Design and Performance Evaluation of 2kva Microcontroller - Based Stabilizer

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DESIGN AND PERFORMANCE EVALUATION OF 2KVA MICROCONTROLLER –


BASED STABILIZER

Article · August 2014

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DESIGN AND PERFORMANCE EVALUATION OF 2KVA MICROCONTROLLER –
BASED STABILIZER

OKUBANJO A. A1 & OGUNNUSI M.O2


Department of Computer and Electrical Engineering,
Olabisi Onabanjo University, Ogun State
Email: djsolax@gmail.com,djmaxwell1977@yahoo.com 1
dupsynusi@yahoo.com 2
Abstract

Servo-motor based or tap-switching stabilizer which is used in countries (such as Nigeria) with
inadequate infrastructure and resources had failed to match pace with the requirements of the
sophisticated electronics it protect. It is not dependable and reliable in performance due to its low
response time and inherent performance limitation. However, a microcontroller –based stabilizer is
suitable in countries (like Nigeria) with inadequate infrastructure for the generation and distribution of
alternating current (A.C) because of its high response time and cycle-by-cycle voltage regulation without
interrupting the load current.

A microcontroller based stabilizer was designed and constructed to protect the household appliances,
such as electrical / electronic appliances from fluctuation of line voltage. This device was tested under
low voltage, very low voltage, extremely low voltage, high voltage, Very high voltage and normal supply
voltage (220 – 240V in Nigeria) and with overload current up to 12A. The voltage sensor’s output was
monitored by the PIC16F877A microcontroller and used analog to digital converter. A computer
program was developed to control the function of microcontroller.

Keywords: microcontroller, line voltage, fluctuation, stabilizer and electrical and electronics
appliances.
1.0 INTRODUCTION

A stabilizer is a device that regulates voltage. It contact points of the relays (P.C. Sen, 1987).
guides against electrical fluctuation and aim to Solid state electronic device stabilizer can
attain a normal voltage level (M.C Sharma, overcome most of the above problems; as they
1987). do not use any moving part and the output can
It has been acknowledge that a typical vary from cycle to cycle (A.Ahmed, 1999,J.M.
convectional stabilizer, switching is done by Jacob,2002). Study has shown that
electromagnetic relays, or servomotors, or microcontrollers have proven abilities to
electronic device, which automatically selected perform well in a wide range of applications
taps in the transformer to get the required (J.B.Peatmann, 1998, R.A.Penfold, 1997).
voltage to boos (add) or buck (subtract) the input The fluctuation of the line voltage in Olabisi
voltage. As one of the required element of a Onabanjo University, College of Engineering
stabilizer the relay tap-changers are noted for and Environmental Studies in Ibogun, Ifo Local
power lost momentarily during relay change Government Area, Ogun State, Nigeria often
over, unstable output and relay contact damages. impose serious damages to sophisticated
Also servo motor has low life in relation to electrical and electronic equipment and also
hampered commercial and Institutional activities
in that area. Research conducted among the 2.0 OVERVIEW OF THE
PROPOSED SYSTEM DESIGN
students in the College of Engineering and
Environmental revealed that the poor The basic building blocks for this design include
performance of the students during examination a DC voltage power supply, auto-transformer,
period was attributed to erratic and fluctuation in microcontroller unit (control unit), switching
power supply by the power holding company of circuit and delay circuit. In this unit, an
Nigeria (PHCN). It was observed that the line alternating voltage source (220V) was applied
voltage of some phases go down to a low at the input of a step- down transformer that
voltage and remain at that level for several supplied 12V output and was further fed to four
hours, sometimes a couple of days until some diodes IN5408 (A bridge Rectifier) that gave
corrective measures are taken by the PHCN 12V DC output with a ripple free effect by the
authority. use of filter capacitor. This filtered 12V DC was
Under such erratic conditions of line voltage, in fed to a switching relay unit for its effective
study area re-wireable fuse or miniature circuit operation. The microcontroller (PIC16F877A)
breaker are normally used to protect different required 5V for its operation, for this purpose
households from under and over- voltage LM371 – IC1 and IC2 (3- terminal voltage
condition. (M.S.Islam and M.A. Zulquarnain, regulator) were used to obtain the +12V and 5V
1991). Considering this factor, M.S.Islam and needed by the regulator. Also the 5V DC voltage
M.Kamruzzaman, 1992, affirmed that a across the LM371 – IC2 were fed at pin 1, 13
protective device like over- voltage and over- and 32 of the PIC16F877A microcontroller as a
current with delay unit has been developed for supply voltage. Pins 33, 34. 35, 36 and 37 of the
ensuring a dependable and an effective microcontroller were switching circuit which
protection to small households. was responsible for driving the relays connected
The convectional stabilizer is op-amp based, to auto-transformer. However, the
which compare the incoming voltage and a microcontroller cannot withstand the current
reference voltage; because of the nature of demand of the coils of the switching relays, thus
analog signals, it introduces inherent errors in a buffer circuit was coupled with the switching
the comparison process. Microcontroller based circuit.
stabilizer has replaced the op-amp based, which A resistance of 4.7 KΩ was soldered between
is more effective and reliable to withstands pin1 and 5V supply which was denoted by R5
fluctuation in the line voltage. Therefore, this and R6. LED1, LED2, LED3, LED4, LED5,
paper explained the design and construction LED6 indicated 103-122V, 123-146V, 147 -
process of a microcontroller based stabilizer to 175V, 176 -209V, 210 -250V and overvoltage
compensate for the erratic power supply and respectively. The display LED in the
fluctuation in the line voltage microcontroller was connected to pins 15,
16,17,18,23 and 24 of the microcontroller. The
block diagram of the system is depicted in figure

