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DC/DC Power Supply: by Rob Mcmurry Jason Wells

This document summarizes the design, implementation, and testing of a DC/DC power supply with multiple outputs. The power supply was designed to convert an input voltage range of 36-48V to outputs of +5V, +12V, and -12V. Testing showed the design met voltage ripple requirements but efficiency was low, partly due to a self-starting resistor. Further work is needed to analyze a FET failure at 12V output and fully integrate the control circuitry.

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58 views23 pages

DC/DC Power Supply: by Rob Mcmurry Jason Wells

This document summarizes the design, implementation, and testing of a DC/DC power supply with multiple outputs. The power supply was designed to convert an input voltage range of 36-48V to outputs of +5V, +12V, and -12V. Testing showed the design met voltage ripple requirements but efficiency was low, partly due to a self-starting resistor. Further work is needed to analyze a FET failure at 12V output and fully integrate the control circuitry.

Uploaded by

Koopaa Tape
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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DC/DC Power Supply

By Rob McMurry Jason Wells

Presentation
Objectives Design Layout Design Issues & Problems Results Conclusions

Objectives
Input range of 36 - 48 Volts Outputs of +5,+12,-12 Volts Total power of 50 W (10/20/20) Ripple 2.5% Improve Line and Load Regulation through the implementation of feedback control Use a switching frequency of 70 kHz

Design Layout

Overview of Circuit Operation


Self starting Resistive Bridge Provides enough voltage to start the first gate drive which then provides voltage for the PWM chips thus eliminating the need for additional external voltages sources or batteries. (adds a loss of approximately 1.5 Watts) Flyback Converters Energy is transferred from the input to the output through storage element. This element is the inductor of the circuit. When switch is on, current flows into the primary side inductor. The switch then turns off and the stored energy is forced to flow in the secondary winding into the output.

Overview of Circuit Operation(cont.)


Flyback Converters (cont.)

Separate switches and sense inductors allows for individual control of each output voltage. Separate secondary windings provides isolation between the outputs and the input voltages.

Gate Drive Circuit

Overview of Circuit Operation(cont.)


PWM switching circuits
The UC3844 takes a generates a gate drive pulse which is used to control the FETs in each of the converters. Since our control did not function correctly in the circuit, two variable resistors were used to control the frequency and duty ratio.

Snubber
A turn-off snubber was added to each of the FETs to reduce voltage over shoot and switching losses.

Control Circuit

Overview of Circuit Operation(cont.)


Control
-6 V reference voltage was generated by using a op-amp to invert and divide the output of a 12 V regulator. Input and out put voltages are added in through a summing inverter circuit to give an ultimate output voltage equation of Vo = (Vref - .05Vin .05Vout)*22,000/Rgain .

Parts Ratings
Parts Vmax Imax

12V Caps
5V Caps 12V FET 5V FET -12V diode 5V diode 12V Inductor 5V Inductor

12V
5V 48V 48V 54V 37V 48V 48V

1.67A
2A 2.38A 2.64A 1.67A 2A 4.4A 4.5A

Flyback Inductor Size Calculation


L=Vin*dt/di In Flyback Converters, di=load current dt=D/freq. For 12V L=103uH For 5V L=34.28uH These are the minimum values for the inductors for continuous mode (i.e. Iload does not equal zero at any point)

Flyback Inductor Physical Design


Must be above critical inductance 1 to 1 transformer turns ratio Must have a core with high permeability that will not saturate Pot Cores were used (L = .1106 mH / turn) 3 transformer/inductors were used
1) and 2) two 10 turn windings and a 25 turn windings were used with resulting inductance of 1.10mH and 2.76mH 3) had two 10 turn windings giving 1.10mH each and a 60 turn winding giving 3.31 mH

Capacitor Design
For Flyback Converters I=C*dv/dt I=(Pout)/(Vout) dv=Vout*5% dt=D/frequency freq.=70kHz Capacitor values for 12V is C=10uF 5V is C=7.14uF Consequently the capacitor values have to be greater than these values for 5% ripple and below

Wire Gauge Sizing


Windings for the 12 V:
Max average current occurs at Pmax, Vmin(in) (Iave(in) +Iave(out)) = 2.22 A Min wire guage = 20 gauge (500 A/cm2) (2.59A)

Windings for the 5 V:


Max ave current occurs at Pmax, Vmin(in) (Iave(in) +Iave(out)) = 2.28 A Min wire guage = 20 gauge (500 A/cm2)(2.59A)

Functional Testing
Voltage Ripple at Various Conditions Efficiency of the Circuit at Various Conditions Duty Ratios

Voltage Ripple
Measured Maximum occurred at full load .15V %Ripple Maximum

12V

1.25%

5V

.12V

2.4%

Efficiency
Vin
36V 40V 44V 48V

Full Power 46.5%


39.0% 41.1% 40.5%

2/3 Power 34.7%


36.5% 36.3% 32.3%

1/3 Power 43.7%


39.2% 36.34% 32.6%

Efficiency vs Voltage
100 90 80 70 60 50 40 30 20 10 0 30 32 34 36 38 40 Voltage Full Power 2/3 Power 1/3 Power 42 44 46 48 50

% Efficiency

Duty Ratio
D=|Vout|/(Vin+|Vout|)
Vin=36 Vout=12 Theorecti .25 cal Measured .31 Vin=36V Vin=48V Vin=48V Vout=5 Vout=12 Vout=5 .12 .2 .094

.15

.26

.12

Major Problems
Designing a self starting circuit that did not require external voltages caused difficulties due to isolation issues with converter design Efficiency was low for our converter
This was partially a result of our self starting resistor Another problem appeared to be in the 12 V FET which was heating excessively and eventually failed.

Failure of the FET in our 12 V supply right before our demo resulted in our 5 V supply acting unstable during our demo.

Conclusions
Design Requirements that need further attention
The 12 V output failure needs to be analyzed and fixed. We believe that the low efficiency of the circuit was possibly due to the problem that caused this failure. The control circuit needs to be successfully integrated into the gate drive circuitry to improve the Line and Load Regulation

Conclusions
Successfully met design requirements
Single power supply providing DC/DC conversion Voltage Ripple requirements at various loads Control Circuit provided desired control function but we were unable to integrate it into the gate drive circuitry

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