Hi everyone!
This is my first post, so I hope everything abides by the rules and you get something out of it! This project was a long time coming for me and I would like to share it here.
I want to make a headphone amplifier, as I think it is a perfect "beginner project". Not too much power, not many unnecessary features, just a simple but performant amp. Going back to the basics if you will 😉
In this first post I will go over the background, some decisions I made for now and share the schematic I came up with.
Thank you all a lot in advance! I am really looking forward to your comments 🙂
Background and Goal
This amp is meant to deliver the best possible performance with the least amount of complexity and cost. Power efficiency is not a primary concern, as it is "just" a headphone amplifier, so naturally I chose a class A topology. The amplifier is meant to be built up entirely of through-hole components. While this makes it a lot nicer to build up for me as a hobbyist, it will also make the amp last a lot longer, as it will be easily repairable - especially as I am using only main-stream components (standard BJTs, standard values and packaging for resistors and capacitors). Furthermore, it is intended to feel premium and make a statement design-wise - audio gear has to look and feel premium as well imo. While the design is still a work in progress, I have some features in mind that I really want to implement. I want to show off certain parts of the electronics as a design-feature; more specifically, the power transistors in a TO-3 package. Therefore, the output-stage is designed in a way that there is only one high-power transistor - a MJ2955 BJT. That transistor was specifically chosen for its good availability and the TO-3 case available in a configuration with the collector connected to the case. The emitter-follower configuration of the output stage in combination with the grounded collector allows the case of the power-transistor to be grounded, which makes it possible to safely display it on the outside of the amp's case. I have always found old TO-3 packages to be really cool to look at and wanted a way to display them safely. I think this will be a really cool design-feature in the later amp!
Schematic
Following the philosophy of simplicity and fully discrete design, the preamp-stage of the amplifier is kept relatively simple as well. The input stage consists of a long-tailed pair. The constant current source is set to a current of approx. 620 uA for a high input impedance (roughly 100 kOhm) of the two input transistors. This stage is followed by a common-emitter voltage amplification stage biased to roughly 2.6 mA. Finally, the power-stage is made up of a PNP-darlington pair in a common collector configuration. The amp is designed for a single voltage rail of roughly 20 V, so a bias-current of roughly 500 mA will flow through the output stage (with the DC-component of the output signal at half the supply voltage). The output is coupled with a large bipolar capacitor (how large exactly will be determined as well by some factors of the final design, but it will be somewhere between 3.3 and 10 mF; the simulations are done with the "best case" of 10 mF). This makes it possible to use a simple power-brick as a supply and therefore circumvent a lot of the headaches with regulation and safety when it comes to the higher grid-voltages. I plan on using a 24 V power-supply with a barrel connector (easy to get, cheap and safe) and filter the supply heavily to get a smooth 20V supply for the amplifier.
Projected Performance
The simulations done for now show a power output of >500 mW into 32 Ohms. The distortion is low (simulations show <0.0001% THD at 1 Vrms into 32 Ohms and <0.0005% THD at 0.5 W into 32 Ohms - both at 1 kHz). The simulated bode-plot shows plenty of phase margin and a flat gain curve (to within 1 dB) from 1.5 Hz to >200 kHz. The clipping behavior and power dissipation of the components seem decent. I am really happy with the schematic so far. To be clear: I know that simulations are just the first step and I fully expect the real-world performance to be worse, but the results encourage me to go further at least. I am curious to see what the real circuit can do!
Outlook
The next steps now are to build up a prototype and - if that works - design and order PCBs to populate. In parallel I am designing a suitable case. This will be a long project, so bear with me; I really want to push this amp to the best possible outcome. To this end, I would love feedback if you have some! I know some parts of this project may seem weird, but I really want to keep the single-PNP-output stage and just keep the whole thing simple and easy to build. I guess the spirit of this forum is to try new stuff after all 🙂
What do you guys think?
This is my first post, so I hope everything abides by the rules and you get something out of it! This project was a long time coming for me and I would like to share it here.
I want to make a headphone amplifier, as I think it is a perfect "beginner project". Not too much power, not many unnecessary features, just a simple but performant amp. Going back to the basics if you will 😉
In this first post I will go over the background, some decisions I made for now and share the schematic I came up with.
Thank you all a lot in advance! I am really looking forward to your comments 🙂
Background and Goal
This amp is meant to deliver the best possible performance with the least amount of complexity and cost. Power efficiency is not a primary concern, as it is "just" a headphone amplifier, so naturally I chose a class A topology. The amplifier is meant to be built up entirely of through-hole components. While this makes it a lot nicer to build up for me as a hobbyist, it will also make the amp last a lot longer, as it will be easily repairable - especially as I am using only main-stream components (standard BJTs, standard values and packaging for resistors and capacitors). Furthermore, it is intended to feel premium and make a statement design-wise - audio gear has to look and feel premium as well imo. While the design is still a work in progress, I have some features in mind that I really want to implement. I want to show off certain parts of the electronics as a design-feature; more specifically, the power transistors in a TO-3 package. Therefore, the output-stage is designed in a way that there is only one high-power transistor - a MJ2955 BJT. That transistor was specifically chosen for its good availability and the TO-3 case available in a configuration with the collector connected to the case. The emitter-follower configuration of the output stage in combination with the grounded collector allows the case of the power-transistor to be grounded, which makes it possible to safely display it on the outside of the amp's case. I have always found old TO-3 packages to be really cool to look at and wanted a way to display them safely. I think this will be a really cool design-feature in the later amp!
