MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 1

1
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

1. INTRODUCTION
Cycloconverter are the direct type converters used in high power applications for driving and
synchronous motors. Cycloconverter are usually phase-controlled device. Cycloconverter is a
device which converts the AC power at one frequency input to a AC power at different
frequency output. A Cycloconverter is a type of power controller in which an alternating
voltage at supply frequency is converted directly to an alternating voltage at load frequency
without any intermediate DC stage. The cycloconverter also allows power to flow freely in
either direction.

Fig. 1 Cycloconverter

Types of Cycloconverter:
1. Single Phase to Single phase Cycloconverter.
2. Three Phase to Three Phase Cycloconverter.
3. Single Phase to Three Phase Cycloconverter

2
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Fig.2: 1 phase to 1 phase Cycloconverter

This work addresses with the continuous improvement of technology in power electronics
and micro-electronics, variable voltage and variable frequency ac motor drives have come to
increased use in various industrial applications. These new approaches need a simple method
of control for ac motors. Control of ac motors become very popular because it is possible to
obtain the characteristics of dc motors by improving control techniques. It is well-known that
the control method of an AC motor is comparatively more difficult to realize because of
involvement of various controllable parameters like voltage, current, frequency, torque, flux
and so on. Though it is possible to achieve almost the same characteristics of dc motor using
induction motor, it is very complicated to realize because of need for on line co-ordinate
transformation and continuous need of either speed or position signal. A cycloconverter is a
type of power controlled in which an alternating voltage at supply frequency is converted
directly to an alternating voltage at load frequency without any intermediate d.c. stage. A
cycloconverter is to controlled through the timing of its firing pulses, so that it produces an
alternating output voltage. By controlling the frequency and depth of phase modulation of the
firing angles of the converters, it is possible to control the frequency and amplitude of the
output voltage. Thus, a cycloconverter has the facility for continuous and independent control
over both its output frequency and voltage. This frequency is normally less than 1/3 of the
input frequency. The quality of output voltage wave and its harmonic distortion also impose
the restriction on this frequency. The distortion is very low at low output frequency.
Cycloconverter eliminates the use of flywheel because the presence of flywheel in machine
increases torsional vibration and fatigue in the component of power transmission system.
Therefore it is eliminated from the design of any machine. Hence variable voltage variable

3
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

frequency (vvvf) method is chosen to design three phase cycloconverter to drive three phase
induction motor to get required frequency varying with different time interval that generates
supply torque characteristics monitoring with demand torque.

4
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 2

2. LITERATURE SURVEY
Sandeep Pande et.al. [1], the process machine including provision for variation in load and
this is achieved by using three phase cycloconverter based variable voltage variable
frequency (VVVF) method. To realize this, a demand torque characteristics of a specific
process machine is studied. The cycle duration of demand torque characteristics is divided
into suitable number of time intervals. The subdivisions of time intervals in form of
frequencies are tabulated to simplify design procedure. Change in frequency on particular
subdivision results in demand torque of the induction motor. To meet this new frequency
hence voltage, three phase cycloconverter is designed. This contribution describes a method
used to simulate an induction motor drive using MATLAB software.
B. SAI SINDURA et.al. [2], This method is used to control the speed of the induction
motor.The speed control by this method is simple and can be made economical by using
different methods to control the operation of cycloconverter which in turn controls the

5
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

performance of motor. The formula for speed for induction motor is Ns=120f/p. from this
formula we can conclude that the speed of the motor can be varied in two ways, one is by
changing the number of poles and the second method is by changing the frequency. The
speed control through the first method is uneconomical and the number of poles can’t be
varied under running conditions and the size of the machine also becomes bulky. These
problems can be overcome by the second method. In this method the frequency can be varied
under running conditions also and there is no change in the size of the motor. In this method
the frequency changing device is cycloconverter. A cycloconverter is a power electronic
device used to convert constant voltage constant Frequency AC power to adjustable voltage
adjustable frequency AC power without a DC link. In among all the methods this method is
simple, reliable and economical. The various speed of induction motor is obtained by varying
the supply frequency by using cycloconverter.
Bhagawati Patil et.al. [3], the project is implemented to control the speed of induction motor
using PWM technique. Induction motor is very robust and therefore it is used in many
domestic application such as washing machines, vaccum cleaners and also used in industries.
Induction motor is also called as a constant speed machine. The AC supply frequency can not
be changed so this project uses a MOSFET to drive the induction motor and to control the
speed of induction motor by using the PWM method. The microcontroller used for this
project is from PIC16 family (PIC16F877A). Among all the different method PWM method
is simple, reliable and economical. PWM also minimize the lower order harmonics. This
concept can be further enhanced and implemented to control the speed of three phase
induction motor

