DC to DC Converter?

mechanix

100 W
Joined
Dec 2, 2008
Messages
202
I have an led headlight that needs around 3-4V input, and contactor that can take 12-24Vdc, and two fans that need around 24volts. My battery pack is about 80v. Is there such a thing as a dc to dc converter that could input ~80V and output ~20 watts at 4 volts and ~10 watts at 24v simultaneously? Is there a better way to accomplish this task?

One option I considered was to use two separate dc to dc converters (80V to 24V and 80V to 4V) but with this option the wiring will be messy and it will also be expensive. I'm open to any option that would be reliable and would solve this problem. Thanks in advance for the responses!

Joel
 
The 80V to ~4V is easy: some celphone chargers are only 4V-ish, maybe 4.2V. Most are about 5V, so you could go with one of those and a diode in series for about 4.3V. Many of the chargers I have tested on DC instead of AC inputs work fine above around 40VDC, the rest seem to need about 50VDC or so to start (although they run on as little as 32V or so once started).

The 24V one is a little harder, but there are a few regular brick supplies I've seen for laptops (especially Apple brand) and for some printers, which will probably run on DC, too. I'm using an Averatec 19V 3A unit on CrazyBike2 to boost the pack voltage for the CFL headlight/taillight, and it's worked fine for quite a while now.

I have also seen a handful of bricks, often from printers but sometimes from laptops like Dell, that have multiple voltages. I don't know that any are 4V, but I have seen 3.3V and 24V on one once, in a bin at Goodwill. Good chance that it would run on 80VDC input instead of AC.
 
brilliant as always.... amberwolf, never change. :)
 
that's what I'm talking about, super cheap and easy! Forgive my ignorance, but why do the wall warts only work with dc at higher voltages?

Joel
 
Partly because the values of resistance/etc. in the various paths limit the currents needed to kickstart the switching process, so below a certain voltage there isn't enough to get it going. That's part of why they will often only start at a significantly higher voltage than they will continue to run at after startup.


Another issue is that if you run it at a lower voltage, it takes more current to create the same power, and thus the same output voltage/current ability. If teh device is capable of sucking more power from the lower-voltage source than it would have from the higher voltage source (most likely), then it will put more strain on all the current-carrying components for that power.

Say you've got input diodes in it that are rated for only an amp, and at it's nominal "low voltage" operation of 100VAC it gets that full amp thru them. At a lower voltage it's now going past the spec on those parts, which they might or might not tolerate. Usually it's not an issue, as the parts tend to be spec'd better than that, but not always. Cheaper is always better in these kinds of things. ;)


Probably lots of other reasons I either am not aware of or cant' think of right now. :)


One more thing to think about is the total wattage output of the adapters: If they say theyr'e rated for up to 100W, for instance, that means 100W at the nominal input voltage. At a lower voltage (DC or AC), it probably won't be able to provide the same power level, and it probably doesn't fall off linearly, but faster than that, though I am not sure of the math.


I started experimenting wtih this stuff when I started on my CFL headlight/taillight setup, and have continued periodically since then with abotu the same results each time. Only time I have had real problems with them, or burned them out, is running on really low voltages after startup, like starting them on 40V and running down to 20V or something. They don't like to run that far below their kickstart voltages, in the case of the tiny little celphone chargers, sometimes. :( Laptop adapters or other larger bricks tend to be more forgiving, but they also tend to require higher start voltages to begin with.


Anyway, usually if it says something like "input power 100-220VAC, 50-60hz", it'll probably also work on DC at some voltage level.
 
never seen a cellphone charger put out more than 0.5 A...

farnell has some super expensive little bricks with such wattage.

I would have run a synchronous converter current mode for the leds (its the only type ive built), from 24v, or put them in series. They don't always take well to strong voltage controlled supplies unless you're careful with the voltage and make sure they're cold. I suppose you are looking for stuff that is more or less readymade, let me know if you find it.

edit: missed the current logic link, looks nice.
 
Back
Top