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Design And Construction Of A 3.5Kva Power Inverter

Electrical Electronics Engineering | Industrial Physics | Physics

The design and construction of a 3.5KVA power inverter entail the meticulous integration of various electronic components to efficiently convert direct current (DC) into alternating current (AC) for powering electrical devices. This intricate process involves the careful selection and arrangement of high-capacity transformers, reliable power switching devices, and sophisticated control circuits. Emphasizing key elements like voltage regulation, frequency stability, and surge protection is essential to ensure the inverter’s robust performance. Additionally, incorporating advanced thermal management systems is crucial to prevent overheating during prolonged operation. Achieving optimal efficiency requires a thoughtful consideration of component specifications, such as power handling capacities and voltage ratings, and a meticulous assembly process to guarantee the inverter’s reliability under varying load conditions.

This project is titled the design and construction of a DC to AC inverter system. It is designed to meet up with the power demand in the offices and in homes in the absence of power supply from the national supply authority, PHCN. In order words the device / item serves as a substitute for PHCN which almost monopolises the power supply to people.

It is designed in such a way that it will take up 12v DC from battery and inverts it to an output of 230v, 50Hz AC. It makes no noise during operation and no hazardous carbon monoxide is generated in the surrounding.

This is a feature that makes it safe to use any where when compared to generator. Also, the circuit is capable of charging the battery (i.e 12v source) when the power from the supply authority is on. This greatly reduces the cost of operation of the system.

This work is aimed at designing a modified sine wave inverter of power rating of 3.5kva that can be used to power appliances both in homes and industries.

 

TABLE OF CONTENTS

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENT

CHAPTER ONE

1.0      INTRODUCTION

1.1      OBJECTIVE OF THE PROJECT

1.2      PROBLEM STATEMENT

1.3      SIGNIFICANCE OF THE PROJECT

1.4   APPLICATION OF THE PROJECT

1.5      SCOPE OF THE PROJECT

1.6      LIMITATION OF THE PROJECT

1.7      PURPOSE OF THE PROJECT

1.8      PROJECT ORGANISATION

CHAPTER TWO

2.0     LITERATURE REVIEW

2.1      REVIEW OF HISTORY OF AN INVERTER

2.2   REVIEW OF HOW TO CHOOSING THE RIGHT INVERTER

2.3      REVIEW OF THE DIFFERENCE BETWEEN SINE WAVE AND MODIFIED SINE WAVE   INVERTER.

2.4      REVIEW OF INVERTER CAPACITY

2.5      SAFETY OF INVERTER

2.6      INVERTER RATING

2.7      WHY CHOOSE A MODIFIED SINE WAVE INVERTER?

2.8      TYPES OF INVERTER

CHAPTER THREE

3.0     CONSTRUCTION

3.1      BASIC DESIGNS OF AN INVERTER

3.2     BLOCK DIAGRAM OF THE SYSTEM

3.3      SYSTEM OPERATION

3.4      CIRCUIT DIAGRAM

3.5      CIRCUIT DESCRIPTION

3.6     DESCRIPTION OF COMPONENTS USED

3.7     HOW TO CHOOSE A RIGHT INVERTER AND BATTERY

3.8      HOW TO CHOOSE THE BEST INVERTER BATTERY

CHAPTER FOUR

RESULT ANALYSIS

4.0      CONSTRUCTION PROCEDURE AND TESTING

4.1      CASING AND PACKAGING

4.2      ASSEMBLING OF SECTIONS

4.3      TESTING OF SYSTEM OPERATION

4.4     COST ANALYSIS

CHAPTER FIVE

5.0      CONCLUSION

5.1      RECOMMENDATION

5.2      REFERENCES

CHAPTER ONE

1.0                                       INTRODUCTION

1.1                          BACKGROUND OF THE STUDY

Electricity supply is one the economic infrastructural facilities that are indispensable to a nation’s economic development. The efficiency of the supply of electricity will not only influence returns on investment on existing enterprises, it also plays a major role in the creation of an economic environment which influences decisions on potential investment [2].

The electricity which is the main source of power for our domestic consumption, industrial development, learning centres and medical centre should really be rehabilitated into enhancement of productivity [2].