M A IN S Autotransform er

AC

R ectification/Filtering/ S am pling/Analog- D igital C om parison S w itching


R egulation to-D igital
C onversion

LED D isplay

B lock D iagram of a M icrocontroller-based S tabilizer

3.0 CIRCUIT DESIGN


(d) Regulator
The overall circuit is broken down into five (e) Output indicator
major sub- circuits. These are listed below;
3.1 DC SUPPLY UNIT A. Transformer
Initial stage of every electronic circuit is power An alternating current (a.c) main was made
supply system which provides required power to available to switching and control circuit via a
drive the whole system. The specification of fused 3-pin 13A plug to ensure polarity and
power supply depends on the power requirement protection. A 240/30V, 2000mA step-down
and this is determined by its rating. The supply transformer was used to ensure a stable direct
unit consists of the following components: current (d.c) voltage at low mains. The choice of
(a) Transformer this transformer was based on the power rating
(b) Rectifier
of the microcontroller and other integrated
(c) Input filter
circuits employed in the design.
B. Rectifier . = 0.6366 ∗ = 0.6366 ∗ 42.42
Rectifier is a circuit which converts a.c to dc. = 27.01
The voltage available at the terminals of the = − . = 42.42 − 27.01
secondary side of the transformer was a.c and a = 15.41
converter circuit (known as rectifier) which Therefore,
convert a.c into d.c suitable for proper operation − = 2 ∗ 15.41 = 30.82
of the electronic components. Rectification of 10
10% =
∗ 30.82 = 3.08
a.c to d.c was achieved through a full wave 100
rectifier (four IN5408 diodes with a current Maximum projected load current is 350mA (5

capacity of 3A). relays at 70mA each)


$
# = ………. 4
%
C Input filter
Where,
After rectification a d.c supply was obtained
1
from an a.c supply but it was not ripple free. To %= ……………. 5
&
minimize these ripples and smooth the voltage For a full wave rectifier, the frequency of the
output of a rectifier, a filter was used. To rectifier d.c output is 2 times the supply
minimize low frequency ripples an electrolytic frequency = 50Hz
capacitor was used. The ripple voltage is the 1
%= = 0.01
deviation of the load voltage from its d.c voltage 100
as derived below: From equation (4)

= − . ….. 1 $ ∗ 3.08
1' =
0.01
Where the d.c voltage is Vo
0.35'
= √2 … … … … … … 2) $ = 0.01 ∗
3.08
Where Vin = 15 $ = 1136(& 1000 ) *
= √2 ∗ 15 = 21.21 The working voltage of a filter capacitor must
The values of the capacitor used with a 50Hz always be more than 1.414 times the expected
supply range from 100μf – 30,000μf secondary voltage of the step-down transformer.
Depending on the load current and the degree For this design 1000μf, 63V is used for C1
of smoothening required.
In selecting capacitors, the ripple voltage D. Regulator
required is 10% of the peak value, thus: Regulator is a device which provides constant
=2∗ …….. 3 output voltage with varying input voltage. There

