Adjustable Power Supply v18.08: Difference between revisions

From Open Source Ecology
Jump to navigation Jump to search
 
(136 intermediate revisions by 2 users not shown)
Line 1: Line 1:
=In Progress=
==Arduino code for voltage sensing and control==


==Arduino PWM code and voltage sensing==
[https://bitbucket.org/telephoneman/ups_pwm/src/3e0b14a3d3ba677face0fc56dc1f67f8a1673296/arduinocode Arduino code is hosted here.] This code is far from finalized and represent only one of many possible design approaches. Post as many variations or improvements as you can as long as they have advantages.


https://bitbucket.org/telephoneman/ups_pwm/src/3e0b14a3d3ba677face0fc56dc1f67f8a1673296/arduinocode
Next steps:
- implement SPI to control [https://www.digikey.com/short/pcqbwv digital potentiometer]


==Design buck/boost converter module==
For affordable buck-boost that can change voltage by a factor of five, high frequencies are needed to reduce inductor size. The Arduino has a limited PWM frequency (less than 100 kHz?).


This code is far from finalized and represent only one of many possible design approaches. Post as many variations or improvements as you can as long as they have advantages.
==Design buck/boost converter circuit/module==
Volt-second balance on the inductor means that the average voltage across it over one switching cycle is zero
Volt-second balance on the inductor means that the average voltage across it over one switching cycle is zero


Discontinuous mode is when current through the output inductor is zero for part of the switching cycle
Discontinuous mode is when current through the output inductor is zero for part of the switching cycle
Next steps:
- simulate main circuit
- design PCB
- research microcontroller options for voltage control and display


==Figure out ways to salvage or build transformers==
==Figure out ways to salvage or build transformers==
Line 16: Line 23:
Investigate ways to use high frequency for more efficiency in power transformation as well as smaller inductors.
Investigate ways to use high frequency for more efficiency in power transformation as well as smaller inductors.


With new Silicon Carbide MOSFET technology, maybe feasible to use flyback transformer at high frequency as described [https://dspace.vutbr.cz/bitstream/handle/11012/43074/eeict2015-621-martis.pdf1200 here]. A [https://www.digikey.ca/short/j2mvd3 suitable MOSFET] for this application costs around $15 but could be offset by smaller transformer.
With new Silicon Carbide MOSFET technology, maybe feasible to use flyback transformer at high frequency as described [https://dspace.vutbr.cz/bitstream/handle/11012/43074/eeict2015-621-martis.pdf1200 here].
 
A flyback transformer could more compact and cheaper initially, but the lifetime cost of replacing a large input capacitor would likely outweigh the initial savings. It is also more complex than an AC transformer, so probably not the best choice for this application.


=Design=
=Design=
[http://www.learnabout-electronics.org/PSU/psu33.php This page] is a great guide.


==Applications==
==Applications==
Line 35: Line 42:


120Vac input
120Vac input
===Microcontroller===
* ~11 I/O pins for 7-segment display
* 2 I/o pins for rotary encoder and power switch
* at least 4 I/O pins for SPI control of digital potentiometer
* 1 ADC for output voltage sensing
* 5V output to power other ICs would be nice
'''minimum requirements:''' 17 I/O pins, 1 ADC


==Research==
==Research==
===Existing Open-Source Projects===
[https://github.com/eez-open/psu-hw Programmable bench power supply EEZ H24005]
[https://hackaday.io/project/4154-bench-power-supply Bench Power Supply]
===General===
[https://www.ieee.li/pdf/essay/safety_considerations_in_power_supply_design.pdf Safety Considerations in Power Supply Design]
[https://www.ieee.li/pdf/essay/safety_considerations_in_power_supply_design.pdf Safety Considerations in Power Supply Design]


[https://www.ti.com/lit/ml/slup127/slup127.pdf Inductor and Flyback Transformer Design]
[https://youtu.be/i0SNb__dkYI How a 555 Timer works]
 
[https://howtomechatronics.com/how-it-works/electronics/how-to-make-pwm-dc-motor-speed-controller-using-555-timer-ic/ 555 Timer for PWM]
 
[https://en.wikipedia.org/wiki/Common_collector Common collector amplifiers] can be used as [https://en.wikipedia.org/wiki/Buffer_amplifier#Voltage_buffer voltage buffers]
 
