DESIGN OF BUCK BOOST CONVERTER TO

OPERATE DC LOAD FROM SOLAR PANEL

Submitted in partial fulfillment of
the requirements for the award of the degree of

Bachelor of Technology
In
Electrical and Electronics Engineering
Submitted by

Roll No Names of Students

BT14EEE019 Dattu Raj Goud

BT14EEE032 Jitesh Khandelwal
BT14EEE048 Abhilash Mallikarjuna
BT14EEE056 Manas Mondal
BT14EEE058 Shashank Reddy

Under the guidance of

Dr. Makarand M. Lokhande

Department of Electrical Engineering

Visvesvaraya National Institute of Technology, Nagpur.
Maharashtra, India ( 440010 )
2017-18.
 Department of Electrical Engineering

Visvesvaraya National Institute of Technology, Nagpur.

Certificate

This is to certify that this is a bonafide record of the project entitled “DESIGN OF
BUCK BOOST CONVERTER TO OPERATE DC LOAD FROM SOLAR
PANEL” presented by the students whose names are given below during the Year
2017-18 in partial fulfillment of the requirements of the degree of Bachelor of
Technology in Electrical and Electronics Engineering.

Roll No Names of Students

BT14EEE019 Dattu Raj Goud
BT14EEE032 Jitesh Khandelwal
BT14EEE048 Abhilash Mallikarjuna
BT14EEE056 Manas Mondal
BT14EEE058 Shashank Reddy

Dr. Mohan Khedkar Dr. Makarand M. Lokhande

Head of Department, Assistant Professor,
Electrical Engineering Electrical Engineering
Department, Department,
VNIT, Nagpur VNIT, Nagpur
 Department of Electrical Engineering
Visvesvaraya National Institute of Technology Nagpur

Declaration

The project entitled “DESIGN OF BATTERY CHARGE CONTROLLER

TO OPERATE DC LOAD FROM SOLAR PANEL” is our own work carried
under the guidance of Dr. Makarand M. Lokhande, Assistant Professor in the
Electrical Engineering Department, VNIT Nagpur. This work in the same form
or in any other form is not submitted by us or anyone else for the award of any
degree.

DATTU RAJ GOUD JITESH KHANDELWAL

ABHILASH MALLIKARJUNA

MANAS MONDAL SHASHANK REDDY

 Acknowledgements

First and foremost, we express our sincere gratitude to the Almighty for
staying with us and giving us the strength and wisdom to perform our tasks. We
would like to thank our project guide,Dr. Makarand M. Lokhande, Electrical
Engineering Department, for his continuous support and guidance throughout
the course of the project. We have been able to compile this report and complete
this project in a comprehensive manner due to his guidance, counselling and
constructive suggestions.
We are also grateful to Dr. Mohan Khedkar, Head of Department,
Electrical Engineering Department for his valuable support and for providing
access to all the laboratories. We are also thankful to M.tech’s and Ph.D’s of
Electrical Engineering Department for their valuable support.
INDEX
Chapter TITLE Page no.
No.
1 INTRODUCTION
1.1 Objective of Project 1
1.2 Solar Power 1
1.3 Air Cooling System 2

2 LITERATURE SURVEY
2.1 Photovoltaic cell module 4
2.2 Types of PV cells 4
2.3 MOSFET 6
2.4 Buck Boost Converter 9
2.5 Battery 13
2.6 Gate Driver 15

3 SYSTEM DESIGN 20
3.1 Design Calculation 22
3.2 Inductor Design 22
3.3 Controller Design Procedure

4 PID Controller
4.1 Introduction 24
4.2 Working 24
4.3 Tuning Methods 27

5 CALCULATIONS
5.1 Calculating Inductance 28
5.2 Calculating Capacitance 28

6 Flowchart for closed loop Programming 29

7 SIMULATION AND RESULTS

7.1 Final closed loop circuit 31
7.2 Buck Boost Circuit 32
7.3 PID Circuit 32
7.4 PWM Generator Circuit 33
7.5 Waveforms 34
7.6 Variation of rise time and Overshoot with change with 𝐾 36

8 Designed System 39
9 CONCLUSION 41

10 FUTURE SCOPE 42

11 REFERENCES 43
FIGURE LIST

Fig No. Title Page No.

1.2 Working of Photovoltaic cell 1
2.1 Mono crystaklline solar silicon cell 4
2.2 Poly crystalline Solar cell 5
2.3 Mono Crystalline solar cell 5
2.4 IRFZ44 pin diagram 7
2.5 MOSFET electrical characteristics 8
2.6 Configuration of Buck Boost Converter 9
2.7 Buck Boost in Mode 1 10
2.8 Buck Boost in Mode 2 10
2.9 Current and Voltage waveforms in Buck Boost Converter 10
2.10 V and I waveforms at the boundary between CCM and DCM 13
2.11 Constant voltage and constant current charging 14
characteristics
2.12 cell current and cell voltage with respect to time. 14
2.13 TLP 250 pin diagram 15
2.14 Low side MOSFET Driver 16
2.15 High side MOSFET Driver 17
2.16 IC7815 17
2.17 Connections of IC 7815 18
3.1 Solar Module Data 20
4.1 P- controller 24
4.2 P-controller Response 24
4.3 PI- controller 25
4.4 PI-controller Response 25
4.5 PID- controller 25
4.6 PID-controller Response 26
7.1 Main simulation circuit 31
7.2 Buck Boost circuit 32
7.3 PID circuit 32
7.4 PWM generator 33
8.1 Lab implementation of the project 39
8.2 Final PCB design of Buck Boost Converter 40
8.3 Voltage waveforms between Gate and Source 40
CHAPTER 1: INTRODUCTION