Where = √2 ∗ . . are two types of regulators:

Therefore, (i) Fixed voltage regulator and


(ii) Adjustable voltage regulator
2 = 2 ∗ √2 ∗ . .
= 2 ∗ √2 ∗ 15 = 42.42
+12V and +5V are available as fixed regulators 3.2 Auto- transformer
with parts number LM71812 and LM7805. The auto-transformer is the regulating portion of
However, due to the low input voltage limit of the entire circuit. It primary function is to add or
the fixed regulators (25V), another regulator subtract from the input mains voltage in order to
(LM317-IC1 and LM317-IC2) were used to provide a regulated output voltage range of 210 -
obtain the +12V and +5V needed by the 220V for the connected load. These windings
microcontroller and other electronic were designed such that it can add or subtract
components. A 220Ω resistor was used between appropriate voltages to or from its input to give
the adjustable voltage regulator and the output 210 – 250V at its output.
terminals of the LM317IC1. A variable 4.7KΩ
resistor was connected between the adjustable 3.2.1 Number of Turns
terminal and ground. The number of turns required to give a
E. Output indicator maximum output of 250V on the output winding
The LED was used to observe the functionality is govern by the equation:
of the system. The LED glowed it confirmed + *, *, = 4.44 ∗ & ∗ - ∗ . *, *, ∗ '
proper functioning of the system. Meanwhile, if ............. (6)
the LED does not glow; it confirms From equation, we can get N output as:
malfunctioning of the system.
+ *, *,
. *, *, = … 7
4.44 ∗ & ∗ - ∗ '/&

POWER
12A FUSE SWITCH
L
LM317 TIP41C
Q1
IC1
220?

N R1
D1 – D4
R2 4.7K
240V/30V
2000mA
T1

LM317
1000uF IC2 100nF
C1 C2

R4 R3
4.7K
; = 176
Where, It thus means that 176 – 209V on winding A
Eoutput = Maximum expected induced voltage (171 turns) produced 210 – 250V on the output
on output winding = 250V winding (204 turns).
Bmax = Maximum linear flux density of the Similarly, 175V on winding B produced 250V
magnetic core (1.3 Tesal) and the corresponding turns required will be:
f = supply frequency = 50Hz 250 204
= … … . . 11
A = cross-sectional Area required for a 2KVA 175 .-

transformer = 49.74 cm² .- = 143 ,*


The lowest threshold of input voltage to give
The actual transformer used has the following
210V as output will be:
parameters:
210 204
Length of former = 8.2cm = … … . . 12
; 143
Breadth of former = 5.8cm
; = 147
C.S.A of former = 8.2cm * 5.5cm = 47.56cm² =
147 – 175V on winding B gave 210 -250V on
0.00475m²
the output winding.
Sf = stacking factor of transformer (typically
On winding C;
between 0.8 and 1).
146V will produce 250V on the output and the
012
. *, *, = ….. 8 number of turns that will allow that will be:
3.33∗12∗4.5∗2.223617∗2.8

. *, *, = 202.4 204 ,* , 9 * 250 204


= … … . . 13
146 .$
Hence, 204 turns on the auto- transformer can
.$ = 119 ,*
accommodate a maximum induced voltage of
The lowest threshold of input voltage to give
250V with minimal losses.
210V as output will be:
A fixed range of 210 – 250V has been chosen as
210 204
the regulated range of the stabilizer. This means = … … . . 14
; 119
that when an input voltage between 210 – 250V ; = 123
is imposed on the transformer, the voltage is 123 -146V on winding C gave 210 -250V on the
passed out without any addition or subtraction. output winding.
Winding (A) is calculated as thus: Likewise on winding D,
250 204
= …….. 9 122V will produce 250V on the output and the
209 .'
number of turns that will allow that will be:
.' = 171 ,*
250 204
The lowest threshold of the input voltage that = … … . . 15
122 .<
will induce 210V on the output winding will
then be: .< = 100 ,*
210 204
= … … . . 10 The lowest threshold of input voltage to give
; 171
210V as output will be
210 204 # *, > ) = 2222=
= … … . . 16
; 100
; = 103 At 250V, the current capacity of the transformer
103 – 122V on winding D gave 210 – 250V on is
the output winding.
# *, > )
The figure is a diagrammatic representation of $* ,= … … . . 20
, A
the auto-transformer showing various windings.
2222
$* ,= = 8.89' … … . 21
210-250V(NOUTPUT) 250

The current density used for this design was =


176-209V(NA)
1500'/ ² and the wire gauge that
accommodates this current adequately was
147-175V(NB)
s.w.g13.