6
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

7
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 3

8
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO.3 DESIGN AND ANALYSIS

3.1 Block Diagram-

Fig. 3 Block Diagram of System

1. MICROCONTROLLER (AT89S52)-
The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8K bytes
of in-system programmable Flash memory. The device is manufactured using Atmel’s high-
density nonvolatile memory technology and is compatible with the industry-standard 80C51
instruction set and pin-out. The on-chip Flash allows the program memory to be
reprogrammed in-system or by a conventional nonvolatile memory programmer. By
combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip,
the Atmel AT89S52 is a powerful microcontroller which provides a highly-flexible and cost-
effective solution to many embedded control applications. The AT89S52 provides the
following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog
timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt

9
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the
AT89S52 is designed with static logic for operation down to zero frequency and supports two
software selectable power saving modes. The Idle Mode stops the CPU while allowing the
RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power-
down mode saves the RAM contents but freezes the oscillator, disabling all other chip
functions until the next interrupt or hardware reset.

Fig.4 AT89S52

 Compatible with MCS®-51 Products

 8K Bytes of In-System Programmable (ISP) Flash Memory
 4.0V to 5.5V Operating Range
 Crystal Frequency 11.0592MHZ
 Three-level Program Memory Lock
 256 x 8-bit Internal RAM
 32 Programmable I/O Lines
 Three 16-bit Timer/Counters
 Eight Interrupt Sources
 Full Duplex UART Serial Channel
 Watchdog Timer

10
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Fig.5 Pin Diagram of AT89S52

2. LED-

Fig. 6 LED
LEDs are semiconductor devices are made out of silicon. When current passes through the
LED, it emits photons as a byproduct. Normal light bulbs produce light by heating a metal
filament until its white hot. LEDs present many advantages over traditional light sources
including lower energy consumption, longer lifetime, improved robustness, smaller size and
faster switching

11
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

3. LM7805 (3 TERMINAL VOLTAGE REGULATER)-

Fig.7 Pin description of LM7805

Fig.8 View of LM7805

This is used to make the stable voltage of +5V for circuits. The LM7805 is three terminal
positive regulators are available in the TO-220 - package and with several fixed output
voltages, making them useful in a wide range of applications. Each type employs internal
current limiting, thermal shut down and safe operating area protection, making it essentially
indestructible. If adequate heat sinking is provided, they can deliver over 1A output current.
Although designed primarily as fixed voltage regulators, More information please refer Data
sheet 0f LM7805

12
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

4. Crystal oscillator-

Fig.9 Crystal Oscillator 12MHz

A crystal oscillator is an electronic circuit that uses the mechanical resonance of a vibrating
crystal of piezoelectric material to create an electrical signal with a very precise frequency.
This frequency is commonly used to keep track of time (as in quartz wristwatches), to
provide a stable clock signal for digital integrated circuits, and to stabilize frequencies for
radio transmitters/receivers.

13
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

3.2 Design of Individual Module-

A] Power Supply-

Fig.10 Block diagram of power supply

Power is derived initially from standard 12V AC/DC adapter or 12V_500ma Transformer.
This is fed to bridge rectifier D1 ~ D4, the output of which is then filtered using 1000uf
electrolytic capacitor and fed to U2 (voltage regulator). U2 +5V output powers the PIC micro
controller. LED L10 and its associate 1K current limiting resistors provide power indication.
The unregulated voltage of approximately 12 V is required for relay driving circuit.
Micro controller required 5V DC supply for operation, we used USB +5V Power from PC or
External +5V power supply via CN10. External Power and USB power cab be selectable via
J1. There is need 12V external Power supply for relay’s and its driver circuits.

