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Randy Inverter Design
Randy Inverter Design
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SchematicDiagram JonathanSw ift:Mayyouliveallthedaysof
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ProjectDescription
Inplacesw hereelectricityisnotavailable,aportableelectricgeneratorandabatteryarealternative
pow ersources.Thelatterischeaperthantheelectricgenerator,caneasilyberecharged,anddoesnot
requireelaboratemaintenanceprocedure.Unfortunately,acarbatteryisaDCsourcelimitedtoapotential
of12volts.Toconvertthistoa220voltsalternatingcurrent,aDCtoACinverterisnecessary.
Apow erinvertersuchasthisfeaturedprojectcanbeused.Itscircuitissimple.Requiringonlytw o
integratedcircuits,foursmallpow ertransistors,andtw opow ertransistorsasactiveelements.Onlythe
transformerisbulkyandcostly.Theinvertercansafelysupplypow erto120w attload.
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AbouttheProject
PowerInverter
AbouttheCircuit
12Vdcto220Vac
Thecompleteschematicdiagramofthepow erinverterisshow ninfigure1A.Byfunction,itcanbe
classifiedasmainlyconsistingofanastableoscillator,aflipflopcircuitthatgeneratespulsew ithopposite
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logicstatesatitsQandQoutputs,asw itchingcircuitandastepuptransformerasshow ninFigure1B. Inplacesw hereelectricity
isnotavailable,aportable
electricgeneratoranda
batteryarealternative
pow ersources.
WatchTheVideoofprojectconstruction
1.Construction1
2.Construction2
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Fig1B.FunctionalDiagramofthePow erInverterproject.
Theastableoscillatorisconfiguredarounda555timerIC.Itsoscillatingfrequencyissetto120Hzby Links
R1,R2,R3andC1.theresultingoutputisatrainsquarew av eshav ingapeaktopeakamplitudenearly NCST
equaltothe12Voltssupplyv oltage.Thew aythisoscillatorw orkscanbeeasilyunderstoodthrough
Templates
Fig.2. Google
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Figure2.Internalblockdiagramofthe555timerIC. Yahoo!
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Immediatelyuponapplicationofthe12v oltsupply
v oltage,thev oltageacrosscapacitorC1isnearlyat
thegroundlev el.Thisv oltagesensedbythetrigger
comparator(pin2)ofthetimer,settingtheinternalflip
flopandhence,causingtheoutputv oltageat(pin3)to
gohighorapproximatethesupplyv oltage. Web yahoo.com
Consequently,itturnsoffthedischargetransistor
50webs.com
andallow ingcapacitorC1tochargethroughresistors
R1,R2andR3.Thecapacitorchargestow ardsthe Search
supplyv oltagebutuponreaching2/3ofthesupply
v oltage,thethresholdcomparator(pin6)isactiv ated.Thiscausestheineternalflipfloptoresetandthe
outputv oltagetogobacktogroundlev el.Thedischargetransistorthenconducts,w hichinturn,causes
capacitorC1todischargethroughR2andR3untilthev oltageacrossitdropsto1/3ofthesupplyv oltage,
alev elatw hichthetriggercomparatorsw itchesthetimeroutputtoahighstate(ornearthesupply
v oltagelev el)again,thenthecycleisrepeated.
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Theoutputoftheoscillatorisfedtotheclockinputofthe74C74Dtypeflipflop.ThisIChasadual
function.Firstitdiv idesequallyintotw othetimerfrequencytoobtainthenominal60Hzoutput,and softwarefor
secondly,itsimultaneouslyprov idescomplementaryoutputs(atitspins5&6)requiredbythesucceeding
sw itchingcircuit.
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Thepartofthesw itchingcircuitthatreceiv estheflipflopoutputsarecomposedofbuffertransistorsQ1
andQ2.ResistorsR4andR5limitthecurrentofthebaseofthesetransistorstoasafev alue.Resistors Clickhereto
R6andR7serv easpullupresistorsthatsetthecollectorbiasofthesetransistors.
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Theoutputofthebuffertransistorsareinturnconnectedtothepushpulltransistorsconsistingofthe
Q3Q4andQ5Q6pairs.ThePNPtransistorsQ3andQ5actasdriv ertransistorstoQ4andQ6, 0.0022s
respectiv ely.Theysupplythecurrentrequirementsofthemainpow ertransistorssothatthefull
saturationcanbeattained.Thecurrentssuppliedbythesedriv erscangouptofiv eamperesdepending
ontheloadconnectedtheoutputoftheinv erter.