123-146V(NC) 3.3 Control Unit

103-122V(ND) The primary function of the control unit is to


sense the sample voltage from the power supply

0V transformer and determine which relay to be


switched by selecting appropriate winding of the
Figure 3.2 Stabilizer Auto-transformer auto-transformer that produced an acceptable
Source: author fieldwork
voltage range (210 – 220V) and this control unit
3.2.2 Wire Gauge Selection
based on >#$16D877' microcontroller. A
The size of copper conductor required to carry
microcontroller is pre-programmed with a
the current capacity that will flow in 2000Watts
firmware that has been designed to provide
transformer is obtained as follow:
logical highs on certain ports (pins) of the
*, *, ) &, & microcontroller when preset threshold on the
= 2000= … … 17 mains voltage are crossed. A sub-routine is
included in the microcontroller program which
Typically, the efficiency of a good transformer
sends out a high to cause relay 5 to open the
varies between 90 – 97%. Choosing a lower
output circuit when the output voltage is equal
limit of 90%, then the input power of the
or greater than 252V. C3 decoupled the power
transformer will be:
supply to the microcontroller and D6 and D7 as
?*, *, > ) well as D9 and D10 were used to maintain the
# *, > ) = … … . . 18
+&& @ voltages on pin2 and 3 of the microcontroller to

2000 5V.
# *, > ) = … … . . 19
0.9
5V
10 uF
C3

R5
L IN P U T 4.7k
R7 32
150 K, 1W R6
4.7k 1
1N 4007
D5
13
100 uF R 22 pF 37
8
C5 10 K C4
36
4.7V P IC 16F 877 A 35
D6
2 34
1 N 4148 33
D7
N

12 31
L OUTPUT
R9
150K , 1W
1N 4007
D8

100 uF R
10
C5 10 K

4.7 V
D9

1N 4148
D 10
N

3.5 Display Circuit


3.4 Switching Circuit
The display circuit shown a visual indication of
The switching circuit is responsible for driving the output voltage of the stabilizer. The display
the relays connected to the auto-transformer. circuit consists of LEDs connected in a bar
However, the microcontroller cannot withstand graph mode such that individual LEDs turn on
the current demand of the coils of the switching when regulated within a specific range. The
relays so a buffer circuit was introduced. indicator was composed of LEDs 1 – 5. LED 1
ULN2003 Darlington chip was used as a buffer. corresponds to 103 – 122V, LED 2corresponds
to 133 – 146V, LED 3 corresponds to 147 -
175V, LED 4 corresponds to 176 -209V, LED 5
corresponds to 210 -220V and LED 6
POWER
12A FUSE SWITCH
L
LM317 TIP41C
Q1
IC1
220?

N
D1 – D4
4.7K
240V/24V
2000mA
T1

LM317
1000uF IC2 100nF 10uF
C1 C2 C3

4.7K 4.7k

20
4.7k
1 27
9 26
150K, 1W 22pF 25
C4
1N4007
24
D5 PIC16F877A 23
100uF 2 22
C5 10K
To
transform
150K, 1W 21
er output 4.7V 100nF
1N4007 C6
3
D6
D5

100uF 1N4148 8 19
C5 10K D7

4.7V 100nF
D6 C6

1N4148
D7

ULN2003
3.6 Software Implementation for the Control Unit
'Select Chip
#chip 16f877A, 4 'PIC 16F877A running at 4MHz
'Hardware Configuration
#config RC_OSC, WDT_OFF, LVP_OFF, CP_OFF
'Set Port Directions
Dir PORTA.0 in 'Set PORTA pin 0 as an input pin
Dir PORTB out 'Set PORTB pins as output
Start:
POKE(6, 0) 'Initialise all PORTB pins to zero
Main:
if ReadAD(AN0) > 0 then set PORTB.0 on 'Turn on LED on PORTB pin 0 if value on PORTA is > 0