B] Power Supply Design

Power supply is the most important part of the project. For project +5V regulated power
supply with maximum current rating 500mA. Following basic building blocks are required to
generate regulated power supply.

Step Down Transformer-

14
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Step down transformer is the first part of regulated power supply. To step down the
mains 230V A.C. we require step down transformer. Following are the main
characteristic of electronic transformer.

1) Power transformers are usually designed to operate from source of low impedance
at a single freq.

2) It is required to construct with sufficient insulation of necessary dielectric

strength.

3) Transformer ratings are expressed in volt–amp. The volt-amp of each secondary

winding or windings is added for the total secondary VA. To this are added the
load losses.

4) Temperature rise of a transformer is decided on two well-known factors i.e. losses

on transformer and heat dissipating or cooling facility provided unit.

Rectifier Unit-

Rectifier unit is a circuit which converts A.C. into pulsating D.C. Generally semi-conducting
diode is used as rectifying element due to its property of conducting current in one direction
only. Generally there are two types of rectifier.

1) Half wave rectifier

2) Full wave rectifier

In half wave rectifier only half cycle of mains A.C. is rectified so its efficiency is very poor.
So we use full wave bridge type rectifier, in which four diodes are used. In each half cycle,
two diodes conduct at a time and we get maximum efficiency at o/p. Following are the main
advantages and disadvantages of a full-wave bridge type rectifier circuit.

Advantages:

1) The need of center tapped transformer is eliminated.

2) The o/p is twice that of center tap circuit for the same secondary voltage.

3) The PIV rating of diode is half of the center-tap circuit.

15
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Disadvantages:

1) It requires four diodes.

2) As during each half cycle of A.C. input, two diodes are conducting
therefore voltage drop in internal resistance of rectifying unit will be twice
as compared to center tap circuit.

Filter Circuit-

Generally a rectifier is required to produce pure D.C. supply for using at various places in the
electronic circuit. However, the o/p of rectifier has pulsating character i.e. if such a D.C. is
applied to electronic circuit it will produce a hum i.e. it will contain A.C. and D.C.
components. The A.C. components are undesirable and must be kept away from the load. To
do so a filter circuit is used which removes (or filters out) the A.C. components reaching the
load. Obviously a filter circuit is installed between rectifier and voltage regulator. In our
project we use capacitor filter because of its low cost, small size and little weight and good
characteristic. Capacitors are connected in parallel to the rectifier o/p because it passes A.C.
but does not pass D.C. at all.

Three terminal voltage regulators-

A voltage regulator is a circuit that supplies constant voltage regardless of change in load
current. IC voltage regulators are versatile and relatively cheaper. The 7800 series consists of
three terminal positive voltage regulators. These ICs are designed as fixed voltage regulator
and with adequate heat sink, can deliver o/p current in excess of 1A. These devices do not
require external component. This IC also has internal thermal overload protection and
internal short circuit and current limiting protection. For our project we use 7805 voltage
regulator IC.

16
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Fig.11- 3-Terminal Voltage Regulator

Design of Step down Transformer

The following information must be available to the designer before he commences for the
design of transformer.

1) Power Output.

2) Operating Voltage.

3) Frequency Range.

4) Efficiency and Regulation.

Size of core

Size of core is one of the first considerations in regard of weight and volume of transformer.
This depends on type of core and winding configuration used. Generally following formula is
used to find area or size of core.

Ai =ÖP1/0.87

Ai = Area of cross - section in Sq. cm. and

P1= Primary voltage.

In transformer P1 = P2

17
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

The project requires +5V regulated output. So transformer secondary rating is 12V, 500mA.

So secondary power wattage is,

-3
P2 = 12 x 500 x 10 w.

= 6w

So Ai = Ö6/0.87

= 2.62

Generally 10% of area should be added to core to accommodate all turns for low Iron losses

and compact size.

So, Ai = 2.88.