1.1 OBJECTIVE OF PROJECT

Most of the people in India experience very hot climate during the summer every year. It
becomes necessary for the people to use air coolers for cooling commercial living spaces and
residential. In addition to the very hot temperatures we also face power outages. Hence, we
felt that we need to run an air cooler driven by a non-conventional source of energy with less
cost. For that, we designed a buck-boost converter to maintain a constant output voltage to
run the DC load (air cooler). As India receives a good amount of sunlight throughout the year
and especially during the summer we decided to use the solar power as input.

1.2 SOLAR POWER

Solar power is the power obtained by converting energy from sunlight into electricity either
directly using Photo-voltaics (PV) or by using concentrated solar power or a combination of
both. Concentrated solar power systems use mirrors or lenses and tracking systems to focus
sunlight on the large area into a small beam.

WORKING
Photovoltaic cells are nothing but a sandwich made up of two slices of semi-conducting
material, usually silicon. Photovoltaic cells need to establish an electric field like a magnetic
field that occurs due to opposite poles. Likewise, an electric field occurs when opposite
charges are separated. To achieve this, manufacturers "dope" silicon with other materials,
giving each slice of the sandwich a positive or negative electrical charge.

Figure 1.1 Working of Photovoltaic Cell

1
When photons hit a solar cell, they knock electrons lose from their atoms. If conductors are
attached to the positive and negative sides of a cell, it forms an electrical circuit. When
electrons flow through such a circuit, they generate electricity. Multiple cells make up a solar
panel, and multiple panels (modules) can be wired together to form a solar array. The more
panels you can deploy, the more energy you can expect to generate.

1.3 AIR COOLING SYSTEM

Solar PV Charge
Air Cooler
Module Controller

Battery

1. PV Module
 Three basic types of PV modules namely single crystal silicon, polycrystalline silicon
and amorphous.
 An array of solar cells.
 Conversion of solar power to electric power.

2. Buck Boost converter

 Buck boost converter works on dc supply
 The duty ratio of control signal defines its operation, either buck or boost.

3. Gate driver circuit

 N-type MOSFET is used for switching.
 Generates 15V pulses for switching MOSFET.
 The duty ratio is generated by the microcontroller.

2
4. Air cooler
 It uses dc motor for pump and fan.
 Low power is consumed.
 These are low voltage, low noise air cooler.

3
CHAPTER 2: LITERATURE SURVEY

2.1 Photovoltaic Cell Module

These are large surface area photodiodes usually made from crystalline or amorphous silicon
that generate up to about 0.5 volts in bright sunlight. The current generated by these
particular cell depends on the type of silicon used and amount of surface area exposed to
sunlight. These cells are arranged in series to achieve particular voltage or in parallel to
obtain specific current necessary.

These then encapsulated or otherwise are secured inside a rigid frame under a transparent
shield to form a panel. Two or more of these panels are wired in parallel, often, to create a
PV array used to generate electricity directly using sunlight.

2.2 Types of photovoltaic cells

(i)Monocrystalline solar silicon cell
The cell is made of a vat of molten silicon where a silicon crystal seed is placed using
Czochralski method. A solid crystal structure is formed around the seed known as an ingot
which is then finely sliced to form a silicon wafer. This is then made into a cell. The
Czochralski process results in large cylindrical ingots and a significant amount of the original
silicon ends up as waste.

Figure 2.1 Monocrystalline solar silicon cell

(ii) Polycrystalline solar silicon cell

Polycrystalline manufacturing also starts in a similar way like monocrystalline. But here
rather than drawing the silicon crystal seed up as done in Monocrystalline the vat of silicon is

4
cooled which forms the distinctive edges and grains in the solar cell. Polycrystalline cells
were less efficient but can be produced by cheaper methods. They have become the
prominent technology in the residential solar panels market.

Figure 2.2 Polycrystalline solar Cell

(iii)Thin film solar silicon cell

Depositing several thin layers of photovoltaic material onto a substrate is the real point of
how thin-film solar cells are prepared. They are also known as thin-film photovoltaic cells.
The different types of thin-film solar cells can be manufactured by depositing different
materials onto the substrate. The photovoltaic substance that is used varies and multiple
combinations of substances can be obtained.
Few examples of these are:
1. Amorphous Silicon
2. Cadmium Telluride (CdTe)
3. Copper indium gallium selenide (CIGS)
4. Dye-sensitized solar cell (DSC)

Figure 2.3 Monocrystalline Solar Silicon cell

5
 Comparison of photovoltaic cells

Mono-Si Panels Poly-Si panels Thin film panels

1. Maximum efficiency of 1. Maximum efficiency is less 1. Maximum efficiency is
21%. than 16% 12%

2. Manufactured from single 2. Manufactured by fusing 2. Manufactured by

silicon crystal. different crystals of silicon. depositing one or more layers
of PV material on the
substrate.

3. Performance best at 3. Performance best at 3. Performance best at high

standard temperature. moderately high temperature. temperature.

