Inexpensive DC-DC converter/SMPS design idea and suitable topologies

[Hasan2019]

Hi there,

I am looking for a customized design where good power solution can be applicable.

My aim is to develop a DC-DC sutable toloplogy ( flyback, buck, isolated ,..so on) converter with following parameter,

INPUT: 250 to 650 VDC

OUTPUT: 24V/5A , 5V/3A, 12V/2A

Take a look at the similar product, https://www.eaton.com/content/dam/e...verter-data-sheet-brochure-emob0008-en-us.pdf


https://www.bosch-mobility-solution...high-voltage-dc-dc-converter-generation-3evo/

 

[Harald Kapp]

flyback, buck, isolated ,..so on)

First you need to decide which topology to use. See e.g. here.
You'll also need to define a few other parameters like e.g. :
- isolated/non-isolated?
- accuracy (regulation) of the different output voltages
- allowable ripple and noise at the output
- max. allowed EMC parameters (emission of EMC noise and susceptibility to external EMC noise)
Next have a look at the websites of e.g. Analog Devices (incl. ex. Linear Technology and Maxim), Texas Instruments )incl.ex. National Semiconductor). There you will find parametric search tools, datasheets, design tools, application notes etc. for any SMPS technology imaginable.
Not to mention other, smaller makers of such products.

Designing a "good" SMPS is not something to be done casually. It requires expertise. As you are dealing with high input voltages, you may be better off buying a commercial product. Maybe a power supply that creates 12V / 10 A and step down the other voltages from there which would be much less dangerous as the voltage is much lower (although high currents can also create hazards, but are imho easier to deal with using e.g. suitable fuses).

 

[Hasan2019]

First you need to decide which topology to use. See e.g. here.
You'll also need to define a few other parameters like e.g. :
- isolated/non-isolated?
- accuracy (regulation) of the different output voltages
- allowable ripple and noise at the output
- max. allowed EMC parameters (emission of EMC noise and susceptibility to external EMC noise)
Next have a look at the websites of e.g. Analog Devices (incl. ex. Linear Technology and Maxim), Texas Instruments )incl.ex. National Semiconductor). There you will find parametric search tools, datasheets, design tools, application notes etc. for any SMPS technology imaginable.
Not to mention other, smaller makers of such products.

Designing a "good" SMPS is not something to be done casually. It requires expertise. As you are dealing with high input voltages, you may be better off buying a commercial product. Maybe a power supply that creates 12V / 10 A and step down the other voltages from there which would be much less dangerous as the voltage is much lower (although high currents can also create hazards, but are imho easier to deal with using e.g. suitable fuses).

Dear Sir Kapp,

I do agree with the good parameters you have mentioned. Yes, it should be commercial product.
TI and AD does not have any solution within this range.
Right at this moment I am thinking about quasi resonant flyback converter topology.
Take a look here what Infineon expart has made a note, 2-9.pdf (mouser.com)

I found also an expensive one which might need many effort on firmware, this one is LLC topology in which primary side is based on a Full bridge stage, CRD-06600DD065N | Wolfspeed