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3 to 80V input - 5V or 12V / 2A output power supply

Francisco Zayas
Prodigy 130 points
Other Parts Discussed in Thread: PMP20127, TPS61088, LM5022

Hi,

We need to design a DC/DC power supply with the following requirements:

  • INPUT VOLTAGE: 3 to 80 Vdc
  • OUTPUT VOLTAGE: 12 or 5 Vdc
  • OUTPUT CURRENT: 2 A
  • ISOLATION: Recommended but not mandatory

We think that an isolated DC/DC power supply with flyback topology could be a good choice, but we are not experienced with this topology.

I used WEBENCH to find a good solution but it didn't offer me any part number or reference design. Also, I searched in TI Designs but nothing similar.

Could you suggest me any part or reference design?

Thanks in advance,

Regards,

Fran.

  • 0
    TI__Expert 6080 points

    Hello Francisco,

    Webench cannot suggest you a reference design because your input voltage goes down to 3V which is not ideal for most of the controllers to operate. Can I ask you the reason why you choose that value. There is PMP7760 which is the closest to your design inputs with 30-800VDC which is a good starting point.

    I have attached the Power stage designer tool with your flyback inputs please use this file as a reference to your power stage. I have also attached the PSD tool where you can open the TXT file, this will be very useful for you, by clicking on each element you can see the current waveforms and how that will vary with input and load conditions.  

    I hope this helps.

    Thank you 

    Sonal

    Power Stage Designer 4 BETA 20170804.zip

    Fullscreen Flyback_3VDC-80VDC.txt Download 
    FLYBACK
3
80
12
2
200
0.7
66
90
3
2
120

  • 0 in reply to Sonal Singh
    Prodigy 130 points
    Hi Sonal,
    First of all, thanks for your prompt response and the attached files.
    The reason for this input voltage range is that our customer wants to power the equipment with the voltage present in the lines that carry the current used in a die-cast aluminium factory. Basically, they plan to use the voltage present in some points of the line where the "current source based system" generates voltage drops in the line due to the high current applied.
    Most of the time, this voltage is about 4 V (not operating), but when the system is operating, the voltage could rise above 40 V (sometimes could reach even 80 V).
    This is a challenging application because they cannot power the equipment with the factory's main supply.
    Please, could you suggest me a solution?
    Kind regards,
    Fran.
  • 0 in reply to Francisco Zayas
    TI__Expert 6080 points
    Hello Fran,

    The only reference designs that I see might fit your application are PMP20127 which has a wide input range from 9Vdc- 125Vdc. I have never seen an Power topology range from 3V to 80V unfortunately and this reference design is the closest we can get to your spec. There are some lower input voltage applications that go from 3VDC-6VDC for medical applications but are not suited for 80VDC input.

    If your query has been solved please hit Answered.

    Kind Regards,
    Sonal
  • 0 in reply to Sonal Singh
    TI__Genius 14455 points
    Hi Fran,
    You could try boosting 3V to 6VDC Vin to 9V Vout at 2.5A using a TPS61088 and OR it with an ORing diode with the LM5022 Reference design in the PMP20127 as Sonal mentioned.

    The TPS61088 will operate under low VIn conditions and LM5022 will operate under high VIn conditions.

    Here is the 3-6VDC to 9V Vout design in WEBENCH.
    webench.ti.com/.../SDP.cgi

    Remember to add the zener clamp at the input to the TPS61088 to prevent the converter from damaged due to large Vin.

    The LM5022 will also need a zener as shown in PMP20127 reference design.

    You can download the SPICE models for these components from ti.com and simulate them to check the operation of the device.

    Regards,
    Gerold
  • 0 in reply to Gerold Dhanabalan - Online Design Tools
    Prodigy 130 points
    Hi Gerold,

    Thanks a lot for your help. I'll study the solution you suggest me.

    Thanks to Sonal for his comments too.

    Kind regards,
    Fran.