Turns per volt

Turns per volt of transformer are given by relation

Turns / Volt = 10000/4.44 f Bm Ai

Here, F is the frequency in Hz

Bm is flux density in Wb/m2

Ai is net area of cross section.

Following table gives the value of turns per volt for 50 Hz frequency.

Flux density Wb/m2 1.14 1.01 0.91 0.83 0.76

Turns per volt 40/Ai 45/Ai 50/Ai 55/Ai 60/Ai

Table No. 1- Value of turns per volt for 50 Hz frequency

18
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Generally lower the flux density better be quality of transformer. For project for 50 H z the

turns per Volt for 0.91 Wb/m2 from above table.

Turns per Volt = 50 / Ai

=50/2.88

@ 17

Thus for Primary winding = 220 x 17 = 3800.

& for Secondary winding = 12 x 17= 204.

Wire size

As stated above size depends upon the current to be carried out by the winding, which
depends upon current density of 3.1 A/mm2. For less copper losses 1.6 A/mm2 or 2.4 A/mm2
may be used. Generally even size gauge of wire are used.

Rectifier Design

R.M.S. Secondary voltage at secondary of transformer is 12V.

So maximum voltage Vm across Secondary is

= Rms. Voltage x Ö2

= 12 x Ö2

= 16.97

D.C. O/p Voltage at rectifier O/p is 2 Vm

Vdc = 2Vm/ p

= 2 x 16.97/ p

= 10.80 V

19
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

PIV rating of each diode is,

PIV = 2 Vm.

= 2 x 16.97

= 34 V

Maximum forward current which flow from each diode is 500mA. So from above parameter
we select diode IN 4007 from diode selection manual.

Design of Filter Capacitor

Formula for calculating filter capacitor is,

C= 1/4Ö3 r f RL.

r = ripple present at o/p of rectifier. (This is maximum 0.1 for full wave rectifier.)

F = frequency of mains A.C.

RL = I/p impedance of voltage regulator IC.

C=1/4Ö3 x 0.1 x 50 x 28

= 1030 mf

@ 1000 mf

Voltage rating of filter capacitor is double of Vdc i.e. rectifier o/p which is 20V. So we choose
1000 mf / 25V filter capacitor.

IC7805 (Voltage Regulator IC)

Specifications:

Available o/p D.C. Voltage = + 5V.

Line Regulation = 0.03

20
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Load Regulation = 0.5

Vin maximum = 35 V

Ripple Rejection= 66-80 (dB)

C] SELECTION FOR CURRENT LIMITING RESISTANCE FOR LED-

Fig.12- Current limiting resistance

The output of microcontroller is equal to supply voltage

i.e. +5V DC. If directly connected LED to
micro controller then very high current flowing
through it because internal resistance of LED is
very small about 5 to 8 ohm so it is possibility to damage LED so we place current limiting
resistance R in series with diode the value of this resistance is calculated.

From ohms low

V = RI

Where

I= If safe forward current flowing through LED which normal intensity glow and
this value near about 8 to 10 mA

5 = Rx 8mA

R = 625 

So we select near about value 680.

3.3 PCB designing and fabrication

21
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

It is called PCB in short printed circuit pattern applied to one or both sides of an insulating
base, depending upon that, and it is called single sided PCB or double-sided PCB. Conductor
materials available are silver, brass, aluminum and copper; copper is most widely used which
is used here as well. The thickness of conducting material depends on the current carrying
capacity of the circuit.

The printed circuit board usually serves three functions:

1. It provides mechanical support to the components mounted on it.

2. It provides necessary electrical interconnection.

3. It acts as heat sink i.e., it provides a conduction path leading to removal of most of the
heat generated in the circuit.

 Cu clad

The base of laminate is either paper of glass fiber cloth. Cu foil, which is produced by the
method of electroplating, is placed on laminate and both are kept under hydraulic pressure for
proper adhesive pressure for proper adhesive. These Cu clad are easily available in the
market.

 Types of Laminates

National Electrical Manufactures Association (NEMA) has various grades of laminates that
are obtained by different resins and filters.

1. Phenol

Phenol and Formaldehyde produce phenolic paper base laminate it has phenolic resins
with proper filter. This is Brown in color and opaque. Disadvantage is poor moisture
resistance.