However power failure has resulted in people buying generators for their own daily activity. Other businesses are also not functioning due to absence of constant power supply. These are the reasons that necessitate the designing and construction of inverter and other standby system that can deliver maximum output power to the load. As society grows from simple to complex, mankind began to spread all over the earth and so it becomes necessary  to enjoy power using inverter [1].

Statistics have shown that the number of business that have been closed simply because of power problem and cannot be over emphasized, so mankind need inverter seriously in other to restore technology development, businesses, communications, learning centre and medical centres. However, the background of the study lies within the reason why and the construction of inverter should be forwarded and factor that enhance inverter marketability [1][2].

Finally, the success of this study will be beneficial to the society at large. Mass production of inverters will lead to improve standard of living of the populace and the nation will move forward in it pursuit of technological development [2].

1.2                                               PROBLEM STATEMENT

As a result of continuous power failure and fluctuation in power supply by Power Holding Company of Nigeria (PHCN), sensitive appliances and system are affected by interruption power supply. Then, this project is to provide a back-up and reliable power supply of 3500VA to power some selected home appliances such as computers, television set, lighting systems.

1.3                         AIM / OBJECTIVE OF THE PROJECT

The aim of this project is to design and construct a circuit that will take a 12v dc input from battery and provide a 220v ac and 3500w output that will be able to supply a electricity to a home. At the end of this work the student involved shall able:-

  1. To design a circuit that will convert dc to ac power for various appliances used in domestic home.
  2. To provide a noiseless source of electricity generation.
  • To have a source of generating electricity that has no negative effect on the environment (i.e. no greenhouse effect).
  1. To provide a source of electricity power with low maintenance cost and zero fuel cost.

1.4                                           PURPOSE OF THE PROJECT

The purpose of this work is to provide a means of having a backup power supply by building an electronic device or circuitry that changes direct current (DC) to alternating current (AC).

1.5                                 PROJECT MOTIVATION

Inverters are the best when it comes to back-up since they can come up very fast and they generate little or no noise unlike generator. Even in an area with constant power supply, power outage due to natural cause and faults are usually unannounced. It is therefore very important to prevent causalities and loss of goodwill by having a reliable back-up power installed.

1.6                                       SIGNIFICANCE OF THE PROJECT

In the recent years, power inverter has become a major power source due to its environmental and economic benefits and proven reliability.

Power inverter is produced by connecting the device on the 12VDC battery as the input to produce 220VAC as the required output. It can also be connected to solar panel [1].

Second, the whole energy conversion process is environmentally friendly. It produces no noise, harmful emissions or polluting gases. The burning of natural resources for energy can create smoke, cause acid rain and pollute water and air. Carbon dioxide, CO2, a leading greenhouse gas, is also produced in the case of burning fuels. Power inverter uses only the power of the battery as its fuel. It creates no harmful by-product and contributes actively to the reduction of global warming [1][2].

1.7                                              SCOPE OF THE PROJECT

A power inverter is a power conversion device. It converts fixed direct current (DC) voltage to frequency sinusoidal alternating current (AC) voltage output.

Power inverters are used to power and control the speed, torque, acceleration, deceleration, and direction of the motor. The use of inverter has become prevalent in wide range of industrial applications; from motion control applications to ventilation systems, waste water processing facilities to machining areas, and many others. Though power inverters offer lower operating costs and higher efficiency, they are not without their problems [3].

The waveform of this work is modified sine wave. The modified sine wave output of such an inverter is the sum of two square waves one of which is phase shifted 90 degrees relative to the other. The result is three level waveform with equal intervals of zero volts; peak positive volts; zero volts; peak negative volts and then zero volts. This sequence is repeated. The resultant wave very roughly resembles the shape of a sine wave [4].

1.8                                         LIMITATION OF THE PROJECT

  • Expensive when compared to traditional generators
  • The inverter can power a few appliances for a short period
  • The input is limited to 12VDC, output to 230VAC and the frequency to 50Hz

1.9                                       APPLICATION OF THE PROJECT

The applications and uses of a power inverter are as follows [5, 6]:

  1. DC power source utilization
  2. Uninterruptible power supplies
  • Induction heating
  1. HVDC power transmission
  2. Variable-frequency drives
  3. Electric vehicle drives
  • Air conditioning
  • Electroshock weapons

1.10                                     METHODOLOGY

To achieve the aim and objectives of this work, the following are the steps involved.

