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Old 25th April 2005, 02:36 AM   #31
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sorry, no pictures

well, i did it. i am succesfully running a 700 watt mono class d amp of the smps i built without any problems. the transformer gets a little warm, but everything else is great. my base circuit is from ESP's smps project. i decided to just go with what was proven to work except i ran 4 mosfets a side on a big self wound two inch ferrite toroid(16 primary 80 secondary). this thing could deliver over 1000watts continuously. it is not feedback regulated so i do encounter some dip in voltage over peak power demand, but never more than 3 volts, its truly amazing. all of the circuits are built on vero board(the cheap radioshack stuff), and the mosfets and diodes are hardwired with the transformer because of current demand. at 700 watts continuous i'm only pulling 75 amps so thats about 75 to 80 percent efficiency throught the amp. its in a huge case though. the ESP project is a great base for any where between 300 to 1000 watts, thanks a bunch for the help. feel free to ask any questions about my project.

michael
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Old 25th April 2005, 06:00 AM   #32
opc is offline opc  Canada
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Eva,

There are some concepts that are pretty sound with SMPS design. Honestly, there isn't much you can screw up with the simple typology used. I am basically switching the primary via a center tap and rectifying the output. I'm not trying anything new and groundbreaking. Also, it's quite hard to prototype something accurately that is such high power... I'd want it to run at its expected capacity.

I have been pretty lucky with these things in the past and hopefully the trend will continue. Or maybe I will get a nice wakeup call and do the best prototyping job possible.

Thanks 'burnedfingers'! You gotta love that attitude! At least if it doesn't work, you can get a good show!

Steve (whoops, on OPC's account )
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Old 25th April 2005, 06:05 AM   #33
opc is offline opc  Canada
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kysoftdrink,

How did you measure this 1000W continuous power from your switching power supply? I am skeptical of core saturation.. I am told that these cores can only produce around 500-600W max., then they saturate

I have only placed an upper limit on mine to be around 500W due to core saturation. This would be the only limitation up to that power lower with my design..

STeve (opc account, whoops )
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Old 25th April 2005, 04:51 PM   #34
Eva is offline Eva  Spain
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opc :

Core saturation is not related to output current at all, it's related to input voltage and dead time


Also :

Quote:
I am using a PSoC microcontroller to create a dual PWM with deadband at 200KHz. These signals are going into non-inverting 6A MOSFET drivers. The drivers switch the MOSFET through 4.7 Ohm gate resistors. The MOSFETs then switch on a custom wound toroidal transformer. Owen Columbus (diy member opc) painstakingly wound the transformer, which is composed of 22 primary turns and around 80 secondary turns, it's beautiful!

I have a bank of capacitors 26400uF 25V on the input a total of 40mH of power inductors and 5440uF capacitors for the output filter. The output is rectified with ultra high speed switching diodes. The DC voltage on both rails is monitored via a zener diode based feedback into an opto isolator. The output of the optoisolator is fed back into the microcontroller's ADC input. The PWM's period is then adjusted accordingly when the voltage starts to exceed the limit.
I was talking about this. It's quite an ambitious project, particularly the stabilisation of such a control loop with dual outputs in the digital domain by means of a DSP
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Old 26th April 2005, 01:11 PM   #35
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well, the toriod came from a blown amp that put out 1200 continuous. so i was planning that if it could put out 1200+ watts continuous, it should do 1000 on a custom design with no problems. but i was able to get the dead time switching frequency of the old amp from the chip design and various resistors and capacitors and i just ran my design on the same frequency and dead time to save trobleshooting. so large toroid with the same switching frequency and dead time putting out 1000 continuous when it is capable of putting out 1200 seemed alright in theory. when put to the test, it performed marvilously.

i recomend, if u have the money, find a high powered amp that uses a single toroid and is blown, and use the toriod, switching frequency and dead time from that amp since it was designed by profesionals.

michael
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Old 27th April 2005, 01:35 AM   #36
JZatopa is offline JZatopa  United States
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I am curious how the PCBs are comming. I would like to one day build a jlh,leach,aleph amp for my car. I know they run hot but when you can put them in the trunk and use fans without worrieing about fan noise I don't see how it would be a problem.
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