[https://www.maximintegrated.com/en/app-notes/index.mvp/id/3081 How to Increase the Bandwidth of Digital Potentiometers 10x to 100x]
 
[https://www.allaboutcircuits.com/technical-articles/why-the-capacitor-in-your-power-supply-filter-is-too-big/ Ripple Port to Reduce Output Capacitor Size]


[https://dspace.vutbr.cz/bitstream/handle/11012/43074/eeict2015-621-martis.pdf 1200 WATT FLYBACK SWITCHING POWER SUPPLY WITH SILICON CARBIDE SEMICONDUCTORS]
[http://www.analog.com/en/technical-articles/isolation-in-digital-power-supply-why-and-how.html Isolation in Digital Power Supply]


[http://eas.uccs.edu/~cwang/ECE5955_F2015/PowerElectronics_f2015/ch2/Sect2-2.pdf Inductor volt-second balance, capacitor charge balance, and the small ripple approximation]
[http://www.ti.com/lit/ml/slua618/slua618.pdf Fundamentals of Gate Driver Circuits]


[http://www.ti.com/lit/an/slva059a/slva059a.pdf Understanding Buck-Boost Power Stages]
[http://iopscience.iop.org/article/10.1088/1742-6596/977/1/012007 Open-source based synthetic medium-voltage grid model for distribution power supply systems]


[https://www.st.com/content/ccc/resource/technical/document/application_note/a4/ef/bc/7d/78/89/49/f1/DM00098381.pdf/files/DM00098381.pdf/jcr:content/translations/en.DM00098381.pdf Current Sharing in Parallel Diodes]
[https://www.st.com/content/ccc/resource/technical/document/application_note/a4/ef/bc/7d/78/89/49/f1/DM00098381.pdf/files/DM00098381.pdf/jcr:content/translations/en.DM00098381.pdf Current Sharing in Parallel Diodes]
===Microcontroller===
[https://electronics.stackexchange.com/questions/167458/flash-and-eeprom Flash and EEPROM]
===Voltage Conversion===
[http://www.learnabout-electronics.org/PSU/psu33.php This page] is a great guide.
[https://en.wikipedia.org/wiki/Multivibrator#Astable_multivibrator Astable multivibrator]
[https://en.wikipedia.org/wiki/Buck%E2%80%93boost_converter Buck–boost converter]
[http://www.ti.com/lit/an/slva059a/slva059a.pdf Understanding Buck-Boost Power Stages]


[https://www.mouser.de/pdfdocs/BuckConverterDesignNote.pdf Buck Converter Design]
[https://www.mouser.de/pdfdocs/BuckConverterDesignNote.pdf Buck Converter Design]


[http://iopscience.iop.org/article/10.1088/1742-6596/977/1/012007 Open-source based synthetic medium-voltage grid model for distribution power supply systems]
[https://www.digikey.com/short/pcfvjt Similar DC/DC converter] with isolation but without adjustable output or display: ~$80
 
===Flyback Transformer===
[https://www.electronicdesign.com/power/active-clamp-flyback-converter-design-whose-time-has-come The Active Clamp Flyback Converter: A Design Whose Time Has Come]
 
[https://ir.lib.uwo.ca/cgi/viewcontent.cgi?article=7074&context=etd A Comparison of Different Snubbers for Flyback Converters]
 
[https://www.ti.com/lit/ml/slup127/slup127.pdf Inductor and Flyback Transformer Design]
 
[https://dspace.vutbr.cz/bitstream/handle/11012/43074/eeict2015-621-martis.pdf 1200 WATT FLYBACK SWITCHING POWER SUPPLY WITH SILICON CARBIDE SEMICONDUCTORS]
 
[http://eas.uccs.edu/~cwang/ECE5955_F2015/PowerElectronics_f2015/ch2/Sect2-2.pdf Inductor volt-second balance, capacitor charge balance, and the small ripple approximation]


===Existing Open-Source Projects===
[https://www.ti.com/seclit/ml/slup338/slup338.pdf Flyback transformer design considerations for efficiency and EMI]
[https://github.com/eez-open/psu-hw Programmable bench power supply EEZ H24005]