2. Epoxy Laminates

Epoxy paper that is also paper based but impregnated with epoxy resin, yellowish white and
translucent.

22
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Epoxy Glass; this base material has high mechanical strength and good electrical properties
usually green in color and semitransparent.

There are a variety of laminates available. We have selected Fiber Glass epoxy laminate.

PCB fabrication includes following steps:

1) Layout of the circuit

2) Artwork designing

3) Printing

4) Etching

5) Drilling

6) Mounting of components and soldering

7) Finishing

 Layout

The layout of a PCB has to incorporate all the board before one can go onto the all work
preparation. Detailed circuit diagram, the design concept and the philosophy behind the
equipment are very important for the layout.

Layout Scale-

Depending on the accuracy required artwork should be produced at a 1:1 or 2:1 or even 4:1
scale. The layout is best prepared on the same scale as the artwork to prevent the entire
problem, which might be caused by redrawing of the layout to the artwork scale. The layout/
artwork scale commonly applied is 2:1 with a 1:1 scale, no demanding single sided boards
can be designed but sufficient care should be taken, particularly during the artwork
preparation.

 Procedure-The first rule is to replace each and every PCB layout as viewed from the
component side. This rule must be strictly followed to avoid confusion, which would
otherwise be caused.

23
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Another important rule is not to start the designing of a layout unless an absolutely clear
circuit diagram is available.

Among the components, the larger ones are placed first and the space in between is filled
with smaller ones. Components requiring input/output connecting come near the connector.
All components are placed in such a manner that de-soldering of other components is not
necessary if they have to be replaced.

 Layout sketch

The end product of the layout designing is the pencil sketched component and conductor
drawing which is caller ‘layout sketched’. It contains all the information for the preparation
of the network.

 Component holes

In a given, PCB most all the holes required are one particular diameter. Holes of a different
are shown with a code in the actual layout sketch.

 Conductor Holes

A code can be used for the conductor with a special width. Minimum spacing should also be
provided.

A) Holes B) Conductor Widths

Standard holes Standard width, 0.5 mm
1.1 mm 1 mm
1.5 mm 2 mm
3.2 mm 4 mm

Table No.2- Standard holes and conductor width

 Artwork

24
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

The generation of PCB artwork should be considered as the first step of the PCB
manufacturing process. The importance of a prefect artwork should not be under estimated.
Problems like inaccurate registered, broken annular rings or too critical spacing are often due
to bad artwork. And even with the most sophisticated PCB production facilities, PCB can be
made better than the quality of the artwork used.

 Basic Approaches

For ink drawing on white cardboard paper, good quality Indian ink and ink-pen set are
minimum requirements. Drawing practice-drawing procedure is very at-least by 0.1 – 0.2,
and solder pad locations. And conductors can be easily displaced by 0.3 – 0.5 mm

 Screen Printing

The process of screening – printing is well known to the printing industry because of its
inherent capabilities of printing a wide range of inks on almost any kind of surface including
glass, metal, plastic fabrics etc.

Found their way into an extremely broad field of applications.

Screen-printing offers the advantage of wide control on the ink deposition, thickness though
the selection of suitable mass density and composition. In the production of PCB’s, it is
successfully employed in printing of

 Etch resists

 Plate resists

 Solder stop lacquers

 Notation printing

In its basic form, the screen-printing process is very simple. A screen fabric with uniform
meshes and opening is stretched and fixed on a solid frame of metal or wood. The circuit
pattern area open, while the meshes in the rest of the area is closed.

In the actual printing step, ink is forced by the moving squeeze thorough the open meshes
onto the surface of the material to be printed.

25
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

The ink deposition, in a magnified cross section, shows the shape of a trapezoid.

 Pattern transfer onto the Screen

There are two different methods in use, and each method has its own advantages and
disadvantages.

With the direct method, the screen is prepared by coating a photographic emulsion directly
onto the screen fabric and exposing it in the pattern area. The indirect method makes use of a
separate screen process film, supported on a backing sheet. The film on its backing sheet that
is there after pressed onto the screen fabric and sticks there. Finally, the backing sheet is
peeled off, opening all those screen meshes, which are not covered by the film pattern.

