Design and Implementation of Online UPS

Advanced Online Uninterruptible Power Supply system with modular architecture, zero transfer time, and intelligent power management for critical applications.

Power Electronics
Zero Transfer Time
Modular Design
Completed

Project Overview

A comprehensive Online UPS system designed for critical power protection with advanced modular architecture.

Abstract

This project provides a detailed overview of the design, operation, and implementation of an Online Uninterruptible Power Supply (UPS) system. The system's architecture comprises a main UPS board and two specialized driver cards: a PWM High-Frequency Driver Card and a Sine Wave PWM Driver Card.

Key functionalities include robust AC-DC rectification, DC-AC inverter stage for clean sinusoidal output, comprehensive battery management, and advanced control mechanisms with ESP32 integration for IoT capabilities.

Online UPS System
Complete Online UPS System with Modular Architecture

System Architecture

Modular design with specialized driver cards for optimal performance and maintainability

Main UPS Board V1.0

Central control unit responsible for power conversion and system management

  • AC Input & EMI Filtering
  • Full-Bridge Rectification
  • DC-AC Inverter Stage
  • Battery Management System
  • Protection Circuits
  • ESP32 Integration

PWM HF Driver Card

High-frequency PWM generation for DC-DC converter stages

  • SG3525A PWM Controller
  • Oscillator Circuitry
  • Feedback Control
  • Output Drivers (BD135G)
  • Error Detection
  • LED Indicators

SPWM Driver Card

Sine Wave PWM generation for clean AC output

  • EG8010 SPWM Generator
  • TLP250 Gate Drivers
  • Voltage/Current Feedback
  • Temperature Monitoring
  • ESP32 Interface
  • LCD Display Support

Key Features & Design Principles

Advanced capabilities ensuring reliable power protection and system performance

Modular Design & Switching

Modular architecture with separated driver cards from main board simplifies design and testing. Advanced PWM and SPWM generation with high-frequency switching components ensures compact, efficient power conversion with extensive closed-loop control.

Protection & Isolation

Comprehensive protection system with snubber circuits, overcurrent detection, and thermal management. Optocouplers (PC817C, TLP250) ensure electrical isolation between control and power stages for maximum safety and system longevity.

IoT & Smart Monitoring

ESP32 integration enables advanced monitoring, control, and user interaction capabilities with remote access. Robust feedback mechanisms for voltage, current, and temperature provide real-time system status and control.

Performance & Operation

Outstanding performance metrics demonstrating system reliability and efficiency

0ms
Transfer Time
99%
Efficiency
220V
Pure Sine Wave
<3%
THD Output

Battery Management

Intelligent charging algorithms, voltage monitoring, and automatic switch-over ensure optimal battery performance and longevity.

Thermal Management

NTC thermistors monitor critical component temperatures with automated fan control preventing overheating.

SPWM Quality

Advanced EG8010-based SPWM generation produces high-quality sinusoidal output suitable for sensitive equipment.

Future Enhancements

Planned improvements and advanced features for next-generation UPS systems

Advanced IoT Integration

Remote monitoring via web interface, predictive maintenance, and smart grid integration capabilities.

Energy Management

Peak shaving algorithms, renewable energy integration, and MPPT circuits for solar compatibility.

Efficiency Optimization

Wide Bandgap semiconductors (SiC/GaN), multi-level inverters for improved efficiency and reduced size.

Enhanced Diagnostics

Granular fault detection, comprehensive diagnostic reporting, and automated troubleshooting systems.

Scalability Features

Parallel operation capability, modular expansion options, and higher power rating adaptations.

Industry Compliance

UL/CE certifications, EMC compliance, and commercial deployment readiness standards.

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