4. It requires less area for

4. It requires least area for given power rating. 4. It requires a large area.
given power rating.
5. Performance degrades with
5. Performance degrades with low light condition. 5. Performance is less affected
low light condition. with low light condition.

6.Cost per watt is 1.418USD 6. Cost per watt is 0.67USD.

6.Cost per watt is 1.589USD.

2.3 MOSFET:-
INTRODUCTION:
MOSFET stands for Metal Oxide Semiconductor Field Effect Transistor and it is the main
component in high frequency and high-efficiency switching applications. FET technology
was invented in 1930’s before the bipolar transistor. The first signal level FET transistors
were built in the late 1950’s while power MOSFETs have been available from the mid-
1970’s.

6
MOSFET Technology:
Fundamentally, both MOSFET and BJT are charge controlled devices, which means that their
output current is dependant on the charge established in the semiconductor by the control
electrode. When MOSFET is used as a switch, it must be driven from a low impedance
source which could sink sufficient current to provide for fast insertion and extraction of the
control charge. So the MOSFETs have to be driven just as “hard” during turn-on and turn-off
as a bipolar transistor to achieve comparable switching speeds. Theoretically, the switching
speeds of the bipolar and MOSFET devices are close to identical, determined by the time
required for the charge carriers to travel across the semiconductor region.

The advantages of MOSFETs over the bipolar junction transistors are the ease of use of the
MOSFET devices in high-frequency switching applications. As their control electrode is
isolated from silicon MOSFET transistors are simpler to drive. So a continuous ON current is
not required. The drive current is zero once the MOSFET is turned ON and the controlling
charge along with the storage time in FET is reduced. This basically eradicates the design
complications between on-state voltage drop and turn-off time resulting much simpler and
more efficient drive circuits with significant economic benefits as compared to other
switches.

Furthermore, MOSFETs are resistive in nature which is implied by the voltage drop across
the drain-source terminals of a MOSFET as a linear function of the current flowing through
it. This straight line relationship is shown by 𝑅 (ON) of the MOSFET and known as the
ON-state resistance. On state-resistance is constant for a given 𝑉 and temperature . As
assuming temperature coefficient of 2.2mV/°C for a p-n junction, the MOSFETs exhibit a
positive temperature coefficient of approximately 0.7%/°C to 1%/°C. This makes it an ideal
switch for parallel operation in higher power applications where use of the a single device is
impossible. Due to the positive 𝑡 of the channel resistance, parallel connected MOSFETs
tend to share the current evenly among themselves. This current sharing works automatically
in MOSFETs since the positive 𝑡 acts as a slow negative feedback system. The device
carrying a higher current will heat up more – don’t forget that the drain to source voltages are
equal – and the higher temperature will increase its 𝑅 (on) value. The increasing resistance
will cause the current to decrease, therefore the temperature to drop. Eventually, an
equilibrium is reached where the parallel connected devices carry similar current levels.
Initial tolerance in 𝑅 (on) values and different junction to ambient thermal resistances can
cause significant – up to 30% – error in current distribution.

7
IRF Z44n

Figure 2.4 N-channel Mosfet

FEATURES
 Dynamic dV/dt Rating
 Repetitive Avalanche Rated
 175 °C Operating Temperature
 Fast Switching
 Simple Drive Requirements
 Compliant to RoHS Directive 2002/95/EC

DESCRIPTION
Advanced HEXFET® Power MOSFETs from International Rectifier utilize advanced
processing techniques to achieve extremely low on-resistance per silicon area. This benefit,
combined with the fast switching speed and ruggedized device design that HEXFET power
MOSFETs are well known for, provides the designer with an extremely efficient and reliable
device for use in a wide variety of applications

Fig 2.5 MOSFET Electrical characteristics

8
2.4 BUCK-BOOST CONVERTER
The general configuration of Buck-Boost converter is shown Figure 3.6. A buck-boost
converter can be obtained by a cascade connection of the two basic converters:
 Step down converter
 Step up converter

The circuit operation can be divided into two modes:

 During mode 1 (Figure 2.7), the switch 𝑆 is turned on and the diode D is reversed biased.
In mode 1 the input current, which rises, flows through inductor L and switch 𝑆 .

 In mode 2 (Figure 2.8), the switch 𝑆 is off and the current, which was flowing through the
inductor, would flow through L, C, D and load. In this mode ,the energy stored in the
inductor (L) is transferred to the load and the inductor current (𝐼 ) falls until the switch 𝑆 is
turned on again in the next cycle.

Figure 2.6 configuration of buck Boost converter

9
 Figure 2.7 Buck-boost in mode 1 Figure 2.8 Buck-boost in mode 2

Figure 2.9 current and voltage waveforms of the buck-boost converter.