The direct method provides very durable screen stencils with a higher dimensional accuracy
but the finest details are not reproduced. The indirect method is more suitable for smaller
series and where the finest details to be reproduced. The indirect method is faster but
dimensionally less accurate and the screen stencils are less durable, more sensitive to
mechanical damages and interruption in printing.

 Etching

In all subtractive PCB process, etching is one of the most important steps. The final copper
pattern is formed by selective removal of all the unwanted copper, which is not protected by
an etching unit.

Solutions, which are used in etching process, are known as enchants.

I) Ferric Chloride

II) Cupric Chloride

III) Chromic Acid

IV) Alkaline Ammonia.

Of these Ferric Chloride is widely used because it has short etching time and it can be stored
for a long time. Etching of PCBs as required in modern electronic equipment production, is
usually done in spray type etching machines.

26
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Tank or bubble etching, in which the boards kept in tank, were lowered and fully immersed
into the agitated, has almost disappeared.

 Component Mounting

Careful mounting of components on PCB increases the reliability of assembly.

1) The leads must be cleaned before they are inserted in PCB holes. Asymmetric lead
bending must be avoided; the ENT leads must fit into holes properly so that they can be
soldered.

2) When space is to be saved then vertical mounting is to be preferred. The vertical leads
must have an insulating sleeve.

3) Where jumper wire crosses over conductors, they must be insulated.

4) For mounting of PCBs, TO5, DIP packages special jigs must be used of easy insertion.

5) While mounting transistors, each lead must insulating sleeve. All the flat radial
components such as resistors, diodes and inductors are mounted and soldered. Then IC
bases are soldered. The vertical components such as transistors, gang condenser and FET
are mounted & soldered.

 Soldering

The next process after the component mounting is soldering; solder pint is achieved by
heating the solder and base metal about the melting point of the solders used.

The necessary heat depends upon:

1) The nature and type of joints

2) Melting temperature of solder

3) Flux

Soldering techniques are of so many types but we are using iron soldering.

 Iron soldering

27
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Soldering iron consists of an insulating handle connected through a metal shaft, os a bit
accurately makes contact with the component parts of the joint and solder and heats them up.
The electrical heating element is located in the hollow shank or handle to heat the bit.

 Functions of the Bit

It stored heat and convey it from the heat source to the work. It may be required to store
surplus solder from the joint. It may be required to store molten solder and flux to the work.

The surface must be lined and wetted; this encourages flow of solder into the joint. When the
surface of the work becomes tested by the solder, a continuous flow of liquid metal between
the bit and the work provides a path of high thermal conductivity through which heat can
flow into the work piece.

Solder bit are made up of copper; this metal has good wetting properly, heat capability and
thermal conductivity. Tin-lead solder affects copper during soldering operation. Production of
copper bit can be made with thick iron coating followed by Ni/Tin plating. The life of the bit
is increased by a factor of 10 to 15. Solder irons are specified in terms of wattage. Depending
on heat input intended for working and types of work (continuous or individual) the choice of
the solder iron can be made.

 Procedure of Soldering

The points to be joined must be cleaned first and fluxed. The hard solder iron and solder wire
is applied to the work. The melted solder becomes bright and fluid. The iron must be
removed after sufficient time and joint is allowed to coal.

At the end, finishing is done.

 PCB designing using computer aided designing (CAD):

CAD has many advantages over manual designing, important among them is:

1) Changes can be easily made because we don’t have to erase our pencil work on paper
repeatedly.

2) Time is saved.

28
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

3) Before taking printout we can have preview of the design etc.

The software which we have used is Quick-route.

