EE 310 Power Supply Design Project

Introduction
The purpose of this lab is to design the transformer, rectifier, and filter for a linear regulated
power supply. After this, the signal will be fed through a diode shunt regulator and an IC
regulator chip to compare the two results. The specifications for this specific design (shown in
Figure 1 below) will have an AC input of 120 V RMS±5%, with frequency 60 Hz, and a DC
output voltage of +5±0.5V, with a nominal +12V at the regulator input. The ripple voltage will
be a maximum 15% of the DC output voltage and the load resistor will be chosen to dissipate 1
watt.
Circuit Designs

B R
C

Figure 1: Schematic of Design A. Terminals A, B, and C are transformer terminals. R and

C are to be determined.

Figure 2 : This figure shows the voltage regulator that will be used to step the voltage from
12V to 5V. An IN4733 zener diode will be used to regulate VOUT to 5V. VPS is to be
attached to the voltage across the capacitor in Figure 1. Resistances are to be determined.
Supporting Analysis

Figure 3: This figure shows a model of the power Transformer used in the power
supply. RW is the winding resistance of the transformer.
To calculate the winding resistance of the transformer, a test resistor was chosen to dissipate 1
watt using the formula:
(𝑉𝐴𝐶 )2
Rtest= 𝑃

With VAC(the voltage between terminals A and C) being 22.2V and the power being 1W, Rtest
was calculated to be 492.84Ω. The actual value of the resistor when measured was 418Ω. This
transformer can be modeled as having an open circuit voltage VAC and two winding resistors in
series with each terminal.

To choose the diode for the rectifier in Figure 1, a PIV rating of twice required by the circuit was
needed. Using the equation PIV=VL+Vγ where VL is equal to VAC and Vγ is a property of the
diode, PIV was calculated to be 11.7V for the chosen 1N4004 diode.
For the rectifier, the voltage across the capacitor and resistor needed to be equal to 12V in order
to get the first step down which would be fed into the regulator. Using the formula:

(𝑉𝐶 )2
RL= 𝑃

For a power of 1W and VC=12V, RL was calculated to need to be 144Ω. Next, using
VR=0.015VC and VM=VC+(VR/2), the required capacitance value for the filter capacitor can be
calculated using the equation:
𝑉
C=2𝑓𝑅𝑚′ 𝑉
𝐿 𝑟

It was calculated that the filter capacitor should have been a value of 150μF, however due to the
limited capacitance choices a 470μF capacitor was used instead at first. This was changed to a
100µF capacitor to increase the ripple voltage to a measurable level.

To predict the maximum current through the diode, ID, the following formula was used:

𝑉 𝑉
ID= 𝑅𝑚 (1 + 2𝜋√2𝑉𝑚 )
𝐿 𝑟
ID was calculated to be 0.295A.

For the voltage regulator circuit, the maximum current (IzMAX) can be calculated by dividing
the dissipated power (0.5W) by the voltage drop across the Zener Diode (5.1V). This gives a
maximum current of 0.098A. From this: IzMIN was calculated to be 30% or IzMAX, or
0.0248A. The remaining 70% is the load current (IL) which was 0.0686A.
Using the formula Ri=(Vc-Vz)/Iz, Ri was calculated to be 88.27Ω.
The final design choice was the load resistor for the regulator. Voltage across this resistor will
be 5.1V, and current (IL) is 0.0686A. This gives a resistance of 74.35Ω. The measured
resistance was 70.4Ω.

Measurements/Data

Table 1: Power Transformer Task

Vab 10.7V
Vac 22.2V
Vbc 10.6V
Vac w load 10.7V
Rtest 418Ω I test 0.0495A
Rw 15.15Ω

Table 2: Rectifier
Vm 14.25
PIV 11.7V

Table 3: Filter Capacitor

Vc 12V
RL 430V
Vr 1.8V
C 100µF

Table 4: Overall
Measurements
Vo 11.6
Vm 14.25
Id Max 0.295A
Id Max Measured 0.360A
This is a figure of the input/output for the diode shunt regulator. VL without load was
5.18V and with load was 4.0V. %regulation was calculated to be 22.78%
This is a figure of the input/output for the LM7805 IC chip regulator. VL without a load
was 5.0V and with a load was 4.99V. This gives a %regulation of 0.2%.

From these calculated regulations, it can be seen that the IC chip is much more efficient at
regulating the voltage with a load attached.
Discussion
The target for this voltage regulator was 12V with a maximum 15% ripple. Experimental
Vm=14.2V, which is 18% off of the target of 12V. However, a ripple voltage of 1.8V falls
within the 15% margin. The regulated final output, however, was almost perfectly in range of
the 5V goal when using the IC chip. With the regulator diode and a load, the 4V reading gives
about 11% error. Some error in this lab could have come from the circuit component choices.
At many times during the process, we didn’t have the exact components needed and had to just
choose the closest values we could find. This circuit dissipates a good amount of power, so
using a low wattage resistor would not be ideal and could just blow. The high wattage resistors
available in the stockroom did not come in as much of a variety.
Conclusion
In summary, a 160VRMS 60Hz AC power supply was taken through a power transformer, a
rectifier, a filter, and a voltage regulator to make it to the end result of 5∓0.5V(5.18V
measured). The set goal was to be within the 0.5V tolerance of the design specification, so an
output of 5.18V fits well within that range.