Buck-Boost Converter Continuous Mode of Operation

Since the switching frequency is considered to be very high, it is assumed that the current
through the inductor ( L ) rises linearly. Hence, the relation of the voltage and current in
mode 1 is given by

10
 𝐼 −𝐼 ∆𝐼
𝑉=𝐿 =𝐿
𝑇 𝑇
∆
𝑇 =𝐿

The inductor current falls linearly from 𝐼 to 𝐼 in mode 2 time 𝑇 and is given by

∆𝐼
𝑉 = −𝐿
𝑇
∆𝐼
𝑇 = −𝐿
𝑉𝑜

The term ∆𝐼 in mode 1 and mode 2, is the peak to peak ripple current through the inductor L.
From equation 1 and equation 2 the relation between the input and output voltage is obtained
as

𝑉 𝑇 𝑉𝑇
∆𝐼 = =−
𝐿 𝐿
The relation between the on and off time, of the switch 𝑆 and the total time duration is given
in terms of duty ratio (D) as
𝑇 =𝐷∗𝑇

𝑇 = (1 − 𝐷) ∗ 𝑇

Substituting the values of 𝑇 and 𝑇 gives:

𝐷
𝑉 = 𝑉
1−𝐷

If the converter is assumed to be lossless, then

𝑉 𝐼 = −𝑉 𝐼
𝐷
𝐼 = 𝐼
1−𝐷

The switching period T obtained from equation 1 and equation 2as:

△𝐼 𝐿△𝐼 𝑉 −𝑉
𝑇 =𝑇 +𝑇 =𝐿 − = 𝐿 △ 𝐼( )
𝑉 𝑉 𝑉 𝑉

The peak to peak ripple current I is obtained from equation 7 as

𝑇𝑉 𝑉 𝐷𝑇 𝑉 𝐷
△𝐼 = = 𝑉 = (8)
𝐿(𝑉 − 𝑉 ) 𝐿 𝑓𝐿

11
where
f=switching frequency

When the switch 𝑆 is turned on, the filter capacitor supplies the load current for the time
duration 𝑇 . The average discharge current of the capacitor 𝐼 = 𝐼 and the peak to peak
ripple current of the capacitor are:
1 1 𝐼 𝑇
△𝑉 = 𝐼 𝑑𝑡 = 𝐼 𝑑𝑡 =
𝐶 𝐶 𝐶
𝐼 𝐷
= (9)
𝑓𝑐

Buck-Boost Converter Boundary between Continuous and Discontinuous

Conduction
In Figure 10 the voltage and load current waveforms of at the edge of continuous conduction
is shown. In this mode of operation, the inductor current 𝑖 goes to zero at the end of the off
interval 𝑇 . From Figure 10, it can be seen that the average value of the inductor current is
given by
𝐼 ∆𝐼
𝐼 = =
2 2
(10)
Substituting the value of I from equation (8) into equation (10)gives:
𝐷𝑇
𝐼 = 𝑉
2𝐿
(11)
In terms of the output voltage, equation (11)can be written as
𝑉 𝑇(1 − 𝐷)
𝐼 =
2𝐿
(12)
The average value of the output current is obtained substituting the value of input current
from equation (6) into equation (12) as:
𝑉 𝑇(1 − 𝐷)
𝐼 =
2𝐿
(13)
Most applications in which a buck-boost converter may be used require that 𝑉 be kept
constant. From equation (12) and equation (13) it ,can be seen that 𝐼 and 𝐼 result in their
maximum values at D  0 as ,
𝑉 𝑇
𝐼 , =
2𝐿

(14)
𝑉 𝑇
𝐼 , =
𝐿2
From equation (10) it can be seen that peak-to-peak ripple current is given by
∆𝐼 = 2𝐼

12
 Figure 2.10 voltage and current waveforms in the boundary between continuous and
discontinuous mode.

2.5 BATTERY

Battery is a collection of one or more cells whose chemical reactions result in the flow of
electrons in a circuit. It consists of three basic components: an anode (the ‘-’ side), a cathode
(the ‘+’ side), and an electrolyte.
When the anode and cathode are connected to a circuit, a chemical reaction is initiated
between the anode and the electrolyte. This causes the flow of electrons through the circuit
and return through cathode where another reaction takes place. When the battery is unable to
produce electricity, the battery is said to be “dead.”

CHARGING METHODS
a) Constant Voltage:

A DC power supply consisting of a step-down transformer with a rectifier to provide the DC

voltage to charge the battery. This type of charging is used to charge lead-acid cells used for
cars and backup power systems. This type of charging involves complex circuitary for
Battery protection and user safety.

b) Constant Current:
The voltage applied to the battery is varied accordingly to maintain a constant current flow
and is switched off when the voltage reaches the level of a full charge. This type of charging
is used for nickel-cadmium and nickel-metal hydride cells or batteries.

13
 Figure 2.11 Battery charging characteristics

c) Pulsed charge:
Batteries are fed with charge current in the form of pulses. We can control the charging rate
precisely by varying the width of the pulses over few seconds. During charging, short gaps of
about 20 to 30 milliseconds are maintained to allow the chemical actions in the battery to
attain stability before beginning to charge again. This helps the reactions to maintain the rate
of inputting the electrical energy. By using this method we can reduce unwanted chemical
reactions at the electrodes.

Figure 2.12 Cell current and cell voltage with respect to time

14
2.6 GATE DRIVER TOPOLOGY

Isolated MOSFET driver TLP250 working

In this article, I will discuss isolated Mosfet driver TLP250. Mosfet driver TL250 like other
MOSFET drivers have input stage and output stage. It also has power supply configuration.
TLP250 is more suitable for MOSFET and IGBT. The main difference between TLP250 and
other MOSFET drivers is that TLP250 MOSFET driver is optically isolated. Its mean input
and output of TLP250 MOSFET driver is isolated from each other. It's works like an
optocoupler. Input stage has a light emitting diode and output stage have photodiode.
Whenever input stage LED light falls on output stage photodetector diode, the output
becomes high.

