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Author: Subject: Homebrew adjustable switched PSU
Twospoons
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[*] posted on 23-2-2025 at 16:03


Electronics is a vast field - I've been doing it professionally for 35 years, and I was a hobbyist since age 8, and I'm still learning stuff.
Switching power supplies are one of those things that look simple on the surface, but actually require a lot of knowledge to build a functional device. As usual, the devil in in the details.




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Rainwater
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[*] posted on 23-2-2025 at 17:54


Quote: Originally posted by khlor  

Do you have any reading material to recommend for this kind of project?

These 3 are public domain now.
Oldies but goody.
I keep all 3 on my desk just to have the equations handy and still use the protoboard to test stuff when doing work
https://archive.org/details/Radio_Shack_-_Basic_Electronics_...

https://engineering.unt.edu/ee/files/Radio_Shack_Electronics...

https://www.zpag.net/Electroniques/Kit/Radio_Shack_Electroni...

Here is a free dr level education about semiconductors
https://youtube.com/playlist?list=PLyYrySVqmyVPzvVlPW-TTzHhN...

[Edited on 24-2-2025 by Rainwater]




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Twospoons
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[*] posted on 23-2-2025 at 20:14


"The Art of Electronics" by Horowitz and Hill is a very good general reference book.



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[*] posted on 24-2-2025 at 02:00


Quote: Originally posted by khlor  
do you have any reading material to recommend for this kind of project?

Schematics. Coupled with simulations, there is much to learned from them, specially alternative solutions to problems.

World Radio History (https://www.worldradiohistory.com/index.htm), formerly known as American Radio History, has a huge collection of electronics and radio books and magazines.




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[*] posted on 23-3-2025 at 20:57


Helo Again, sorry for the long hiatus, work scheduled has been hectic the last two months. all time I had was the commute to and from work, so I did simulations on my phone, I used everycircuit and ECStudio, I didn't got to simulate the whole thing as I wanted, but I did simulate bits and pieces just so I got the idea of what to do, these simulators don't play well with the 555, both gave me a hard time, but they did plenty well with linear circuits and simple stuff.

Now, to the business at hand, I did rebuilt the "control board/portion" for the sixth time, this time nothing fried, which is G O O D. the gate drivers I still hadn't changed, but based on rainwater work, I might just change it a little, by replacing the bc327 and 337 for something beefier, I think BD140/139 will do fine.

I considered the idea of elevating the ground, but since the voltage control is done only for the gate driver of the mosfets and the current design is holding its ground, I think I will keep it this way, keep using the 7809 and work at 0 v without that idea f virtual ground. I finished assembly of the board and here are the facts:

controlBoard2.jpg - 362kB
Picture 01: Circuit Diagram update.

As you can see, the 555 is now halted by cutting the reset pin, all is on the same ground level. I did. bit of a "level shifter" on the output pin of the 555 and it feeds on a current divider that feeds the circuit for the mosfet gate driver, which remains the same to date(planned changes after I decided what to do with this mess) this circuit worked just fine, RV-control is the potentimeter I use to regulate voltage and it works fine, like before. I scoped the mosfet gate on both sides and, no more quasi-linearity issues, it is oscillating like it should with Vgs -12v. The problem, like before, remains with current control.
As shown in the diagram, I did as rainwater suggested and made a lowpass filter, but initially it did not quite worked, then I looked at the internet for sugestions and came up with the current control loop you can see the diagram above and situation improved, but it is still very bad, as it can be seen on Picture 02.


ResizedImage_2025-03-24_01-13-31_1.jpg - 753kB
Picture 02: Scoped Output

When the circuit is on voltage control mode, all is smooth, ripple bellow 0.07V(70mV) but once current control starts to kick in, things get ugly and this, on the Picture 02 is the result. it used to be worse, but still, far from tolerable, and everyday that goes one and I think of this, makes me question my decisions in life, I mean, I might just go forth with the idea of switched voltage control and linear current control, if any has a suggestion on this particular issue, I am all ears, however I believe that the way my circuit works won't allow for proper current control, though, in the future, I will make sure to go with the commercial options.

grievances aside, I am glad I decided to "reinvent the wheel" in the hardest way possible because the goal wasn't the wheel(though it was a desired byproduct ) but the learning that came with it was absurd, the amount of things I got to at least get a glance at is incredible and the help you guys gave is truly something else!




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