[https://hackaday.io/project/4154-bench-power-supply Bench Power Supply]
[http://www.ee.bgu.ac.il/~pel/pdf-files/smnr13.pdf PASSIVE LOSSLESS SNUBBERS FOR HIGH FREQUENCY PWM CONVERTERS] (page 41)


==Modules==
==Modules==
<html><iframe src="https://drive.google.com/file/d/14E6jdRYcacSnh8N1ed87tpt4PYiifUkv/preview" width="800" height="300"></iframe></html>
<html><iframe src="https://drive.google.com/file/d/14E6jdRYcacSnh8N1ed87tpt4PYiifUkv/preview" width="800" height="300"></iframe></html>
[https://drive.google.com/file/d/14E6jdRYcacSnh8N1ed87tpt4PYiifUkv/view?usp=sharing edit]
[https://drive.google.com/file/d/14E6jdRYcacSnh8N1ed87tpt4PYiifUkv/view?usp=sharing edit]


[https://wiki.opensourceecology.org/wiki/Arduino_Power_Supply_v18.08 Arduino Power Subcircuit]
[https://wiki.opensourceecology.org/wiki/Arduino_Power_Supply_v18.08 Arduino Power Subcircuit]
===Flyback Transformer===
A flyback transformer would most likely be operated in continuous conduction mode, so transformer size will be limited by core saturation. A toroid with powder core could be a suitable solution.
Switching speeds of MOSFET and diodes should be minimized to reduce switching losses. Winding losses should be minimized as well.
[https://www.mag-inc.com/Products/Selecting-a-Distributed-Air-Gap-Powder-Core-for-Fl Selecting a Distributed Air-Gap Powder Core for Flyback Transformers]
[https://micrometalsarnoldpowdercores.com/design-software Inductor Design Tool]
==Calculations==
<html><a href=https://wiki.opensourceecology.org/images/8/8a/BuckBoostCalc.jpeg>With only 30 kHz, a large and expensive inductor would be needed.</a></html>
[https://www.electronics-tutorials.ws/amplifier/transistor-biasing.html Transistor biasing]
[https://www.google.ca/url?sa=t&source=web&rct=j&url=http://www.ti.com/lit/an/slva721a/slva721a.pdf&ved=2ahUKEwjX3L_Nv-LdAhVLHzQIHViWBzcQFjABegQIBxAB&usg=AOvVaw1Rfq8vmjUTgXz3TBK5JtWO Buck-Boost Design Calculations]
[https://drive.google.com/file/d/160fBKhaJohxqErDVsghaS8F-OIE37cVb/view?usp=sharing Digital potentiometer calculations]
==Conceptual Design==
'''''These designs may not be safe or functional. Use at your own risk.'''''
[http://kicad.rohrbacher.net/quicklib.php KiCAD Symbol Generator], <html><a href=https://drive.google.com/file/d/1LtR22AovAHlzEcM65HuDW818-tB03zNA/view?usp=sharing>DB9851.lib</a>, <a href=https://drive.google.com/file/d/1uvr8XZ4-E1sGj2WWG3NTgnj2rY3qOkTe/view?usp=sharing>UC24612.lib</a></html>
===Buck-Boost Converter===
<html><a href=https://wiki.opensourceecology.org/wiki/File:BuckBoostSch.jpg><img src=https://wiki.opensourceecology.org/images/c/cf/BuckBoostSch.jpg width=1000 height=500></a><a href=https://drive.google.com/drive/folders/1GTlBO0V6huO2SHp2aWkBbo3RVD3Nfane?usp=sharing>edit</a></html>
===Flyback Configuration===
https://wiki.opensourceecology.org/images/thumb/f/fc/FlybackDraft.jpg/800px-FlybackDraft.jpg
[https://drive.google.com/file/d/1dRuDUdYCjfiMH3gN5b1DNvURy5PTcsm4/view?usp=sharing edit]
'''DRAFT, values are not correct'''
10 gauge wire for secondary winding. Primary has 8.5 turns, try 3 or 3.5 for secondary.