Pin configuration isolated MOSFET driver TLP250

Pin layout of TLP250 is given below. It is clearly shown in the figure that led at input stage
and photo detector diode at output stage is used to provide isolation between input and
output. Pin number 1 and 4 are not connected to any point. Hence they are not in use. Pin 2 is
anode point of input stage light emitting diode and pin 3 is cathode point of the input stage.
Input is provided to pin number 2 and 3. Pin number 8 is for supply connection. Pin number 5
is for the ground of power supply.

Figure 2.13 TLP250

Pin number one and four is not connected to any point physically. Therefore they are not in
use.

Pin number 8 is used to provide power supply to TLP250 and pin number 5 is ground pin
which provides a return path to power supply ground. Maximum power supply voltage
between 15-30 volt dc can be given to TLP250. But it also depends on the temperature of the
environment in which you are using TLP250.

15
Pin number 2 and 3 are anode and cathode points of input stage LED. It works like a normal
light emitting diode. It has similar characteristics of forward voltage and input current.
Maximum input current is in the range of 7-10mA and forward voltage drop is about 0.8 volt.
TLP250 provides output from low to high with a minimum threshold current of 1.2mA and
above.

Pin number six and seven is internally connected to each other. Ouput can be taken from
either pin number 6 and 7. Totem pole configuration of two transistors is used in TLP250. In
case of high input, output becomes high with output voltage equal to the supply voltage and
in case of low MOSFET driver TLP250 can be used up to 25kHz frequency due to slow
propagation delay.

TLP250 as a low side MOSFET driver

Circuit diagram of low side MOSFET driver using TLP250 is shown below. In this circuit
diagram, TLP250 is used as non-inverting low side MOSFET driver. You should connect an
electrolytic capacitor of value 0.47uf between power supply. It provides protection to
TLP250 by providing stabilize the voltage to IC.

Figure 2.14 low side MOSFET driver

As shown in the figure above input is drive signal that drives the output. Vin is according to
signal ground. It should not be connected with supply ground and output ground. It is clearly
shown in above figure TLP250 and load ground is referenced to the power ground and it is
isolated from input signal reference ground. When the input is high, MOSFET Q1 get a high
signal from TLP250 and it is driven by power supply and current flows through the load.
When the input is low, MOSFET Q1 get a low signal from the TLP250 output pin and
MOSFET Q1 remains off and there is no current flow to load. Value of supply voltage

16
ranges between 10-15 volt. Input resistor at the gate of MOSFET is used depend on the
amplitude of input signal. Usually, input signal is provided through microcontroller and
microcontroller input signal level is in the order of 5 volts. Capacitor C1 is used as
decoupling capacitor.

TLP250 as a high side MOSFET driver

Circuit diagram of MOSFT driver TLP250 used as high side driver is shown below. It is used
as non-inverting high side mosfet driver. Because input signal ground is connected to cathode
of input stage light emitting diode. Therefore it is used as a non-inverting high side mosfet
driver.

Figure 2.15 High side MOSFET driver

In high side configuration, there are three grounds as shown in the figure above. The ground
of input signal, the ground of supply voltage and ground of power supply voltage. Remember
that while using TLP250 as high side MOSFET driver, all grounds should be isolated from
each other.

Voltage regulator

7815 Voltage regulator is a type of self-contained fixed linear voltage regulator integrated
circuit. The IC belongs to 78xx voltage regulator family which is commonly used as the
regulated power supply in electronic circuits. The 7815 voltage regulator IC is ease-of-use
and available at very low cost. The last two digits of 7815 indicate the output voltage that is
voltage.

17
 IN COM OUT

Figure 2.16 IC7815

The 7815 regulator line is a positive voltage regulator that is the 7815 voltage regulator ic
generate the voltage which is positive with respect to the common ground. In case if both the
positive and negative voltage supply is needed in the same circuit. The voltage regulator 7815
is combined with its corresponding 79XX family IC. The voltage regulator 7815 is available
most commonly in TO-220 package, moreover the IC is also available in TO-3, TO-92, and
surface mount Packages.

The 7815 Voltage regulators do operate at their optimal capability if the input voltage is at
least 2.5 volts greater than the output voltage and the current is 1 or 1.5 Amperes more.
Though the voltage and current different is different for other IC Packages.

How to use IC 7815

Fig2.17 7815 Connections

The 7815 IC has 3 pins, Pin 1 is a positive input, Pin 3 is a positive output and pin 2 is
negative common ground between both input as well as an output voltage. When using the

18
voltage regulator setup, you need to take care of the current through the voltage regulator IC
do not exceed beyond the capacity which is mentioned in the datasheet or else it may blow
off. You also have to be careful with the connection you are making with the voltage supply.
Reverse polarity does get the IC heat up really quickly, you can also use a p-n junction diode
in order to prevent such a condition.

You can use the capacitors in order to minimize the voltage fluctuations in the circuit and
maintains the constant voltage across the input as well as the output of the circuit.

Advantages
7815 voltage regulator IC does not require any component to balance or saturate their output
voltage.

The 7815 ic has a built-in protection from the high current. There is a heat-sink with the
common ground connected with which is helpful in order to prevent our regulator IC from
overheating and short-circuits making it uncompromising in the most application.

19
CHAPTER 3: SYSTEM DESIGN

While designing the Air cooling system with an aim to keep the cost to a minimum, we
designed a system which works on D.C supply. A standard small sized cooler was selected
and accordingly appropriate sized motors and pumps were used.

