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Design and Analysis of Modified Sine Wave Inverter

Technical Report · May 2015

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 Design and Analysis of Modified Sine Wave Inverter
PWM (Pulse-Width-Modulator) – H-bridge parts
Salman Y. Mansour, Prof. Dr. Mohamed Abdelati
Islamic University Of Gaza –Engineering Faculty –Electrical Department

ABSTRACT: -
This project discussed on An Analysis of Modified Sine Wave Inverter, This paper mainly focuses
on Pulse-Width-Modulation Control Circuits using TL494 and H-bridge parts. We will explain DC-to-AC inverter
from 300V DC to 220V AC, and Mechanism of PWM IC (TL494) with feedback and safety stages. Test
results showed that the design was reasonable and had reliable performance.
Keywords: Power electronics, Inverter,PWM, H-bridge

I. INTRODUCTION
A power inverter, or inverter, is an electronic device or circuitry that changes direct current
(DC) to alternating current (AC).[1]
The input voltage, output voltage and frequency, and overall power handling depend on the design of
the specific device or circuitry. The inverter does not produce any power; the power is provided by the
DC source.

Pulse width modulation (PWM): is a very important aspect in power electronics course. There are
many dedicated commercially available PWM chips like SG3524, TL494 etc. The most popular one is
TL494 or AZ7500ep due to its low cost, simplicity and robustness. They call it magic chip.
 The TL494 device incorporates all the functions required in the construction of a pulse-width-
modulation (PWM) control circuit on a single chip. Designed primarily for power-supply
control, this device offers the flexibility to tailor the power-supply control circuitry to a specific
application.

 The TL494 device contains two error amplifiers, an on-chip adjustable oscillator, a dead-time
control (DTC) comparator, a pulse-steering control flip-flop, a 5-V, 5%-precision regulator, and
output-control circuits.
 The error amplifiers exhibit a common-mode voltage range from –0.3 V to VCC – 2 V. The
dead-time control comparator has a fixed offset that provides approximately 5% dead time. The
on-chip oscillator can be bypassed by terminating RT to the reference output and providing a
sawtooth input to CT, or it can drive the common circuits in synchronous multiple-rail power
supplies.
 The uncommitted output transistors provide either common-emitter or emitter-follower output
capability. The TL494 device provides for push-pull or single-ended output operation, which
can be selected through the output-control function. The architecture of this device prohibits the
possibility of either output being pulsed twice during push-pull operation.
 The TL494C device is characterized for operation from 0°C to 70°C. The TL494I device is
characterized for operation from –40°C to 85°C.[3]
 Figure (1): TL494 internal content
H bridge:
An H bridge is an electronic circuit that enables a voltage to be applied across a load in either
direction. Most DC-to-AC converters (power inverters), most AC/AC converters, the DC-to-DC push–
pull converter, most motor controllers, and many other kinds of power electronics use H bridges. In
particular. [1-2]
A common use of the H bridge is an inverter. The arrangement is sometimes known as a single-phase
bridge inverter. The H bridge with a DC supply will generate a square or modified wave voltage
waveform across the load. For a purely inductive load, the current waveform would be a triangle wave,
with its peak depending on the inductance, switching frequency, and input voltage.

Figure (1): H- Bridge

II. DESIGN CONSIDERATION

We can conclude our design as shown below at figure (3) that we will input +300V DC and the
output rms voltage 220AC V.
1- Oscillator circuit.
2- H-Bridge
3- Feedback and safety stages.
 Figure (3): The circuit chart.
1- Oscillator: Pulse-Width-Modulation Control Circuits that we use IC AZ7500ep or TL494 to generate
complementary PWM as we see below in figure (4) and the output at the figure (5).

Figure (4): Oscillator schematic diagram.

We connect GND (pin 7) and Vcc (pin 12) are usual power pins. Max Vcc is about 40V. REF (pin
14) is 5V reference output. Low power output- about 10mA.
1. Frequency select :
RT (pin 6) and CT (pin 5) are used for setting clock (1 … 300 kHz). The frequency of the clock is
calculated using table from data sheet and changing resistor (1.8 … 500 KΩ) and capacitor (0.47 …
10000nF).
 Or the on-chip oscillator can be bypassed by terminating RT to the reference output and providing
a sawtooth input to CT, or it can drive the common circuits in synchronous multiple-rail power
supplies.
For our design, we work at (50Hz) and we use frequency formula below:
1.1 1.1
𝐹𝑜𝑠𝑐 = = = 50𝐻𝑧
𝑅𝑇 ∗ 𝐶𝑇 100 ∗ 10−9 ∗ 220 ∗ 103
The oscillator charges the external timing capacitor, CT, with a constant current, the value of
which is determined by the external timing resistor, RT. This produces a linear-ramp voltage
waveform. When the voltage across CT reaches 3V, the oscillator circuit discharges it, and the
charging cycle is reinitiated.
2. DTC and Feedback:
DTC (pin 4) is Dead Time Control. This pin is similar to feedback, but it used to make soft
start. Regardless to Feedback, it controls the width of the pulse. If it is more than (~2.8V) the output
is disabled, if zero- output is maximum and controlled by FEEDBACK.
Pin FEEDBACK (pin 3) used to control the pulse width. Is the input is zero; the width is
maximum, if it is ~5V or more (compared to REF) than output is disabled. Input must be less than Vcc.
3. Error Amplifiers:
Both high-gain error amplifiers receive their bias from the VI supply rail. This permits a
common-mode input voltage range from –0.3 V to 2 V less than VI. Both amplifiers behave
characteristically of a single-ended single supply amplifier, in that each output is active high only.
This allows each amplifier to pull up independently for a decreasing output pulse-width demand.
With both outputs Order together at the inverting input node of the PWM comparator, the amplifier
demanding the minimum pulse out dominates. The amplifier outputs biased low by a current sink to
provide maximum pulse width out when both amplifiers biased off.
4. Output CTRL:
When the Output CTRL pin (13) be ground, the TL494 is operating in single-ended or parallel
mode. When the Output CTRL be VREF, the TL494 is operating in normal push-pull operation. This
mode we adjusted it in our application.
5. Output Transistors:
Two output transistors are available on the TL494. Both transistors configured as open
collector/open emitter, and each is capable of sinking or sourcing up to 200 mA. The transistors have
a saturation voltage of less than 1.3 V in the common-emitter configuration and less than 2.5 V in the
emitter-follower configuration. As we see the complementary output on output transistor in figure (5).

