FINAL REPORT

“BUCK CONVERTER”

Arranged by:

Name : Vila Dwi Nur Aini

NRP : 1310171008
Class : 3 D4 LA
Lecturer : Ir Moh. Zaenal Efendi, M.T.

PROGRAM STUDI D4 TEKNIK ELEKTRO INDUSTRI

DEPARTEMEN TEKNIK ELEKTRO
POLITEKNIK ELEKTRONIKA NEGERI SURABAYA
2020
 FINAL REPORT
BUCK CONVERTER

1. INTRODUCTION
Buck converters are non isolated switched-mode step-down DC–DC converters. To
obtain a purely dc voltage, a low pass filter is inserted after switch on the switching
regulator. The diode provides a path for inductor current when switch is opened. This
circuit is called a Buck Converter or a step-down converter because the output voltage
is less than the input.

2. THEORY

Buck DC-DC Converter

If the low-pass filter is ideal, the output voltage is the average of the input
voltage to the filter. The input to the filter, vx is Vs when the switch is closed and is
zero when the switch is open, provided that the inductor current remains positive,
keeping the diode on. If the switch is closed periodically at a duty ratio D, the average
voltage at the filter input is VsD, as in Eq:

Vo=Vs . D

Circuit operation when switch is turned on (closed)

When the switch is closed in the buck Converter circuit,

- The diode is reverse biased
- Switch conducts inductor current
- This result in positive inductor voltage
di
V L=V s −V o =L L
dt
Rearranging,
di L V s −V o
=
dt L
- Since the derivative of iL is a positive constant, the current increases linearly
- By modifying the preceding equation, the change in current while switch closed
is:
di L Δi L ΔiL V s −V o
= = =
dt Δt DT L
V s −V o
(
( Δi L )closed =
L ) . DT
Circuit operation when switch is turned off (opened)

When the switch is opened in the buck Converter circuit,

- Diode is forward biased to carry the inductor current
- The inductor voltage is:
di L
V L=−V o =L
dt
Rearranging,
di L −V o
=
dt L
- Since the derivative of iL is a negative constant, the current iL decreases linearly.
- The change in current while switch opened is:
di L Δi L ΔiL Vo
= = =−
dt Δt (1−D)T L
−V o
( L ) .(1−D )T
( Δi L )opened =

Steady-state operation

Steady-state operation requires that iL at the end of the switching cycle is the same
as that at the beginning of the next cycle, meaning the change of i L over one
period is zero:
( Δi L )closed +( ΔiL )opened =0
V s −V o −V o
( L ) ( )
. DT +
L
.(1−D )T =0
V o =DV s

Average, Maximum and Minimum Inductor Current

Average inductor current = Average current in load
V
I L=I R = o
R
Maximum current:
Δi L
Vo 1 V o
I max =I L +
2
+
R 2 L
=( 1−D )T ) ( )
1 (1−D)
(
I max =V o +
R 2 Lf )
Minimum current:
ΔiL 1 (1−D )
I min=I L −
2
=V o −
R (
2 Lf )
Continuous current operation

From previous analysis,

ΔiL 1 (1−D )
I min=I L −
2
=V o −
R (
2 Lf )
For continuous operation, Imin > 0
1 (1−D) (1−D)
(
⇒V o −
R 2 Lf )
> 0⇒ L > Lmin =
2f ❑
This is the minimum inductor current. To ensure continous mode of operation,
normally L is chosen be >>Lmin

Output voltage ripple:

i c=i L−i R
ΔQ
Q=CV o ⇒ ΔQ=CΔV o ⇒ ΔV o=
C
iC
1
Q iL
2
t
1
T
2

From above figure, use triangle area formula :

 1 T Δi L TΔi L
ΔQ= ( )( )
2 2 2
=
8
TΔi (1−D)V o
ΔV o = L =
8C 8 LCf 2
So,the ripple factor,
ΔV (1−D)
r= o =
V o 8 LCf 2

3. PARAMETER CALCULATION
The Buck Converter has following parameter:
Vs(max) = 50 Volt
Vs(min) = 40 Volt
Vo = 20 Volt
Io =2A
Switching Frequency (fs)= 40 kHz