==Software==
==Software==
Line 71: Line 162:


Output Inductor: Bobbin or rod-core cause more noise [http://www.ti.com/lit/an/slva059a/slva059a.pdf]
Output Inductor: Bobbin or rod-core cause more noise [http://www.ti.com/lit/an/slva059a/slva059a.pdf]
Isolator: [https://www.digikey.ca/short/jw00p5 DGTL ISO 2.5KV 2CH GEN PURP 8DIP]
Synchronous Rectifier IC: [https://www.digikey.ca/short/jnc47m SOT-23-5]
Digital Potentiometer: [https://www.digikey.com/short/jv7n34 IC DGTL POT 10BIT NV 14-TSSOP]
Voltage regulator: [https://www.digikey.com/short/jv7558 IC REG BUCK 12V 1A TO220-5]
===Buck-Boost Converter===
=====Main Circuit=====
Switching Transistors: [https://www.digikey.ca/short/jnjmwq MOSFET N-CH 60V 100A POWERDI5060] or [https://www.digikey.ca/short/jnjmwh MOSFET N-CH 60V 200A TO-220-3]
Inductor: [https://www.digikey.ca/short/jnjh8c FIXED IND 33UH 30A 1.9MOHM SMD] (would require 2.5 MHz switching frequency)
Rectifier Diode: [https://www.digikey.com/short/jwt9dh DIODE SCHOTTKY 250V 40A TO220AB]
PWM Controller: [https://www.digikey.com/short/jnjwcd IC REG CTRLR BUCK/BST 20HTSSOP-B] or [https://www.digikey.com/short/pc3rrv IC REG CTRLR BUCK-BOOST 20QFN] or 555 Timer
555 Timer: [https://www.digikey.com/short/pc3r5z IC OSC SINGLE TIMER 3MHZ 8-SOIC]
Digital Potentiometer: [https://www.digikey.com/short/j0rqqt IC DGTL POT 10BIT 16TQFN] and 50 kOhm resistor, or [https://www.digikey.com/short/pcqbwv IC DGTL POT 100K SPI 16-TSSOP] and 2 x 16kOhm resistor
Input/Output Capacitor: [https://www.digikey.com/short/j075p3 CAP CER 15UF 100V X7S SMD]
=====PWM Control=====
High-side gate driver: [https://www.digikey.com/short/jv7b44 IC HIGH-SIDE DVR HS HV 8-MSOP]
Gate driver bootstrap diode: [https://www.digikey.com/short/jv75jm DIODE GEN PURP 100V 200MA SOD80]
Oscillation setting: [https://www.digikey.com/short/j0r7f0 CAP CER 47PF 50V C0G/NP0 0201], 4.7 kOhm resistor
Short circuit protection timer: [https://www.digikey.com/short/j0rtrj CAP CER 0.47UF 100V X7R 0805]
Error Amp Feedback: [https://www.digikey.com/short/j0rttm CAP CER 0.068UF 100V X7R 0805], 100 Ohm resistor
=====Voltage Sensing=====
Voltage divider: [https://www.digikey.ca/short/jvt1rm RES SMD 442K OHM 1% 1/16W 0402], [https://www.digikey.ca/short/jvt1rw RES SMD 4.99M OHM 1% 1/16W 0402]
Op amp for voltage buffer: [https://www.digikey.com/short/jvt1cd IC OPAMP GP 1MHZ RRO SOT23-5]
=====User Interface=====
Microcontroller: [https://www.digikey.com/short/pcf1cb IC MCU 32BIT 64KB FLASH 44LGA] ($5, higher resolution ADC) or [https://www.digikey.com/short/pcf1tq IC MCU 32BIT 128KB FLASH 64LQFP] ($6, similar specs to Arduino Mega)
LCD: [https://www.digikey.com/short/pcfdpd LCD 4.5 DIGIT .4" TRANSFL]
BJTs: [https://www.digikey.com/short/pcfdp9 IC PWR RELAY N-CHAN U-DFN3030-10]


===Forward Configuration===
===Forward Configuration===
Line 83: Line 221:
[https://www.infineon.com/dgdl/irf540n.pdf?fileId=5546d462533600a4015355e396cb199f IRF540N "IR" MOSFET N-Channel 33A 100V]
[https://www.infineon.com/dgdl/irf540n.pdf?fileId=5546d462533600a4015355e396cb199f IRF540N "IR" MOSFET N-Channel 33A 100V]
[https://www.digchip.com/datasheets/parts/datasheet/161/IRFP250N-pdf.php IRFP250N]
[https://www.digchip.com/datasheets/parts/datasheet/161/IRFP250N-pdf.php IRFP250N]
Switching Transistor: [https://www.digikey.ca/short/jwnc84 MOSFET N-CH 40V 95A TO-220AB]


