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Registered Member #2906
Joined: Sun Jun 06 2010, 02:20AM
Location: Dresden, Germany
Posts: 727
Man, did i just hear my name ^_^
Now everyone knows we're without a life hanging around skype each day developing the biggest doomsday machine ever. Maybe i should spoiler my charger too. Btw if yan and i stop posting, maybe the CIA assassinated us.... ...or if just yan stops posting, hes maybe assassinated for trolling the forum. -.-
Registered Member #2906
Joined: Sun Jun 06 2010, 02:20AM
Location: Dresden, Germany
Posts: 727
Yan allowed me to hijack his thread and maybe show an other - more powerfull approach to charging caps . It somehow fits in the thread though, because the design in its basic principle is also verry simple. Of course the whole system is more complex, but the difference to Yans charger, my circuit has clear functional blocks, instead of one big blob that spits out voltage. So overall complexity is greatly reduced. I have designed a two phase discontiousmode Flyback with around >420W output power. Its a four-layer PCB due to the high current paths, and has two self wound 1:8 transformers. One phase consists of one transformer and its Mosfet and a current measuring 4mOhm Shunt. Its voltage is amplified and fed into a comparator, that creates some digital signals representing the state of the transformer. The digital part is compressed into one tiniy CPLD which implements all logic and generates the mosfet gate signals. When the output voltage (220-360V) is reached, the converter automatically deceases its peak-current to achieve better efficiency while holding the charge on the caps. Also under continous load like lightbulbs the current reduces to the minimum needed to sustain the output voltage. The design is input-power limited to around 30A and is designed to operate from 6s LiFePO4 Batteries. (~19V; less uner load). Efficiency is around 91% in simulations. Real measurements shows somewhat around 87% which is fine with the simulation. Discontinous mode sucks for the ferrite core - so its ok, expected, and given the achieved output power its a good tradeoff. The heat sink is one solid 4mm thick aluminium plate. Its designed to have heat capacitance only, however it successfully ran the device with 420W output power for around 15min without any symptom of overheating. The thing ran on first go, since it was verry well simulated before (and having a solid layout - FTW).
If someone feels that i should give away the schematics, please ask. but please keep in mind thats this is Yans thread and you clicked on this topic to discuss HIS design
As a simple version of a flyback converter, here is my simplified schematic: Design is critical to the transformer quality - high coupling is a requirement. k=99... is good enough. It is achieved by winding transformer like "secondary1-primary-secondary2" (separating secondary by two parts - under and over primary winding). Otherwise the Q1 will burn out all stray inductance' energy in avalanche mode and quickly overheat. 100W of output power is not a problem, radiator on Q1 is required for such power, though. D1 is recommended to be a schottky diode (SiC are awesome) as converter works in continuous mode. The output current is measured by a voltage drop on R1. When it falls below 1.2V, the new charging cycle starts (Q1 opens). The duration of the charging period is determined by R6 and limited by R7 (in fact, single resistor can be used instead both of those). The minimum duration of discharge cycle is limited by R4. It is also recommended to put a diode in antiparallel to the output cap C1 in case the output is short-circuited or connected directly to the inductive load (to prevent repolarisation of C1 - it will blow the converter). And mention that HV- and Gnd are not the same pins, so Gnd can not be used as common ground for HV circuits (conventionally it is, but not here).
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Simple and robust flyback voltage converter
. It somehow fits in the thread though, because the design in its basic principle is also verry simple. Of course the whole system is more complex, but the difference to Yans charger, my circuit has clear functional blocks, instead of one big blob that spits out voltage. So overall complexity is greatly reduced.