Components:
Q : MOSFET IRFP460
D : MUR 1560 (Ultra Fast Recovery Diode)
Inductor (L) : Ferrit Core PQ 3535 with Cross sectional are (Ac=1.96 cm2);
Bobbin diameter (Dbob = 17 mm)
Rs : Snubber resistor (….. Ohm, 5-10 watt)
Cs : Snubber capacitor (….. nF, 1 kVolt)
Ds : Snubber diode (FR3017)
SOLUTION :
 Duty Cycle
V 20
D= o = =0,4
V s 50

 Filter Inductor
∆ i L=20 % x I L (avg )
¿ 0.2 x 2
¿ 0,4 A
 1 V o+ V f 1
L= x ( V s (max )−V o ) x
f [ x
]
; V =1,5 Volt
V s (max) +V f ∆i L f
1 20+1,5 1
¿
40 x 10 3
x ( 50−20 ) x
50+1,5
x
0,4[ ]
¿ 2,5 x 10−5 x 30 x 0,42 x 2,5
¿ 7,875 x 10−4 H
¿ 787,5 μH

 The Maximum Inductor Current

V V 20 20
i L (avg )= o = o = = =2 A
R V o 20 10
Io 2

∆i L
i L (max )=i L (avg )+
2
0,4
¿ 2+
2
¿ 2,2 A

 Winding Number of Inductor

Bmax =0,25 Tesla ; A c =1.96 cm2

L∗i L(max) 4
n= 10
Bmax∗A c

787,5 x 10−6∗2,2 4
¿ 10
0,25∗1,96
¿ 35,3 ≈ 35

 Wire Size is Based on RMS Current of Inductor

2
∆ i L /2
√ 2
i L (rms ) t = ( i L ( avg) ) +( √3
0,4 /2 2
)
√
¿ ( 2 ) 2+

¿2 A
( √3 )
 Calculation of Wire Size
 Cross Sectional Area of wire (qw)
i ( )
q w(t )= L rms t ; J =¿ 4,5 A/mm2
J
2
¿
4,5
¿ 0,44 mm 2

 Diameter of Wire (dw)

4
d w (t )=
√xq
π w (t )
 4
¿
√
3,14
¿ 0,75 mm
x 0,44

 Recalculate by Assuming Number of Split Wire (split=9)

i ( ) 2
i L (rms ) split = L rms t = =0,22 A
∑ split 9
i L ( rms ) split 0,22
q w (t ) split = = =0,049 mm2
J 4,5

4 4
d w (t ) split =
√ π
x q w ( t ) split =
√
3,14
x 0,049=0,25 mm

 Wire Size
Diameter of Bobbin PQ3535 (Dbob) = 17 mm = 1,7 cm
Circumference of Bobbin (Kbob) = π x Dbob = 3,14 x 1,7 = 5,34 cm
Total Wire Length = (n(winding) x Kbob x split) + 40% * (n(winding) x Kbob x split)
= (35 x 5,34 x 9) + 0,4 (35 x 5,34 x 9)
= 2354,94 cm
= 23.54 m
≈ 24 m

 Output Capacitance
∆ V o=0,001 x V o =0,001 x 20=0,02 Volt = 20 mV

∆ Q ∆ iL . T
∆ V o= =
Co 8C o
1
0,4 .
40 x 103
0,02=
8 Co
1 x 10−5
0,02=
8 Co
0,16 C o=1 x 10−5
C o=62,5 μF
C o ≈ 100 μF , 50 Volt

 Snubber Circuit
I ON =I o=2 A
V Off =V s=50 Volt
I xt
C s ≈ ON fall
2 x V Off
2 x 58.10−9
≈
2 x 50
≈ 1,16 nF
C s ≈2 nF ,1 kVolt
 DT
R s<
2 x Cs
1
0,4 x
40 k
¿
2 x 2.10−9
¿ 2500
R s ≈ 1 k , 10 watt

 Determine air gap length

μo . L . I 2 max 4
lg= 2
10
B max . A c

4 π . 10−7 .787 .5. 10−6 . ( 2.2 )2 4

lg= 10
0,252 .1,96
lg=0,39 mm

4. PWM GENERATOR
4.1 PWM Generator Circuit

4.2 Schematic of PWM Generator Circuit

4.3 Board of PWM Generator Circuit

TOP

BOTTOM
4.4 List of PWM Generator Circuit Component
No. Component Total
1. Terminal 2 PTR 2
2. Terminal 3 PTR 2
3. Potensiometer 50k 1
4. Potensiometer 100k 1
5. Diode 1N4004 4
6. Kapasitor 470 µF 1
7. Kapasitor 47 µF 1
8. Kapasitor 1nf 1
9. IC 7815T 1
10. IC NE555 1
11. IC LM393N 1
12. Resistor 1k 3
13. Resistor 8k 2
14. Resistor 2.2k 2
15. Resistor 10Ω 2
16. Transistor BD 139 1
17. Transistor BD 140 1
18. Socket IC kaki 8 2