===Flyback Configuration===
===Flyback Configuration===
Bridge Rectifier: [https://www.digikey.com/short/j2rtq3 50A, 1000V BRIDGE RECTIFIER, GBJ]
Cost of components ~$80
 
Fuse: [https://www.digikey.com/short/jwncf2 FUSE GLASS 15A 250VAC 5X20MM]
 
Bridge Rectifier: [https://www.digikey.com/short/jw71qw 50A, 600V BRIDGE RECTIFIER, GBJ], [https://www.digikey.com/short/j2d0dw DIODE BRIDGE FAST DIODE ECO-PAC1], [https://www.digikey.com/short/j2rtq3 50A, 1000V BRIDGE RECTIFIER, GBJ]
 
Input Capacitor: [https://www.digikey.com/short/jw7vw0 CAP ALUM 18000UF 20% 160V SCREW]
 
====Snubber====
Snubber Diode: [https://www.digikey.com/short/jwt9dh DIODE SCHOTTKY 250V 40A TO220AB]
 
Snubber Capacitor: [https://www.digikey.com/short/jwzccj CAP CER 0.18UF 250V X7R 1812]
 
Active Snubber Control: [https://www.digikey.com/short/jwjj5m Active clamp flyback controller UCC28780D]
 
Gate Driver Transistors: [https://www.digikey.com/short/jwm5wn TRANS NPN 60V 3A TP], [https://www.digikey.com/short/jwm1d2 TRANS PNP 60V 5A TO-126]
 
Integrated Gate Driver: [https://www.digikey.com/short/jwhc5v IC DRIVER HI/LO SIDE 600V 14-DIP]
 
====Coupled Inductor====
Switching Transistor: [https://www.digikey.com/short/jw729f MOSFET NCH 650V 21A TO247N], [https://www.digikey.ca/short/j2mvd3 MOSFET NCH 650V 39A TO247N]
 
Transformer: [https://www.digikey.com/short/jwtcn5 FIXED IND 10UH 16.9A 5.1 MOHM TH], [https://www.mag-inc.com/Media/Magnetics/Datasheets/0077130A7.pdf Kool Mu 77130A7 (11.2mm outer diameter, permeability = 125 u)]
 
====Output Rectifier====
Output Diode: [https://www.digikey.com/short/j2dvjj DIODE SCHOTTKY 45V 60A TO247AD]
 
Synchronous Rectifier IC: [https://www.digikey.ca/short/jwnc78 SYNC RECTIFIER FLYBACK]
 
Synchronous Rectifier Transistor: [https://www.digikey.ca/short/jwnc84 MOSFET N-CH 40V 95A TO-220AB]
 
=Bill of Materials=
==Buck/Boost Converter Module==
<html><iframe src="https://docs.google.com/spreadsheets/d/e/2PACX-1vRuPxZK24d7GdTwqzsNq4B9LgWyOsCs7YT73sC7Tw-9Zj6UBEbbaalxfD7FPRa9jBx9acQkj_Dh0Ln1/pubhtml?widget=true&amp;headers=false" height=500 width=900></iframe></html>


Switching Transistor: [https://www.digikey.ca/short/j2mvd3 MOSFET NCH 650V 39A TO247N]
[https://docs.google.com/spreadsheets/d/17jSD9Ku_RUkiSY8j9lGMdcOUFeJdl2H1anW0THEKH-g/edit?usp=sharing edit]

Latest revision as of 01:16, 28 December 2018

In Progress

Arduino code for voltage sensing and control

Arduino code is hosted here. This code is far from finalized and represent only one of many possible design approaches. Post as many variations or improvements as you can as long as they have advantages.

Next steps: - implement SPI to control digital potentiometer

Design buck/boost converter module

For affordable buck-boost that can change voltage by a factor of five, high frequencies are needed to reduce inductor size. The Arduino has a limited PWM frequency (less than 100 kHz?).

