Real Time DC DC Converter Data Visualization
DC to DC converters or DC choppers are those power electronics circuits that convert a dc voltage source to another dc source of different value.The fourth industry revolution constitutes all engineering domains to be centralized against cloud and IOT networks solutions. This research
2025-06-28 16:28:54 - Adil Khan
Real Time DC DC Converter Data Visualization
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryDC to DC converters or DC choppers are those power electronics circuits that convert a dc voltage source to another dc source of different value.The fourth industry revolution constitutes all engineering domains to be centralized against cloud and IOT networks solutions. This research focuses on monitoring physical variables like current, voltages, temperature and visualizes the data in real time on a cloud dashboard, this allows remote troubleshooting and control of a power converter via cloud network. We design the development of a firmware for smart control which can successfully be automated and minimize human interaction. We used microcontroller a popular open source of IOT platforms to execute the process. The system intended to control the physical variables with relatively low cost design, user friendly ease of installation. The system is design to assist the and provide support in order to fulfill the needs.
In this project we used three different circuits
• DC-DC Converter.
• Signal conditioning.
• Embedded system.
The dc buck converter produces an output voltage that is less than its input. The buck converter is so named because the inductor always “bucks” or acts against the input voltage. The inductor and capacitor are used to control, store and transfer energy from input to output depending on the state of the switch, either on or off. Control of the output voltage is achieved through the switching.
In the sensing circuit we used LM358.LM358 can be used as transducer amplifier, DC gain block etc. The LM358 is a versatile uses it can be used as comparator to compare different signals, amplifying signals from a variety of transducers or sensors to dc gain blocks or any op-amp function. Operational amplifier. The ideal op amp is an amplifier with infinite input impedance, infinite open-loop gain, zero output impedance, infinite bandwidth, and zero noise. It has positive and negative inputs which allow circuits that use feedback to achieve a wide range of functions. The LM358 is a versatile uses it can be used as comparator to compare different signals, amplifying signals from a variety of transducers or sensors to dc gain blocks or any op-amp function.
Project Objectives• Remote Troubleshooting
Remote Troubleshooting is a method to securely log into and attempt to identify and resolve issues.
Technological advances make it easier to conduct generator remote monitoring.
• Continuous Data Monitoring
By automatically collecting and analysing data to reflect possible outages and critical trends.Consistent system monitoring and timely, appropriate warnings assist in maintaining system uptime by raising the alarm when a service outage or application performance issues occur. This allows for quick response to security risks or functional stop-gaps, limiting harm and allowing for speedier system restoration to optimal levels of functioning.
• Data visualization and analysis
Visualization is central to advance analytics for similar reasons. When a data scientist is writing advanced predictive analytics or machine learning algorithms, it becomes important to visualize the outputs to monitor results and ensure that models are performing as intended. This is because visualizations of complex algorithms are generally easier to interpret than numerical outputs.
• Preventive maintenance
Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure.A successful maintenance strategy requires planning and scheduling maintenance of equipment before a problem occurs.
Improved reliability and life of equipment
Fewer costly repairs and downtimes associated with unexpected equipment failure
Fewer errors in operations as a result of equipment working incorrectly
Reduced health and safety risks
Project Implementation MethodFirst we provide a 15V DC input to voltage regulator(LM2596), this regulator acts as a buck converter, it converts 15V to 3.3V.A buck converter (step-down converter) is considered one of the switched-mode power supplies devices that decreases the voltage as an output . The buck converter contains passive filter components such as a filter inductor and a filter capacitor and a load resistor that is connected to the output side of the DC-DC buck converter.
For signal conditioning we provides the DC-DC Converter Input and Output to Operational Amplifier,Connect VCC To turn ON Operational Amplifier this Amplifier sense the Voltage,Current and Tempertaure.
1.The voltage sensing at input max 15V is divided and fed to unity gain op-amp configuration. Connect the 15V from input of DC DC converter.The output shall be 2.7V at 15V max.