3.4 System Costing

Quantit Cost per

Component Name y unit
Resistors    
330R 1 1
10K 2 2
3.3K 1 1
4.7K 6 6
22K 2 2
1K 6 6
10K PRESET 1 1
BC547 2 2
Capacitors    
Opto coupler 400
SCR 500
470uF /1000uF (PREFERABLE) /35V 1 10
10uF/63V 2 10
33pF Ceramic 2 2
0.1uf(104) Ceramic 1 2
Integrated Circuits    
7805 1 15
7812 1 20
AT89S52 1 500
IC Bases    
40 Pin Base 1 20
16-PIN BASE 1 15
14-PIN BASE 1 10
DIODE    
1N4007 9 9
Miscellaneous    
CRYSTAL 11.0592MHz 1 15
LED-RED 5 5
Railway demo model 1000
2-PIN PUSH BUTTON 1 5
12V RELAY 2 80
PCB CONNECTOR 2-PIN 8 30
POWER CORD 1 40
AC CONNECTOR 2-PIN 1 30
TRANSFORMER 12V, 1 AMPERE MUST 1 70
MALE BURGE 2-PIN 2 50

29
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

FEMALE BURGE 2-PIN 2 50

FEMALE BURGE 16-PIN 1 50
HEAT SINK 1 50
SCREW NUT FOR HEAT-SINK 1 50
COPPER WIRE FOR LOAD   40
PLAIN PCB 1 140
SOLDERING LED (50 gm)   100
CONNECTING WIRE   40

1.5 Layout

30
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

Fig. 8051 Layout

E47, E49, E50, E51, E52, E53, E54, E55, E56, E57, E58 – Male Burge for Connection
E48 – Power jack
All values of components mention in layout itself.

31
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

32
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 4

33
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

4. Applications of Thyristor Cycloconverter

Due to the power capability of the devices and the upper frequency limitation of the output, it
is possible to use the thyristor line-commutated cycloconverter to control low speed but very
large horsepower motors. There are presently two main applications for the cycloconverter.
In first application area, the Cycloconverter is used as a variable frequency variable speed
drives for AC machines. The input of the cycloconverter is connected to a power supply with
fixed frequency and the machine to be driven is connected to the output of the
cycloconverter. In the second application area, in contrast, the cycloconverter is used to
provide constant frequency power output from a variable frequency power source. 2.1 The
Basic Principle of the Cycloconverter The line-commutated cycloconverter consists of a
number of phase-controlled converter circuits connected to a poly-phase AC supply system
that provides the voltages necessary for natural commutation. The individual circuits are
controlled so that a low-frequency output voltage waveform is fabricated from segments of
the polyphone input voltages.

34
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 5

35
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO.5 CONCLUSION

From this work and result analysis, it is observed that speed of an motor can be efficiently
controlled by using Cycloconverter. The role of Cycloconverter in speed control of induction
motor is to vary the supply frequency which in turn, changes the speed of motor. In the
present work, the Simulation of speed control of motor at different frequencies by using
Cycloconverter is simulated and waveforms are discussed.

36
MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

CHAPTER NO. 6

37
 MICROCONTROLLER BASED CYCLO CONVERTER USING THYRISTORS

6.REFERENCE
[1] Sandeep Pande, Hashit Dalvi, “SIMULATION OF CYCLOCONVERTER BASED
THREE PHASE INDUCTION MOTOR”, International Journal of Advances in Engineering
& Technology, July 2011. ©IJAET ISSN: 2231-1963
[2] B. SAI SINDURA 1, B. N. KARTHEEK 2, “Speed Control of Induction Motor using
Cycloconverter”, International Journal of Engineering Trends and Technology (IJETT) -
Volume4Issue4- April 2013
[3] Bhagawati Patil1,Rushali Aute2, Pramila Mhaske3 ,Nitin Patil4, “CYCLOCONVERTER
TO CONTROL SPEED OF INDUCTION MOTOR”, Department of Electronics And
Telecommunication (SITRC) Nashik Savitribai Phule Pune University India
[4] Vinamra Kumar Govil, Yogesh Chaurasia “Modeling & Simulation of PWM Controlled
Cycloconverter FED Split Phase Induction Motor” International Journal of Advanced
Research in Electrical, Electronics and Instrumentation Engineering, Vol. 1, Issue 3,
September 2012.
[5] E A Lewis “Cycloconverter Drive Systems” Power Electronics and Variable Speed
Drives, Conference Publication No. 429, IEEE, 1996.

38