3.1 Design Calculations

 Consider the DC Air cooler system employing DC motor and DC pump Power
rating of the DC motor = 45.6 W.

 Power rating of the DC water pump = 14.4 W.

 Total Power required = Power rating of the DC motor + Power rating of the DC
water pump.

 Total wattage required= wattage of the motor+ wattage of the pump.

= 45.6 +14.4
= 60 W.

 Assuming efficiency of converter as 96%.

Total Power to be supplied to the Air Cooler = 60/.96 = 62.5 W

 Total current required= 62.5/12 = 5.2 A

 Therefore rating of panel= 5.2*12 = 62.4. Hence nearest rating panel available= 100
W.

Study of Photovoltaic Panel

For implementation purpose a 100 W Photovoltaic Panel was used for the project.
Following is the data sheet of the Photovoltaic Panel.

20
 Figure 3.1 solar module

SOLAR PANEL TILT ANGLE

Season Tilt angle formulae
Winter Latitude angle*0.9+29 degree
Summer Latitude angle*0.9-23.5 degree
Spring and Fall Latitude angle-2.5 degree

3.2 Inductor design:

Ferrites are ceramic structures created by combining iron oxide with oxides or carbonates of
other metals such as manganese, nickel, or magnesium. The mixtures are pressed, fired in a
kiln at very high temperatures, and machined into the required shapes.
They are well suited for low power applications such as high Q inductors. Use of ferrite for
high power inductors is achieved by increasing cross-sectional area to prevent saturation. The
operating frequency range falls somewhere between MPP cores and Powdered Iron typically
10KHz to 1 or 2 MHz.
Data sheets often give a range of recommended inductor values. If this is the case,
choose an
inductor from this range. The higher the inductor value, the higher is the possible maximum
output current because of the reduced ripple current.
Normally, the lower the inductor value, the smaller is the solution size. Note that the inductor
must always have a higher current rating than the largest value of current given from
Equations
5 and 8; this is because of the peak current increases with decreasing inductance.
For device datasheets, where no inductor range is given, an inductor that satisfies both buck
and boost mode conditions must be chosen.

21
A good estimation for the inductor ripple current is 20% to 40% of the output current, or
0.2 < 𝐾 < 0.4.

3.3 CONTROLLER DESIGN PROCEDURE

𝑑𝑒(𝑡)
𝑢(𝑡) = 𝐾 𝑒(𝑡) + 𝐾 𝑒(𝑡)𝑑(𝑡) + 𝐾
𝑑𝑡
Transfer function is

𝑈 (𝑠 ) 𝐾 1
𝐶(𝑠) = = 𝐾 + +𝐾 𝑠 = 𝐾 1+ = 𝑠𝑇
𝐸(𝑠) 𝑠 𝑠𝑇
Where 𝐾 , 𝐾 , 𝐾 are the proportional, integral,differential gains and constants

𝐾 𝐾
𝑇 = ,𝑇 =
𝐾 𝐾

The control signal enters the pulse generator and over it affects the length of switching of the
switch within a switching cycle. Level of the control signal is
theoretically limited between zero and one which is symbolized by the limiter in the
schematic circuit of the buck-boost converter ( Fig), this limitation introduces a new
nonlinearity which was not taken into account when deriving the mathematical model (8) and
the transfer function of the system (9). Level of the control signal out of range of the limiter
will have the limit values or the system becomes insensitive to further change in the error
signal. Due to this fact, we should very careful when determining the parameters of
thecontroller.As the controlling signal dose does not overcome one, for maximum allowed
proportional gain we will adopt the inverse value of the reference voltage :
1
𝐾 =
𝑉

To obtain the maximum critical gain we will multiply the allowable gain 𝐾 by the d
factor
𝑑
𝐾 = 𝑑𝐾 =
𝑉

Critical period of oscillations 𝑇 measuring period of oscillations related to the maximal

allowed proportional gain 𝐾 .in the case of buck boost converter it is the minimal
oscillatory period can be measured at all and corresponds to undamped oscillations of the
output. It will be assumed that this period approximate system critical period with adequate
accuracy for the purpose of PID tuning which is given by

𝑇 = 2𝜋√𝐿𝐶

22
Using adopted values for 𝐾 , 𝑖, 𝑇 recommendations [17,18,19] for PID tuning without
overshoot, unknown parameters of PID controller could be evaluated as

𝑑 2𝐾
𝐾 = 0,2 𝐾 =
𝑉 𝑇
𝐾 𝑇
𝐾 =
3

23
CHAPTER 4: PID CONTROLLER
4.1 Introduction
PID stands for Proportional-Integral-Derivative. These three controllers are combined in such
a way that it produces a control signal.

4.2 Working
With the use of low cost simple ON-OFF controller, only two control states are possible, like
fully ON or fully OFF. It is used for limited control application where these two control states
are enough for control objective. However oscillating nature of this control limits its usage
and hence it is being replaced by PID controllers.
PID controller maintains the output such that there is zero error between the process variable
and setpoint/ desired output by closed-loop operations. PID uses three basic control behaviors
that are explained below.

Fig 4.1 P-Controller

P- CONTROLLER: Proportional or P- controller gives an output which is proportional to
current error e (t). It compares desired or set point with actual value or feedback process
value. The resulting error is multiplied with a proportional constant to get the output. If the
error value is zero, then this controller output is zero.