2.Voltage sensing at output 3.3V is divided and fed to unity gain op-amp configuration. Connect the 3.3V output from the DC DC converter.The output shall be 1.8V at 3.3V max.
3.The current senses at 3.3V output and is fed to amplifier with a gain of 800
4.The temperature senses of DC DC converter at 10kOhm NTC output.
After Signal Conditioning , the sensors are interfaced with the ESP32. The converted data is then pushed to the cloud and viewed on the dashboard, which is accesible remotely.
Benefits of the Project- A buck converter is just a step-down chopper. It's just like a transformer but conversion is in DC
- Buck converter has so many applications like solar photo voltaic cell, Electrical and hybrid vehicles, robotic
- It is used in Electric power supplies for Telecommunication systems
- Buck converter is used in Electric power transmission systems
- Buck converter is used in Switched-mode power supplies for electric and electronic circuits
- Buck converter is also used in DC motor drive systems
• Cloud dashboard
Live monitoring and control , lighting and metering devices across all locations
Take a peek into individual or overall building operations to evaluate energy costs and compare performance across sites.
Things like declining performance in a chiller could indicate equipment failure. You now have the power to dispatch maintenance before a crisis occurs.
Unexpected events and out-of-spec conditions can trigger automatic alerts that give you the time needed to take swift action and solve problems.
Overall building services are improved when decision makers, from local maintenance to corporate planners, are kept in the loop.
• Physical board: PCB/Veroboard based design
A very basic printed circuit board is a flat, rigid, insulating material that has thin conductive structures adhering to one side. These conductive structures create geometric patterns consisting of, for example, rectangles, circles, and squares. Long, thin rectangles function as interconnections
Zero PCB is basically a general-purpose printed circuit board (PCB), also known as perfboard or DOT PCB. It is a thin rigid copper sheet with holes pre-drilled at standard intervals across a grid with 2.54mm (0.1-inch) spacing between holes. Each hole is encircled by a round or square copper pad so that component lead can be inserted into the hole and soldered around the pad without short-circuiting the nearby pads and other leads. For connecting the lead of component with another lead, solder these together or join these using a suitable conducting wire.
• Technical documentation
Documentation is the product of technical writing that refers to different documents with product-related data and information.
By technical documentation, we mean the whole abundance of notes, templates, standards, rules, and guides produced on the way through development. They include any copies that describe the product's functionality or architecture.
Final Deliverable of the Project HW/SW integrated systemCore Industry Energy Other IndustriesCore Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Affordable and Clean Energy, Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 15194 | |||
| ESP32 Dev kit | Equipment | 1 | 1500 | 1500 |
| LM2596 | Equipment | 2 | 1784 | 3568 |
| LM358p | Equipment | 4 | 40 | 160 |
| Inductor | Equipment | 2 | 642 | 1284 |
| PCB Board | Equipment | 2 | 800 | 1600 |
| Soldering iron | Equipment | 1 | 1200 | 1200 |
| Capacitor | Equipment | 20 | 10 | 200 |
| Resistor | Equipment | 20 | 5 | 100 |
| Schottky Diode | Equipment | 10 | 30 | 300 |
| LED | Equipment | 10 | 5 | 50 |
| Soldering Wire | Equipment | 500 | 1 | 500 |
| Jumper Wires | Miscellaneous | 40 | 3 | 120 |
| Brass Spacer | Equipment | 10 | 40 | 400 |
| Sil header | Equipment | 50 | 10 | 500 |
| Relay | Equipment | 130 | 1 | 130 |
| Power Resistor | Equipment | 12 | 35 | 420 |
| Toggle Switch | Equipment | 3 | 70 | 210 |
| Acrylic Sheet | Equipment | 1 | 350 | 350 |
| Shunt Resistor | Equipment | 2 | 529 | 1058 |
| Combicon Connector | Equipment | 8 | 193 | 1544 |