4.5 Experiment Result

Frequency Duty Cycle Vin Vout Vout theory
(kHz) (%) (Volt) (Volt) (Volt)
40 50 12.64 4.75 6.32
40 12.23 3.84 4.89
30 12.05 3.15 3.615
50 50 12.64 4.90 6.32
40 12.59 4.11 5.036
30 12.54 3.23 3.762

Calculation:
1) Frequency = 40 kHz
Duty Cycle 50 %
Vout theory = Vin x Duty Cycle
= 12,64 x 0,5 = 6,32 Volt
Duty Cycle 40 %
Vout theory = Vin x Duty Cycle
= 12,23 x 0,4 = 4,89 Volt
Duty Cycle 30 %
Vout theory = Vin x Duty Cycle
= 12,05 x 0,3 = 3,615 Volt

2) Frequency = 50 kHz
Duty Cycle 50 %
Vout theory = Vin x Duty Cycle
= 12,64 x 0,5 = 6,32 Volt
Duty Cycle 40 %
Vout theory = Vin x Duty Cycle
= 12,59 x 0,4 = 5,036 Volt
Duty Cycle 30 %
Vout theory = Vin x Duty Cycle
= 12,54 x 0,3 = 3,762 Volt
5. Main Circuit PCB
5.1 Main Circuit PCB (Individual)
 Schematic

 Board

Top

Bottom
5.2 Main Circuit PCB (Group)
 Schematic

 Board
 Top

Bottom

5.3 Module Template of Buck Converter

6. Software Design of Buck Converter
6.1 Display of Buck Converter Software Calculation

Display after “CALCULATE”

Display after “RESET”

 Display after “CLEAR”

6.2 Program of Buck Converter Software Calculation

Public Class Form1

Private Sub CALCULATE_Click(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles CALCULATE.Click
Dim Vsmaximum, Voutput, frekuensiswitching, Jumlahsplit As Integer
Dim Dutycycle, Ioutput, Rbeban, iLavg, RiL, DeltaiL, iLmax, DeltaVo,
rVo, A, B, C, D, L, Csnubber, LA, tfall, Ion, Voff, T, Rsnubber,
Coutput, Ac, n, Dbob, Kbob, Wirelength, G, miu0, AirGap, H, F, VI,
iLrmst, iLrmssplit, qwtsplit, dwtsplit As Double
Dim Vf As Double = 1.5
Dim Bmax As Double = 0.25
Dim J As Double = 4.5

Vsmaximum = Val(Vsmax.Text)
Voutput = Val(Vo.Text)
Ioutput = Val(Io.Text)
RiL = Val(DiL.Text)
rVo = Val(DrVo.Text)
frekuensiswitching = Val(fs.Text)
tfall = Val(tf.Text)
Ac = Val(Ae.Text)
Jumlahsplit = Val(split.Text)
Dbob = Val(Db.Text)

Dutycycle = Voutput / Vsmaximum

Duty.Text = Dutycycle * 100

Rbeban = Voutput / Ioutput

RL.Text = Rbeban

iLavg = Voutput / Rbeban

iLaverage.Text = iLavg

DeltaiL = (RiL / 100) * iLavg

DeltaRIL.Text = DeltaiL

iLmax = iLavg + (DeltaiL / 2)

iLm.Text = iLmax

DeltaVo = ((rVo / 100) * Voutput) * 1000

DVo.Text = DeltaVo

A = 1 / (frekuensiswitching * 1000)
B = Vsmaximum - Voutput
C = ((Voutput + Vf) / (Vsmaximum + Vf))
D = 1 / DeltaiL
 L = (A * B * C * D) * 1000000
Induktor.Text = Math.Round(L, 2)

Coutput = (DeltaiL / (8 * (frekuensiswitching * 1000) * (DeltaVo /

1000))) * 10 ^ 6
Co.Text = Coutput

Ion = Ioutput
Voff = Vsmaximum
Ion1.Text = Ion
Voff1.Text = Voff
Csnubber = (((Ion * (tfall * 10 ^ -9)) / (2 * Voff))) * 10 ^ 9
Cs.Text = Csnubber

