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WEBENCH® Tools/LM3481: Webench Power Supply Circuit Not Working as Expected

Part Number: LM3481

Tool/software: WEBENCH® Design Tools

Hi,

I've designed a simple LM3481-based boost power supply circuit in Webench with the following parameters:

Vin: 14-20VDC

Vout: 24VDC

Iout: 3A (max)

I then tweaked various parts' values of the original design  - within the specified limits - to match more commonly found parts.

The final design can be found here.

(The said design is also attached below in pdf format in case the above link doesn't work)

I subsequently move on to breadboard the circuit with a good quality 18.5V/6A power supply for Vin, but instead of the expected 24VDC output, only got the same voltage as the input, that is, ~18.5V (either with or without a load).

It's worth noting that I only used quality parts (resistors/caps/etc.) and made sure the resistor values precisely match those in the schematics. I also checked all the connections and they looked ok.

In case one of the original parts was a dud, I subsequently re-built the entire circuit with new parts (including a new LM3481 and a different good quality 16VDC power supply), but got the exact same result, that is, Vout equal to Vin, or in this case: 16VDC. 

Given the repeated result, it seems likely to me that the problem isn't in the parts or the build, but rather somewhere in the design itself. My guess is that the switcher isn't working at all and that's why the input & output are the same, but that's only a guess (unfortunately, I don't have access to anything beyond a simple multimeter so I can't offer oscilloscope data or similar).

Having spent a fair amount of time and money on this design so far, I'm rather exasperated by the poor outcome and was hoping someone would be able to shed light on why this circuit isn't working.

Many thanks in advance,

Nadav

webench_design_4687533_44_360104643.pdf

  • Hi Nadav,

    The compensation components in the design you shared are not optimal.  I created a WEBENCH design for the criteria you mentioned (VinMin=14V, VinMax=20V, Vout=24V, and Iout=3A).  Please take a look at the shared design here.  I’ve attached the pdf report as well.  Please let me know if you have any questions.

    Regards,

    LaRita Gwie

    LM3481.pdf

  • Hi LaRita,

    Thank you for getting back to me on this.

    I'm not sure what you mean by 'optimal' in this context. WEBENCH ranks the design I submitted as having 96% efficiency which certainly seems fairly efficient to me.

    Given that I did use the WEBENCH's own tools to select parts that were within the limiting parameters set by the software, there shouldn't be any reason why my design shouldn't work, and work well at that (even if not 'optimally' as you put it).

    Re the revised design you've kindly sent me, there are two points I'd like to make:

    (1) It contains a fundamental mistake in that I'm looking for a 3A output rather than 13A output.

    (2) The revised design is simply unfeasible (or entirely theoretical), that is, it cannot be built in real-life. Where, for example, would one possibly obtain a 7.3uH inductor,? or a 2.49mR resistor? These and other parts in the revised design are just non-existent and that's precisely why they are marked as being 'custom'. 

    Hence, I find myself still without an answer to my original question, namely: why doesn't the design I originally submitted not working as it should?

    Kind regards,

    Nadav

  • Hi Nadav,

     

    I shared a 13A design because the design you sent had a very small (2mΩ) sense resistor for a higher current limit.

    I’m not sure why the inductor and sense resistor values showed as custom in the design report.  You can use the following part numbers:

    Component Name

    Manufacturer

    Manufacturer Part #

    L1

    Wurth Electronics

    7443551730

    Rsense

    Vishay / Dale

    WSL25122L500FEA18

     

    If you want a 3A design, please take a look at the shared design here.  I’ve attached the pdf report for the 3A design.

    Please let me know if you have any questions.

     

    Best Regards,

    LaRita Gwie

    LM3481_15uH.pdf