#Inspiration We thought of designing a Power Supply Unit (aka PSU) for our high-watt RGB LED setup to work. It was a set of addressable LEDs and by calculating theoretically it was supposed to consume 9 Amps at 5V a total Power of 45 Watts. But unfortunately, we didn't have such a high-watt power source, also at 5V.
It is a High Watt Power Supply Unit rated 60W, 5V output at a max current draw of 12 Amps, and that too in a small form factor.
First, we tinkered with TI’s Webench Power Supply Design and found some really decent designs, as a perfect match for our requirements. After a while, by getting a balanced result from all ways, i.e a small size, high current draw (12A) ample to source our LEDs, high efficiency; we started making the schematic in EasyEDA. Next, we designed the PCB and rechecked every connection thoroughly.
Main Components Used
- Bridge Rectifier
- Coupled Transformer
- CV CC UCC28740 flyback controller by TI
- UCC24630 Synchronous Rectifier Controller by TI
- Optocouplers
- Power Mosfets
- TL431 adjustable Zener
- Schottky Diodes
- Power Inductors
- Complementary Passive components
Orienting the PCB Layout was a bit challenging, Along with that routing and connecting the components was bit tricky.
Making the PCB design and the completing the project on time with video and presentation was our greatest achievement.
It was a good experience, about learning about the fly-back controller, which not only provides isolation but also has great efficiency. How SMPS have been so efficient and small yet delivering such high power.
Later this week we are thinking of fabricating this PCB along with component sourcing, to make it real. Meanwhile, it was a good experience, about learning about the flyback controller, which not only provides isolation but also has great efficiency.
This Circuit deals with AC mains (aka High Voltage that can kill you). Take precautions before performing. You have been warned.