TransistorsQ4andQ6,w iredinapushpullmode,alternatelysupplycurrentthrougheachhalfofthe
primaryw indingofthetransformer.Alternateconductionheremeansw henonetransistorisfully
saturated,theotheroneisatcutoff,andv icev ersa.Thisalternatesw itchingofthetw otransistors
createsamagneticfieldonthetransformercoreresultingtoatransferofenergyfromthesecondary
w indingoftheprimaryw inding,aprocesstermedasmagneticinduction.Thepow erav ailableatthe
secondaryofthetransformerhasbeentranslatedalreadyto220v oltsalternatingcurrentintheformof
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squarew av es.Theprimarytosecondaryw indingturnsratiocausesthe12v oltprimaryv oltagetobe
steppedupto220Voltsinthesecondaryw inding.
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SchematicDiagram
PCBLAYOUT
Thepowerinverteralthoughcomposedofonlyafewcomponentshandleslargeamountsofcurrentthus
necessitatingextraprecautionarymeasures:
UseonlyAWG#10insulatedwireinwiringconnectionsindicatedbyheavylinesinFigure1A.Usesimilarwire
sizeforconnectionstothebattery.
TransistorsQ4andQ6mustbemountedonaheatsinksufficientenoughtodissipatetheexpectedheatthat
maybegenerate.Afintypeheatsinkisspecificallyrecommendedforthispurpose.
TransistorsQ4andQ6mustbebothelectricallyisolatedfromtheheatsink
Therestofproceduresaremainlyamatteroffollow inggoodconstructiontechniquesasindoingother
electronicprojects:
1.SecurethereadymadePCB(SeeFigure3and4).Carefullycheckthefoilpath.
2.InsertandsolderthecomponentsintendedforthePCB.Takenoteoftheleadpolarityorleadorientations
oftheelectrolyticcapacitorsandthetransistors.
CapacitorsC4ismountedatthefoilsideofthePCBatthelocationindicatedinfigure4.ResistorsR10to
R13arenotmountedinthePCB,refertoFigure6.
3.Mountthepow ertransistorsontheheatsink.Iftheheatsinkistobegroundedbesuretoputmica
insulatorsbetw eentheheatsinkandthepow ertransistors.
4.Plantheoverallworktobedonetocompletetheprojectwithemphasisonthelayoutintheenclosureof
thePCB,transistorsontheheatsink,andthetransformer.
Note:dothewiringconnectionsasillustratedinthewiringguideaftertheTESTINGprocedures.
Figure3.FoilpatternlayoutofFigure4.partsplacementguideof
thePow erInverter.thePowerInverter.
*C4issolderedatthefoilsideofthePCBatthelocationindicated.
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MaterialsUse
Pow erInverter
PartsList
Semiconductor:
IC1555,TimerIC
IC274C74,CMOSDUALDFlipFlop
Q1,Q29418,NPNTransistors
Q3,Q5NA52W,PNP40W45V4ATransistors
Q4,Q6MJ15015,NPN180W120V15ATransistors
Application
ThemainfunctionofthepowerinverteristomakeavailableACpowerininstanceswhenandwhere
electricityisnotavailable.Thisinvertercansupplypowertoanynoncriticalapplianceprovidedthatitspower
ratingiswithinthe120Wattlevel.However,sincetheoutputofthisinverterisasquarewaveandnot
sinusoidalasthesuppliedhousecurrent,theinvertercouldnotbeusedforTVandsimilarelectronic
appliances.(Note:WehaveactuallytestedthisinverterusingaTVloadandencounterednoproblematall.
Butthisisnotaguarantee,however,thatthesameresultswillbeobtainedwithotherTVbrands.Somemay
performedaswellorbetterbutothersmaybedamagedwhenpoweredbyasquarewaveACsource.)
Somepossibleapplicationsofthepowerinverterarethefollowing:
1.Lamps(fluorescentorincandescent)
2.Electricfan
3.Lowwattageheatingapplianced(120wattsmaximum)
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TotalCost
ItemQuantityPrice(P)
AWG#224m10
P.InverterKit1kit1282.50
BatteryClip1pair25
Footings4pcs.8
Screw s1/8x1/220pcs.15
Heatsink12"12"155
TW#102m73
Housing450
Paint25
Transportation2times250
TOTALCOST2293.50
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municationsEngineering
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