Schematic
Following the philosophy of simplicity and fully discrete design, the preamp-stage of the amplifier is kept relatively simple as well. The input stage consists of a long-tailed pair. The constant current source is set to a current of approx. 620 uA for a high input impedance (roughly 100 kOhm) of the two input transistors. This stage is followed by a common-emitter voltage amplification stage biased to roughly 2.6 mA. Finally, the power-stage is made up of a PNP-darlington pair in a common collector configuration. The amp is designed for a single voltage rail of roughly 20 V, so a bias-current of roughly 500 mA will flow through the output stage (with the DC-component of the output signal at half the supply voltage). The output is coupled with a large bipolar capacitor (how large exactly will be determined as well by some factors of the final design, but it will be somewhere between 3.3 and 10 mF; the simulations are done with the "best case" of 10 mF). This makes it possible to use a simple power-brick as a supply and therefore circumvent a lot of the headaches with regulation and safety when it comes to the higher grid-voltages. I plan on using a 24 V power-supply with a barrel connector (easy to get, cheap and safe) and filter the supply heavily to get a smooth 20V supply for the amplifier.
Projected Performance
The simulations done for now show a power output of >500 mW into 32 Ohms. The distortion is low (simulations show <0.0001% THD at 1 Vrms into 32 Ohms and <0.0005% THD at 0.5 W into 32 Ohms - both at 1 kHz). The simulated bode-plot shows plenty of phase margin and a flat gain curve (to within 1 dB) from 1.5 Hz to >200 kHz. The clipping behavior and power dissipation of the components seem decent. I am really happy with the schematic so far. To be clear: I know that simulations are just the first step and I fully expect the real-world performance to be worse, but the results encourage me to go further at least. I am curious to see what the real circuit can do!
Outlook
The next steps now are to build up a prototype and - if that works - design and order PCBs to populate. In parallel I am designing a suitable case. This will be a long project, so bear with me; I really want to push this amp to the best possible outcome. To this end, I would love feedback if you have some! I know some parts of this project may seem weird, but I really want to keep the single-PNP-output stage and just keep the whole thing simple and easy to build. I guess the spirit of this forum is to try new stuff after all 🙂
What do you guys think?
Attachments
Thank you for the response @lineup!
You're right, the resistor has to dissipate a lot of power. To make it capable of 500 mW into 32 Ohms, I will probably keep the 22 Ohms.
I plan to use a 10 W (should be a good choice with around 5W of nominal power) resistor that can be bolted to a heatsink, exactly as you mentioned!
You're right, the resistor has to dissipate a lot of power. To make it capable of 500 mW into 32 Ohms, I will probably keep the 22 Ohms.
I plan to use a 10 W (should be a good choice with around 5W of nominal power) resistor that can be bolted to a heatsink, exactly as you mentioned!
500mW is an awful lot.
When I design headphone amps I test them at 3.162 mW and sometimes 10 mW.
I never go any further.
3.162mW is +10dB and 10mW is +20dB ... almost noone needs +20dB.
500 mW would make most headphone burn. And your ears would break.
You are right, the amplification factor is really quite high. I also agree that 500 mW is probably way too much for almost every application.
Both points in my view help the design be a bit more versatile though.
The amplification factor of roughly 5.7 (~15 dB) was chosen such that with an input of 1 Vrms (1.41 Vpeak) the output swing covers most of the supply voltage, 16 Vpp. I assume that 1.41 V is available from almost any source, and with this source the amp can be used "fully". This way, with volume controls, the amp will also be a very competent preamp and be suitable for high-impedance headphones (I only used 32 Ohms for the simulations, I want to use it with higher impedances as well).
The power of 500 mW will never be used, I guess I saw them mostly as "headroom". I also have to admit that I was "going with the flow" of the spec-sheet amplifiers that sometimes put out multiple watts 😉
I guess both the power and the voltage amplification is really only necessary for reeeeally specific applications.
Both points in my view help the design be a bit more versatile though.
The amplification factor of roughly 5.7 (~15 dB) was chosen such that with an input of 1 Vrms (1.41 Vpeak) the output swing covers most of the supply voltage, 16 Vpp. I assume that 1.41 V is available from almost any source, and with this source the amp can be used "fully". This way, with volume controls, the amp will also be a very competent preamp and be suitable for high-impedance headphones (I only used 32 Ohms for the simulations, I want to use it with higher impedances as well).
The power of 500 mW will never be used, I guess I saw them mostly as "headroom". I also have to admit that I was "going with the flow" of the spec-sheet amplifiers that sometimes put out multiple watts 😉
I guess both the power and the voltage amplification is really only necessary for reeeeally specific applications.