T = 1 / (frekuensiswitching * 1000)
Rsnubber = (((Dutycycle * T) / (2 * Csnubber * 10 ^ -9)) / 1000) * 0.5
Rs.Text = Math.Round(Rsnubber, 2)

n = ((L / 1000000 * iLmax) / (Bmax * Ac)) * 10 ^ 4

n1.Text = Math.Round(n, 0)

Kbob = (Dbob / 10) * 3.14

G = 0.4 * (n * Kbob * Jumlahsplit)
Wirelength = ((n * Kbob * Jumlahsplit) + G) / 100
w1.Text = Math.Round(Wirelength, 0)

miu0 = 4 * 3.14 * 10 ^ -7
VI = miu0 * (L * 10 ^ -6) * (iLmax ^ 2)
LA = (Bmax ^ 2) * 1.96
AirGap = (VI / LA) * 10 ^ 7
lg.Text = Math.Round(AirGap, 2)

F = ((DeltaiL / 2) / (Math.Sqrt(3))) ^ 2
H = iLavg ^ 2
iLrmst = Math.Sqrt(H + F)
iLrmssplit = iLrmst / Jumlahsplit
qwtsplit = iLrmssplit / J
dwtsplit = Math.Sqrt((4 / 3.14) * qwtsplit)
dw1.Text = Math.Round(dwtsplit, 2)
End Sub

Private Sub Button2_Click(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles CLEAR.Click
Vsmax.Text = ""
Vsmin.Text = ""
Vo.Text = ""
Io.Text = ""
fs.Text = ""
DiL.Text = ""
DrVo.Text = ""
tf.Text = ""
Db.Text = ""
Ae.Text = ""
split.Text = ""
Duty.Text = ""
RL.Text = ""
iLaverage.Text = ""
DeltaRIL.Text = ""
DVo.Text = ""
Induktor.Text = ""
Co.Text = ""
iLm.Text = ""
Ion1.Text = ""
Voff1.Text = ""
Cs.Text = ""
Rs.Text = ""
n1.Text = ""
w1.Text = ""
lg.Text = ""
dw1.Text = ""
End Sub
 Private Sub RESET_Click(ByVal sender As System.Object, ByVal e As
System.EventArgs) Handles RESET.Click
Duty.Text = ""
RL.Text = ""
iLaverage.Text = ""
DeltaRIL.Text = ""
DVo.Text = ""
Induktor.Text = ""
Co.Text = ""
iLm.Text = ""
Ion1.Text = ""
Voff1.Text = ""
Cs.Text = ""
Rs.Text = ""
n1.Text = ""
w1.Text = ""
lg.Text = ""
dw1.Text = ""
End Sub
End Class

6.3 Error Calculation

Error calculation can be calculated by the formula:

%error= |manual calculation−software

manual calculation
calculation
|x 100 %
No Parameter Manual Software Error
Calculation Visual Basic
1 Duty Cycle 40 % 40 % 0%
2 RL 10 Ω 10 Ω 0%
3 iL (avg) 2A 2A 0%
4 ΔiL 0.4 A 0.4 A 0%
5 ΔVo 20 mV 20 mV 0%
6 L 787.5 µH 782.77 µH 0.6 %
7 Co 62.5 µF 62.5 µF 0%
8 iL (max) 2.2 A 2.2 A 0%
9 Ion 2A 2A 0%
10 Voff 50 V 50 V 0%
11 Cs 1.16 nF 1.16 nF 0%
12 Rs 2.155 kΩ 2.16 kΩ 0.23%
13 Winding Number (n) 35 35 0%
14 Wire Length 24 m 24 m 0%
15 Air Gap (lg) 0.39 mm 0.39 mm 0%
16 Wire Diameter (dw) 0.25 mm 0.25 mm 0%

7. CONCLUSION
 Buck converter is a series of DC-DC Converter or a step-down converter
because the output voltage is less than the input.
Vo<Vs

 PWM (Pulse Width Modulation) circuit use IC NE555 as a pulse generator

that used to switching MOSFET. Error in PWM Generator testing is caused by
errors in the selection of component type.

 Software calculation is made to calculate the parameters of buck converter

automatically. Error between manual calculation with software calculation is
around 0% to 0.6%. The biggest error is in inductor (L) that is 0,6%, the error
is due to the rounding factor.
8. ATTACHMENT