Study of the previous work on the project so as to improve it efficiency. The block diagram and the working principle of the project was studied, followed by drafting out a schematic diagram and arrangement the entire materials / components on the vero board, testing the completed system to see if the design works and finally, implementation of design of the project.

1.11                                      PROJECT WORK ORGANISATION

The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:

Chapter one of this work is on the introduction to a power inverter. In this chapter, the background, significance, aim/objective problem statement, purpose, application, limitation and problem of a power inverter were discussed.

Chapter two is on literature review of a power inverter. In this chapter, all the literature pertaining to this work was reviewed.

Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.

Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.

Chapter five is on conclusion, recommendation and references.

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Design And Construction Of A 3.5Kva Power Inverter:

A power inverter is a crucial device that converts DC (Direct Current) power into AC (Alternating Current) power, allowing electronic devices to operate from a battery source or other DC power supply when there is no grid power available. In this project, we will discuss the design and construction of a 3.5KVA (Kilovolt-ampere) power inverter, capable of providing enough power to run small household appliances, computers, and other electronic devices during power outages or in off-grid situations.

Understanding the Basics

Before diving into the design and construction process, it’s essential to understand the basic components and principles behind a power inverter:

  1. DC Power Source: The inverter will be powered by a DC source, typically a battery bank or solar panels.
  2. Inverter Circuit: This circuit consists of power transistors or MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors) that switch the DC input into AC output.
  3. Control Circuitry: This part of the inverter regulates the switching of the power transistors to produce a stable AC output voltage and frequency.
  4. Output Transformer: In larger inverters like this one, an output transformer is often used to step up the voltage and provide isolation between the input and output.

Design Specifications

For the 3.5KVA power inverter, we’ll set the following design specifications:

  1. Output Power: 3.5KVA (3500 watts)
  2. Output Voltage: 220V AC, 50Hz (Adjustable if necessary)
  3. Efficiency: Target efficiency of at least 85%
  4. Waveform: Pure sine wave output for compatibility with sensitive electronics
  5. Protection: Overload, short circuit, overheat, and low battery voltage protection mechanisms

Design Steps

Step 1: Component Selection
  1. Power Transistors: Select high-power transistors or MOSFETs capable of handling the desired output power (3500 watts) and voltage (220V).
  2. Control IC: Choose a suitable integrated circuit for controlling the switching of the power transistors and generating the PWM (Pulse Width Modulation) signals.
  3. Output Transformer: Select an appropriate output transformer capable of handling the power and voltage requirements, with low core losses.
  4. Heat Sink: Ensure adequate heat sinking for the power transistors to dissipate heat efficiently.
  5. Protection Components: Include fuses, relays, and temperature sensors for overcurrent, short circuit, and overheat protection.
Step 2: Circuit Design
  1. DC-DC Conversion: Design the DC-DC conversion stage to boost the battery voltage to the desired level for the inverter circuit.
  2. Inverter Circuit: Design the inverter circuit using the selected power transistors and control IC. This circuit should generate a PWM signal to control the switching of the transistors.
  3. Output Stage: Include the output transformer and filtering components to convert the PWM signal into a pure sine wave AC output.
  4. Control Circuitry: Design the control circuitry to monitor the output voltage and frequency and adjust the PWM signal accordingly.
Step 3: Construction
  1. Printed Circuit Board (PCB): Design and fabricate a PCB to accommodate all the components and ensure proper connections and isolation between circuits.
  2. Assembly: Mount the components on the PCB, including the power transistors, control IC, transformer, and protection components.
  3. Wiring: Connect the components according to the circuit design, ensuring proper routing of high-current paths and adequate insulation.
  4. Testing: Test the inverter under various load conditions to ensure it meets the design specifications for output voltage, frequency, and efficiency.
  5. Enclosure: Install the inverter circuitry in a suitable enclosure with proper ventilation and safety features to protect against accidental contact.

Conclusion

Designing and constructing a 3.5KVA power inverter requires careful consideration of component selection, circuit design, and construction techniques. By following the steps outlined above and testing the inverter thoroughly, you can create a reliable power backup solution for off-grid applications or during power outages. Remember to prioritize safety and efficiency throughout the design and construction process to ensure the inverter performs reliably under various conditions