Volt-second balance on the inductor means that the average voltage across it over one switching cycle is zero

Discontinuous mode is when current through the output inductor is zero for part of the switching cycle

Next steps: - simulate main circuit - design PCB - research microcontroller options for voltage control and display

Figure out ways to salvage or build transformers

Investigate ways to use high frequency for more efficiency in power transformation as well as smaller inductors.

With new Silicon Carbide MOSFET technology, maybe feasible to use flyback transformer at high frequency as described here.

A flyback transformer could more compact and cheaper initially, but the lifetime cost of replacing a large input capacitor would likely outweigh the initial savings. It is also more complex than an AC transformer, so probably not the best choice for this application.

Design

Applications

Powering 3D printer

Workbench power supply

Charging batteries

Requirements

At least 360W output (12V at 30A)

Adjustable DC voltage output up to 24V

120Vac input

Microcontroller

  • ~11 I/O pins for 7-segment display
  • 2 I/o pins for rotary encoder and power switch
  • at least 4 I/O pins for SPI control of digital potentiometer
  • 1 ADC for output voltage sensing
  • 5V output to power other ICs would be nice

minimum requirements: 17 I/O pins, 1 ADC

Research

Existing Open-Source Projects

Programmable bench power supply EEZ H24005

Bench Power Supply

General

Safety Considerations in Power Supply Design

How a 555 Timer works

555 Timer for PWM

Common collector amplifiers can be used as voltage buffers

How to Increase the Bandwidth of Digital Potentiometers 10x to 100x

Ripple Port to Reduce Output Capacitor Size

Isolation in Digital Power Supply

Fundamentals of Gate Driver Circuits

Open-source based synthetic medium-voltage grid model for distribution power supply systems

Current Sharing in Parallel Diodes

Microcontroller

Flash and EEPROM

Voltage Conversion

This page is a great guide.

Astable multivibrator

Buck–boost converter

Understanding Buck-Boost Power Stages

Buck Converter Design

Similar DC/DC converter with isolation but without adjustable output or display: ~$80

Flyback Transformer

The Active Clamp Flyback Converter: A Design Whose Time Has Come

A Comparison of Different Snubbers for Flyback Converters

Inductor and Flyback Transformer Design

1200 WATT FLYBACK SWITCHING POWER SUPPLY WITH SILICON CARBIDE SEMICONDUCTORS

Inductor volt-second balance, capacitor charge balance, and the small ripple approximation

Flyback transformer design considerations for efficiency and EMI

PASSIVE LOSSLESS SNUBBERS FOR HIGH FREQUENCY PWM CONVERTERS (page 41)

Modules

edit

Arduino Power Subcircuit

Flyback Transformer

A flyback transformer would most likely be operated in continuous conduction mode, so transformer size will be limited by core saturation. A toroid with powder core could be a suitable solution.

Switching speeds of MOSFET and diodes should be minimized to reduce switching losses. Winding losses should be minimized as well.

Selecting a Distributed Air-Gap Powder Core for Flyback Transformers

Inductor Design Tool

Calculations

With only 30 kHz, a large and expensive inductor would be needed.

Transistor biasing

Buck-Boost Design Calculations

Digital potentiometer calculations

Conceptual Design

These designs may not be safe or functional. Use at your own risk.

KiCAD Symbol Generator, DB9851.lib, UC24612.lib

Buck-Boost Converter

edit

Flyback Configuration

https://wiki.opensourceecology.org/images/thumb/f/fc/FlybackDraft.jpg/800px-FlybackDraft.jpg

edit

DRAFT, values are not correct

10 gauge wire for secondary winding. Primary has 8.5 turns, try 3 or 3.5 for secondary.