if ReadAD(AN0) = 0 then set PORTB.0 off 'Turn off LED on PORTB pin 0 if value on PORTA is = 0

if ReadAD(AN0) > 51 then set PORTB.1 on 'Turn on LED on PORTB pin 1 if value on PORTA is > 51

if ReadAD(AN0) <= 51 then set PORTB.1 off 'Turn off LED on PORTB pin 1 if value on PORTA is <= 51

if ReadAD(AN0) = 0 then set PORTB.0 off 'Turn off LED on PORTB pin 0 if value on PORTA is = 0

if ReadAD(AN0) > 103 then set PORTB.2 on 'Turn on LED on PORTB pin 2 if value on PORTA is > 103

if ReadAD(AN0) <= 103 then set PORTB.2 off 'Turn off LED on PORTB pin 2 if value on PORTA is <= 103

if ReadAD(AN0) <= 51 then set PORTB.1 off 'Turn off LED on PORTB pin 1 if value on PORTA is <= 51

if ReadAD(AN0) = 0 then set PORTB.0 off 'Turn off LED on PORTB pin 0 if value on PORTA is = 0

if ReadAD(AN0) > 154 then set PORTB.3 on 'Turn on LED on PORTB pin 3 if value on PORTA is > 154

if ReadAD(AN0) <= 154 then set PORTB.3 off 'Turn off LED on PORTB pin 3 if value on PORTA is <=154

if ReadAD(AN0) <= 103 then set PORTB.2 off 'Turn off LED on PORTB pin 2 if value on PORTA is <=103

if ReadAD(AN0) <= 51 then set PORTB.1 off 'Turn off LED on PORTB pin 1 if value on PORTA is <= 51

if ReadAD(AN0) = 0 then set PORTB.0 off 'Turn off LED on PORTB pin 0 if value on PORTA is = 0

if ReadAD(AN0) > 205 then set PORTB.4 on 'Turn on LED on PORTB pin 4 if value on PORTA is > 205

if ReadAD(AN0) <= 205 then set PORTB.4 off 'Turn off LED on PORTB pin 4 if value on PORTA is <=205

if ReadAD(AN0) <= 154 then set PORTB.3 off 'Turn off LED on PORTB pin 3 if value on PORTA is <=154

if ReadAD(AN0) <= 103 then set PORTB.2 off 'Turn off LED on PORTB pin 2 if value on PORTA is <=103

if ReadAD(AN0) <= 51 then set PORTB.1 off 'Turn off LED on PORTB pin 1 if value on PORTA is <= 51

if ReadAD(AN0) = 0 then set PORTB.0 off 'Turn off LED on PORTB pin 0 if value on PORTA is = 0

goto Main 'Go back to label "Main" and repeat the process again indefinitely.
4.0 Performance Evaluation
The system was successfully designed and its >> LV = [103 123 146 175 180 190 210 230
performance was evaluated using MATLAB. 240 250]; % line voltage to the system
The system is effective in terms of operation and >> MOV = [5 5 5 5 5 5 5 5 5 5]; %
it is highly reliable when subjected to fluctuation microcontroller output @ different line
of line voltage. The system employed a local, >> SOV = [210 215 215 218 220 220 218 220
low cost >#$16D877' microcontroller. To 220 220];
avoid the complex comparator and A/D >> % output voltage of the microcontroller-
converter circuit, a microcontroller with an in- based stabilizer
built comparator and A/D converter was used. >> figure(1)
The low voltage power supply unit was designed >> plot(LV,MOV,'b',LV,SOV,'r--')
for highly regulated output to bias the >> grid on
microcontroller. In this design, the input a.c >> xlabel('Line voltage [volt]')
voltage varied from 103 volt to 220volt while >> ylabel('output voltage [volt]')
the output of the microcontroller remains >> axis([103 250 0 240]))
constant at 5 volt DC. The output of the system >> title(' output of the low-power supply &
over variation of input line voltage is depicted in micro microcontroller-based stabilizer')
figure 1.0. >> legend(‘output of the low-power
4.1 MATLAB Commands supply'),('microcontroller-based stabilizer
output'
>> % MATLAB script to generate the output of DC output of the low-power supply & microcmicrocontroller-based stabilizer

the low-power supply


200
>> % & the DC output level of the
microcontroller-based stabilizer
output v oltage [v olt]