Figure (5): output from A and B

 C1 (pin 8) is collector of output transistor #1, E1 (pin 9) is emitter of output transistor #1.
C2 (pin 11) and E2 (pin 10) are like C1 and E1, but for the transistor #2, In addition, we use R68,
R67 as pull up resistor.

2- H-Bridge: An H bridge is an electronic circuit that enables a voltage to be applied

across a load in either direction. We use four IRF740LC MOSFET because of it’s good properties
that [ VDSS =400V – RDS(on)=0.55Ω - ID=10A ].

Figure (6): H-Bridge schematic with feedback output

Probably cases for H- Bridge work:

Input Input B N6 N7 V6 V5 V7 V8
A
First Path High Low OFF ON OFF ON OFF ON
Second Path Low High ON OFF ON OFF ON OFF
 Feedback and safety stages: this circuit contained three-safety stages to protect power
inverter from most common issues.
1. The current-limiting circuit.
2. 220v~ locked loop feedback.
3. High and Low Voltage Protection.
1. The current-limiting circuit: is shown in Figure (7). From P1 to the second
comparator when it current consumption reached to the overload level it will
turnoff :

Figure (7): The current-limiting circuit

Resistors R1 and R2 set the reference of about 1 V on the inverting input of the current-
limiting amplifier, Resistor R11, in series with the load, applies 1 V to the noninverting terminal of
the current-limiting amplifier when the load current reaches 10 A. The output-pulse width is reduced
accordingly. The value of R11 is:
1𝑉
𝑅11 = = 0.1𝛺
10𝐴
2. 220v~ locked loop feedback: the responsible circuit shown below in figure (8), which
conserved the output voltage on the desired rms voltage. the feedback output (P2) connected to
DTC pin. We use in our project 220Vrms by controlling on DTC pin 4 voltage it controls the
width of the pulse. If it is more than (~2.8V) the output is disabled, if zero- output is maximum.

Figure (8): 220v~ locked loop feedback circuit P2 from H-bridge and PWM circuit
 • Voltage on pin (4) controls the width of the pulse. If it is more than (~2.8V), the output
is disabled, if zero- output is maximum.
We used D9 (30v zener diode) to allow the exceeded voltage above 30v to go to DTC pin to
control with duty cycle of the PWM wave The voltage coming to the DTC pin is between (0-2.5v),
in 0v the duty will be maximum, and in 2.5v the duty will be minimum
And we used variable resistor (RV2) to adjust the output voltage at load in the required volt (in
our case 220Vrms), The voltage on point A at (RV2)terminal must be below 32.5v upper that circuit
will be off. Firstly we calculate approximate average voltage at node B and it will be like C we
found it about 141v
DTC = 5% from T ”Period” and T equal 20ms
Then We calculate average voltage about 138.2v as shown below:
300 ∗ 3
(300 − ) ∗ 0.475 = 138.2𝑣
100
So we adjust the value of variable resistor to control with output voltage to be 31.4v at the Zenr
terminal at this value DTC will Be 1.4 that satisfied output rms voltage 220v:
R + 10
31.4 = 138.2 ∗
68 + 10 + R

𝑅𝑉2 ≅ 9.9 𝐾Ω

3. High and Low Voltage Protection : the circuit shown below is very important circuit
that protect system by let PWM works on voltage between (250 – 350 DCV)

Figure (9): High and Low Voltage Protection circuit P10 from H-bridge and PWM circuit

This circuit controls with input DC voltage to keep PWM works only between (250-350) V. upper to
low battery and below to the overload voltage.
(P10) voltage will be at 250V = 5.4V, and on 350V it will be 6.8V this will control with two
transistors on circuit to on and off in desired region.

III. Experimental results and notes

1. Over View of All Project:

Figure (10): Over View of All Project

2. Pulse-Width-Modulation Control Circuits schematic and layout:

Figure 1: Oscillator
3. H-Bridge:

Figure 2: H-Bridge

Figure 13: simulation output

 Figure 3: Output Results

Figure 4: Load Output

REFERENCES
[1] Al Williams (2002). Microcontroller projects using the Basic Stamp (2nd ed.). Focal Press. p. 344.
ISBN 978-1-57820-101-3.
[2] http://en.wikipedia.org/wiki/H_bridge.
[3] Texas Instruments Datasheet for TL494 and AZ7500ep.
[4] Texas Instruments Datasheet for TL494 and AZ7500ep.

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