Software

Git Repository

Possible Parts

Output Capacitor: Aluminum (cheaper but more lossy), organic semiconductor (good overall), tantalum (best for surface mount) [1]

Output Inductor: Bobbin or rod-core cause more noise [2]

Isolator: DGTL ISO 2.5KV 2CH GEN PURP 8DIP

Synchronous Rectifier IC: SOT-23-5

Digital Potentiometer: IC DGTL POT 10BIT NV 14-TSSOP

Voltage regulator: IC REG BUCK 12V 1A TO220-5

Buck-Boost Converter

Main Circuit

Switching Transistors: MOSFET N-CH 60V 100A POWERDI5060 or MOSFET N-CH 60V 200A TO-220-3

Inductor: FIXED IND 33UH 30A 1.9MOHM SMD (would require 2.5 MHz switching frequency)

Rectifier Diode: DIODE SCHOTTKY 250V 40A TO220AB

PWM Controller: IC REG CTRLR BUCK/BST 20HTSSOP-B or IC REG CTRLR BUCK-BOOST 20QFN or 555 Timer

555 Timer: IC OSC SINGLE TIMER 3MHZ 8-SOIC

Digital Potentiometer: IC DGTL POT 10BIT 16TQFN and 50 kOhm resistor, or IC DGTL POT 100K SPI 16-TSSOP and 2 x 16kOhm resistor

Input/Output Capacitor: CAP CER 15UF 100V X7S SMD

PWM Control

High-side gate driver: IC HIGH-SIDE DVR HS HV 8-MSOP

Gate driver bootstrap diode: DIODE GEN PURP 100V 200MA SOD80

Oscillation setting: CAP CER 47PF 50V C0G/NP0 0201, 4.7 kOhm resistor

Short circuit protection timer: CAP CER 0.47UF 100V X7R 0805

Error Amp Feedback: CAP CER 0.068UF 100V X7R 0805, 100 Ohm resistor

Voltage Sensing

Voltage divider: RES SMD 442K OHM 1% 1/16W 0402, RES SMD 4.99M OHM 1% 1/16W 0402

Op amp for voltage buffer: IC OPAMP GP 1MHZ RRO SOT23-5

User Interface

Microcontroller: IC MCU 32BIT 64KB FLASH 44LGA ($5, higher resolution ADC) or IC MCU 32BIT 128KB FLASH 64LQFP ($6, similar specs to Arduino Mega)

LCD: LCD 4.5 DIGIT .4" TRANSFL

BJTs: IC PWR RELAY N-CHAN U-DFN3030-10

Forward Configuration

Transformer: XFRMR TOROIDAL 500VA CHAS MOUNT, Investigating ways to salvage transformers

Rectifier: RECT BRIDGE FAST 3PHASE I4-PAC-5

IRFP250NPower transistor (MOSFET) driven by TC1411 1A High-Speed MOSFET Driver with pulse signal originating from arduino.

(Alternative mosfets requiring no mosfer driver) IRF540N "IR" MOSFET N-Channel 33A 100V IRFP250N

Switching Transistor: MOSFET N-CH 40V 95A TO-220AB

Flyback Configuration

Cost of components ~$80

Fuse: FUSE GLASS 15A 250VAC 5X20MM

Bridge Rectifier: 50A, 600V BRIDGE RECTIFIER, GBJ, DIODE BRIDGE FAST DIODE ECO-PAC1, 50A, 1000V BRIDGE RECTIFIER, GBJ

Input Capacitor: CAP ALUM 18000UF 20% 160V SCREW

Snubber

Snubber Diode: DIODE SCHOTTKY 250V 40A TO220AB

Snubber Capacitor: CAP CER 0.18UF 250V X7R 1812

Active Snubber Control: Active clamp flyback controller UCC28780D

Gate Driver Transistors: TRANS NPN 60V 3A TP, TRANS PNP 60V 5A TO-126

Integrated Gate Driver: IC DRIVER HI/LO SIDE 600V 14-DIP

Coupled Inductor

Switching Transistor: MOSFET NCH 650V 21A TO247N, MOSFET NCH 650V 39A TO247N

Transformer: FIXED IND 10UH 16.9A 5.1 MOHM TH, Kool Mu 77130A7 (11.2mm outer diameter, permeability = 125 u)

Output Rectifier

Output Diode: DIODE SCHOTTKY 45V 60A TO247AD

Synchronous Rectifier IC: SYNC RECTIFIER FLYBACK

Synchronous Rectifier Transistor: MOSFET N-CH 40V 95A TO-220AB

Bill of Materials

Buck/Boost Converter Module

edit

Retrieved from "https://wiki.opensourceecology.org/index.php?title=Adjustable_Power_Supply_v18.08&oldid=183628"