. Texas
Instruments Inc.
Storr, W. (2013). Full Wave Rectifier and Bridge Rectifier Theory. Basic Electronics Tutorials.
Retrieved 4 December 2014, from http://www.electronics-tutorials.ws/diode/diode_6.html
Durhamcollege.desire2learn.com,. (2014). PSU original 2014-05-27. Retrieved 5 December
2014, from
https://durhamcollege.desire2learn.com/d2l/le/content/82188/viewContent/1370338/View

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Appendices
Appendix A: Complete Schematic

Figure 1-A: Schematic diagram of layout of circuits inside PSU.

29

Figure 1-B: Schematic diagram of PCB circuit layout.

30

Figure 17: Eagle schematic that was the basis for the PCB design
31

Appendix B: Printed Circuit Board Drawing

Figure 12: Screen capture of the PCB final layout.

32

Figure 13(A): CAM output Foil.

Figure 13(B): CAM output Top.

Appendix C: Power Supply Enclosure Drawing

Figure 18: Template sheet for modifications to case of PSU.

33