Fig 4.2 P-Controller Response

This controller requires biasing or manual reset when used alone. This is because it never
reaches the steady state condition. It provides stable operation but always maintains the
steady state error. The speed of the response is increased when the proportional constant Kc
increases.

24
I-Controller

Fig 4.3 PI Controller

Due to the limitation of p-controller where there always exists an offset between the process
variable and set point, I-controller is needed, which provides necessary action to eliminate the
steady state error. It integrates the error over a period of time until error value reaches to
zero. It holds the value to the final control device at which error becomes zero.
Integral control decreases its output when a negative error takes place. It limits the speed of
response and affects the stability of the system. Speed of the response is increased by
decreasing integral gain Ki.

Fig 4.4 PI Controller Response

In above figure, as the gain of the I-controller decreases, steady state error also goes on
decreasing. For most of the cases, PI controller is used particularly where high-speed
response is not required.
While using the PI controller, I-controller output is limited to somewhat range to overcome
the integral windup conditions where the integral output goes on increasing even at zero error
state, due to nonlinearities in the plant.

25
D-Controller

Fig 4.5 PID Controller

I-controller doesn’t have the capability to predict the future behavior of error. So it reacts
normally once the set point is changed. D-controller overcomes this problem by anticipating
future behavior of the error. Its output depends on the rate of change of error with respect to
time, multiplied by derivative constant. It gives the kickstart for the output thereby increasing
system response.

Fig 4.6 PID Controller Response

In the above figure response of D controller is more, compared to PI controller and also
settling time of output is decreased. It improves the stability of the system by compensating
phase lag caused by I-controller. Increasing the derivative gain increases the speed of
response.

26
4.3 Tuning methods of PID Controller
Before the working of PID controller takes place, it must be tuned to suit with dynamics of
the process to be controlled. Designers give the default values for P, I and D terms and these
values couldn’t give the desired performance and sometimes leads to instability and slow
control performances. Different types of tuning methods are developed to tune the PID
controllers and require much attention from the operator to select best values of proportional,
integral and derivative gains. Some of these are given below.

Trial and Error Method: It is a simple method of PID controller tuning. While system
or controller is working, we can tune the controller. In this method, first, we have to set Ki
and Kd values to zero and increase proportional term (Kp) until the system reaches to
oscillating behavior. Once it is oscillating, adjust Ki (Integral term) so that oscillations stop
and finally adjust D to get a fast response.

Process reaction curve technique: It is an open loop tuning technique. It produces a

response when a step input is applied to the system. Initially, we have to apply some control
output to the system manually and have to record response curve.

After that we need to calculate slope, dead time, the rise time of the curve and finally
substitute these values in P, I and D equations to get the gain values of PID terms.

Zeigler-Nichols method: Zeigler-Nichols proposed closed loop methods for tuning the
PID controller. Those are continuous cycling method and damped oscillation method.
Procedures for both methods are same but oscillation behavior is different. In this, first, we
have to set the p-controller constant, Kp to a particular value while Ki and Kd values are
zero. Proportional gain is increased till system oscillates at a constant amplitude.

Gain at which system produces constant oscillations is called ultimate gain (Ku) and period
of oscillations is called ultimate period (Pc). Once it is reached, we can enter the values of P,
I and D in PID controller by Zeigler-Nichols table depends on the controller used like P, PI or
PID, as shown below.

Zeigler-Nichols table

27
CHAPTER 5: CALCULATIONS

5.1 Calculating inductance

(1 − 𝐷)𝑉
𝐿 =
∆𝐼 𝑓

𝐷 = 0.413
𝑉 = 12𝑣
∆𝐼 = 10%
𝑓 = 20𝑘 Hz

By substituting above values in 𝐿 we get 𝐿 = 570𝜇𝐻

5.2 Calculating capacitance

𝐷
𝐶 =
∆𝑉
𝑅𝑓
𝑉
𝐷 = 0.413
R=5Ω
∆𝑉 = 10%
By substituting above values in 𝐶 we get 𝐶 = 68𝜇𝐹
~100𝜇𝐹

28
CHAPTER 6: FLOW CHART FOR CLOSED LOOP
PROGRAMMING

END
yes

Vo=12V A
START no

Vo= (arus*12)
Vref=12

arus=
Set Kp,Ki compare/2

Sensor=Read pin Compare=

A0 (sensor*5)/1024

29
 yes
A time=now error= Vref-Vo

no

time= lastTime

timeChange= now-
lastTime Output=
Kp*error+Ki*errSum

errSum= B
err*timeChange

Above flowchart represents the algorithm for the variation of the duty cycle for the closed
loop buck-boost converter.In th8is algorithm, first output voltage is compared with the
reference voltage, then Kp and Ki values are set for the PI controller.Then, the output voltage
is reduced to lower level of voltage by using voltage sensor and this voltage is sensed at the
Arduino input terminal. Then this error voltage is used as input for PI controller. Then, PI
controller gives the output which is duty cycle required to obtain the desired output.

