ElectricGod
10 MW
Hi Endless-Sphere...
I thought this might interest some folks. I've built quite a few chargers and thought it was time to share my charger projects.
I want to talk about two different kinds of chargers I have built.
1. PSU only based chargers
2. PSU + DC-DC converter based chargers
PSU only based chargers have the advantage of whatever is the current output of any one of the PSU's, is what the output max current will be. If you have multiple identical PSU's and the outputs are 100% isolated from frame ground, earth ground, line an neutral, then you can "stack" them in series and get just about any voltage you can imagine. I've built 3 and 4 PSU's in series and they work fine. There is no reason you couldn't put 10 fully isolated PSU's in series. I've also used laptop power supplies and put 4 of them is series to get 81 volts. Isolated outputs are the rule!!! Decent PSU's (Meanwell) that have overload protection will cost $40-180 or more each depending on the specific voltage and amperage you are wanting. This option gets expensive quickly, but it's a great option.
PSU + DC-DC converters allows you to have an output voltage that can be adjusted a LOT. Many DC-DC converters will up convert from 24 to 90 volts out from a source voltage of 12-60 volts. As you can imagine, the DC-DC converters make for a very flexible option. You are limited by a couple of things. You can build one from a single PSU so that cost is fairly minimal and converters can be quite inexpensive. The DC-DC converter is not 100% efficient and so some of the total wattage of the PSU is used in the converter. Also to gain voltage, you lose amperage. If you are using a 24 volt, 30 amp PSU and up converting to 80 volts, don't expect to get 30 amps out. You are limited by the DC-DC converters current handling ability and the fact that you lose current to get more voltage. Transformers work the same way. In building this type of charger, I've used several converters in parallel and then doubled up the mosfets on them to enhance their individual current output to maximize the current usage of the PSU. All converters tend to be rated in watts. If you have a 500 watt converter, that means at higher output voltage you can output less current. At lower output voltage, more current all the while staying under 500 watts.
The next few posts will be specifics about PSU only chargers and PSU + DC-DC converter chargers.
I thought this might interest some folks. I've built quite a few chargers and thought it was time to share my charger projects.
I want to talk about two different kinds of chargers I have built.
1. PSU only based chargers
2. PSU + DC-DC converter based chargers
PSU only based chargers have the advantage of whatever is the current output of any one of the PSU's, is what the output max current will be. If you have multiple identical PSU's and the outputs are 100% isolated from frame ground, earth ground, line an neutral, then you can "stack" them in series and get just about any voltage you can imagine. I've built 3 and 4 PSU's in series and they work fine. There is no reason you couldn't put 10 fully isolated PSU's in series. I've also used laptop power supplies and put 4 of them is series to get 81 volts. Isolated outputs are the rule!!! Decent PSU's (Meanwell) that have overload protection will cost $40-180 or more each depending on the specific voltage and amperage you are wanting. This option gets expensive quickly, but it's a great option.
PSU + DC-DC converters allows you to have an output voltage that can be adjusted a LOT. Many DC-DC converters will up convert from 24 to 90 volts out from a source voltage of 12-60 volts. As you can imagine, the DC-DC converters make for a very flexible option. You are limited by a couple of things. You can build one from a single PSU so that cost is fairly minimal and converters can be quite inexpensive. The DC-DC converter is not 100% efficient and so some of the total wattage of the PSU is used in the converter. Also to gain voltage, you lose amperage. If you are using a 24 volt, 30 amp PSU and up converting to 80 volts, don't expect to get 30 amps out. You are limited by the DC-DC converters current handling ability and the fact that you lose current to get more voltage. Transformers work the same way. In building this type of charger, I've used several converters in parallel and then doubled up the mosfets on them to enhance their individual current output to maximize the current usage of the PSU. All converters tend to be rated in watts. If you have a 500 watt converter, that means at higher output voltage you can output less current. At lower output voltage, more current all the while staying under 500 watts.
The next few posts will be specifics about PSU only chargers and PSU + DC-DC converter chargers.