Friends,
You are invited to be a part of this DC-DC Converter design and development experience.
Developing HF Inductors / XFRs for DC-DC Converters for operating frequencies from 25kHz to 10MHz range.
Inductors formed are 2uH to 1.3mH range. Number of turns 1 to 28 and wire size 22 AWG.
We are yet to work on different designs of Transformers.
Selected core has operating frequency of 10kHz to 500MHz, made of base material Mn-Zn type in 16mm OD toroidal shape and can be operated from room temperature to 150C. Curie Temperature is >200C. Copper winding used is normally of 22AWG 200C Hermetic Transformer wire to be used for peak pulsed current <3A.
Initially we will like to use MC33063 / MC34063 DC-DC converter IC for different designs to operate with 24V 1.5A 36W input power source and will try to see how well this IC can be used for output voltages from 24V to 500V in step up and 24V to 3.3V in step down modes.
I also have a plan to use NCP1012AP100 and NCP1013AP100 100kHz step down DC-DC converters operating on input voltages 200V-400VDC and output voltage 24V/15V/12V/5V/3.3V etc with isolation voltages as high as 12kV.
Main Component List
1) FR4 PCB 3"x3" Single sided or double sided, PTH, solder masked
2) IC MC33063 On Semi / Texas Instrument / Fairchild
3) Capacitors (3 numbers)
4) Inductor / Transformer
5) 3A 1kV Diode
6) 5W/10W current sense resistor
7) Metal Film 1/4W resistors (2)
8) Ripple filter inductor
9) Ripple filter Capacitor (2)
10) Wago 2-PIN PCB Connector (2)
11) MOSFET Driver (only for 50V to 500V step up designs)
12) 600V 3A MOSFET (only for 50V to 500V step up designs)
PCB to be designed using Protel PCB Software.
You can find design calculators on websites and also circuit diagrams for this IC
Those of you are interested in these designs and want to know about the development and will like to evaluate the designs at their place can give their name and contact address through my email on my website. I expect the development cost of about US$50 initially per board fully assembled with all components.
First Design parameters are
Input Voltage 24V +/-2V (12V +/-2)
Regulated Output Voltage 24V to 500V range (12V to 500V for 12V input type)
Output Current < 20mA
Output Ripple <10mV
Operating Frequencies 25kHz to 100kHz range to be selected
Developing HF Inductors / XFRs for DC-DC Converters