30
CHAPTER 7: SIMULATIONS AND RESULTS

7.1 Main Circuit:

Fig 7.1 Main Simulation circuit

The simulation circuit above shows the closed loop buck-boost converter, where the input is
from the solar panel and the R-L load is connected to the circuit. For closed-loop control, PID
controller is used, whose input is error signal obtained by taking the difference of output
voltage and the reference voltage. The output of PID controller is the duty cycle required to
maintain the desired output voltage

31
7.2 Buck Boost Circuit:

Fig 7.2 Buck Boost circuit

Above circuit shows buck-boost converter circuit, which acts as a buck converter for d<0.5
and boost for d>0.5.Minimum L required for continues conduction mode is 570uH and output
capacitance is 100uF.Switch used for this converter is MOSFET IRF Z44n.

7.3 PID Circuit

Fig 7.3 PID Circuit

Above diagram represents PID controller used for closed-loop control of the circuit. PID
controller is tuned for the constants to get the desired output result.

32
7.4 PWM Generator

Fig 7.4 PWM Generator

The input of the PWM generator is the value of duty cycle.It generates the control signal
according to the duty cycle.Then it is compared with the reference signal generated by the
sawtooth generator and according to the relational operator used pulses are generated

33
Input voltage = 10V

Inductor current vs time

Inductor current vs time (steady state )

Output voltage vs time (transcient state)

34
Output voltage vs time (steady state)
Input Voltage=17V

output voltage vs time

35
7.6 Variation of Rise time and Overshoot with change in 𝒌𝒑 & 𝒌𝒊 :
1) 𝑘 = -0.01

𝑘 Overshoot (%) Risetime (sec)

1.67 0.65
-0.2
2 0.35
-0.4
2.25 0.22
-0.6
2.25 0.17
-0.8
2.25 0.134
-1
2.25 0.0165
-2

2) 𝑘 = -0.02

𝑘 Overshoot (%) Risetime (sec)

-0.2 1.5 0.77

-0.4 2.25 0.395

-0.6 2.25 0.265

-0.8 2.25 0.198

-1 2.25 0.158

-2 2.25 0.08

36
From the above two observations, we can see that, as 𝐾 value increases, peak overshoot
increases and rise time decreases. Thus, the system becomes faster by using the integral control
in the system along with the proportional control and if we increase 𝐾 the overshot decreases.

𝑲𝑷 = 𝟎 𝑽𝒊 = 𝟏𝟕𝑽
𝑘 = −1

4) 𝐾 = −2

37
5) 𝐾 = −5

38
8. Designed System

Fig 8.1 Lab implementation of project

39
 Fig 8.2 Final PCB design of Buck Boost Converter

Fig 8.3 Voltage waveform between Gate and Source

40
9.CONCLUSIONS
 Simulation of Closed-loop Buck-Boost Converter for constant voltage applications is
completed using PID controller with RL load.
 The hardware of open loop Buck-Boost converter is designed. Any DC load whose
voltage rating is less than 12V is operated using this converter and is maintained at a
constant voltage by changing the reference voltage value.
 Depending on the gain values of the PID controller output response of the system is
changed like decreasing rise time, decreasing overshoot etc.

41
10. FUTURE SCOPE:

1.Implementation of Solar Tracking: A solar tracker is a device that orients toward the sun.
Payloads are usually solar panels, parabolic troughs, Fresnel reflectors, mirrors or lenses.For flat
plate PV systems, trackers are used to minimizing the angle of incidence between the incoming
sunlight and a photovoltaic panel.This increases the amount of energy produced from a fixed
amount of installed power generating capacity.

2.Implementation of MPPT Algorithm: MPPT or Maximum Power Point Tracking is an

algorithm that included in charge controllers used for extracting maximum available power from
PV module under certain conditions.The voltage at which PV module can produce maximum
power is called Maximum power point.Maximum varies with solar radiation, ambient
temperature, and solar cell temperature.

42
11.REFERENCES
1.Abhinav Dogra, Kanchan Pal “Design of Buck-Boost Converter for Constant
Voltage Applications and Its Transient Response Due To Parametric Variation of
PI Controller”, IJIRSET, Vol. 3, Issue 6, June 2014

2.Farah Shabila Dinniyah, Wahidin Wahab, Muhammad Alif,”Simulation of Buck-Boost

Converter for Solar Panels using PID Controller”, International conference -Alternative and
Renewable Energy Quest, AREQ 2017,1-3 Feb 2017, Spain

3.Muhanad D. Almawlawe 1, Marko Kovandzic,”Modified Method for Tuning PID Controller

for Buck-Boost Converter”, International Journal of Advanced Engineering Research and
Science(IJAERS), Vol-6, Issue-12, Dec-2016

4.K.Vijaykaran1, Mrs.J.Jeyashanthi,”A Positive Buck-Boost DC-DC Converter with Mode-

Select Circuit Using PID Controller”2014 International Conference on Innovations in
Engineering and Technology (ICIET’14).

5.ELPROCUS, Working with a PID controller https://www.elprocus.com/the-working-of-a-pid-

controller/

6.TEXAS INSTRUMENTS “ Understanding Buck-Boost power stages in Switch mode power

supplies”

7. Dinesh Bista Virginia Commonwealth University, [email protected] “Understanding and

Design of an Arduino-based PID Controller”

8.Micheal Green,” Design Calculations for Buck-Boost Converters”, Texas Instruments

9. Ms. Kashmira Rathi(Kasat)a and Dr.M.S.Ali “Design and Simulation of PID Controller for
Power Electronics Converter Circuits”, International Journal of Innovative and Emerging
Research in Engineering Volume 3, Issue 2, 2016

43