150

>> % written by OKUBANJO, A.A DC output of the low-power supply


Microcontroller-based stabilizer output

>> % @ Olabisi Onabanjo University 100

>>% College of Engineering and


50
Environmental Studies
>> % Ibogun Campus, Ogun State 0
120 140 160 180 200 220 240
>> % Nigeria Line voltage [volt]

>> % Let 'output voltage of the microcontroller'


Figure 1.0
be denoted by MOV
The PIC accepts voltage at the auto-transformer
>> % Let 'Line voltage ' be denoted by LV
tapping and senses the regulator terminal voltage
>> % Let 'output voltage of the stabilizer' be
and feedback it to the PIC. Alternating current
denoted by SOV
line voltage is typically under 220V in Nigeria.
The output of the stabilizer was maintained at available. Based on foregoing it can be
220V constant supply irrespective of the level of concluded that this device can easily protect
the line voltage at the mains. The graph in figure appliances against fluctuation of line voltage.
1.0 depicted the performance of the
microcontroller with varying input voltages
ranging from low voltage to high voltage. The REFERENCES
double dotted red line indicated the dc output of
[1] A.Ahmed, Power Electronics for
the input voltages and the output of the voltage
Technology, Prentice-Hall International, 1999.
at microcontroller (indicated by blue line) is
maintained at 5V constant supply for effective [2] B.L. Theraja and A.K. Theraja, (2010) A
operation of microcontroller and to prevent the Textbook of Electrical Technology, Scand &
microcontroller from excess voltage due to company Ltd. New Delhi.
fluctuation of line voltage at the mains and this
[4] J.B. Peatmann, Design with
was depicted by blue straight line in the graph.
Microcontrollers, Prentice-Hall, 1998
The performance of the design system was
studied by comparing its accuracy, reliability [5] J.M. Jacoab, Power Electronics: Principles
and cost. and Applications, Vikas publishing House,
A series of laboratory experiments were 2002.
conducted with the help of the unit, with
[6] M.A.A.Mashud, E.Haque and S.Islam,
satisfactory results.
(2001) Jahangirnagar Physics Studies, Vol. 17,
pp 151 ISSN 1999-6632.
5.0 Conclusion
This paper explained the design and construction [7] M.A.Mazidi, R.M.Kinlay & D.Causey,
of microcontroller-based stabilizer. The design (2008) “PIC Microcontroller”, Prentice Hall
system was put under series of test by the Inc., pp 24.
students of Olabisi Onabanjo University during
[8] M.C.Sharma, Voltage Stabilizers and
Examination period (busy hour and when power
Automatic Cutouts, 1987.
supply by the PHCN was either erratic or
extremely low) to ascertain its performance as a [9] [4] M.O.Ogunnusi, Design and Construction
protective device and a very satisfactory of 2000VA Microcontroller- based Stabilizer,
outcome were obtained. This device is very Unpublished B.Sc project. Department of
sensitive to undesired transient condition of the Electrical and Electronics Engineering, Olabisi
main supply. The design was also not complex Onabanjo University, Ago –Iwoye, Ogun State,
in design, reliable in operation and cost Nigeria.
competitive with any other conventional product
[10] M.S.Islam and M.A.Zilquarnain (1991),
Journal of the Bangladesh Electronics Society,
pp 21.

[11] M.S. Islam and M.Kamruzzaman, (1992),


Journal of the Bangladesh Electronics Society,
Vol.2, No.1, pp 29.

[12] P.C. Sen, Power Electronics, Tata McGraw-


Hill Publishing Company Limited, New Delhi,
1987.

[13] R.A.Penfold, An Introduction to PIC


Microcontrollers, Bernard Babani Publishing,
1997.

[14] S.Islam, (1994), Nuclear Science and


Applications, Vol.3, No.2.

[15] Sollateck (UK), Automatic Voltage


Regulator. www.sollateck.com.

[16] Suvik Electronics Static Voltage Stabilizer.


www.indiamart.com/suvik/Voltage-stabilizer.

[17] V.K.Mehta and R.Mehta, (2007) Principles


of Electronics, S.Chand & Company Ltd. New
Delhi.

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