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Documents A Noise-Free DIY Switching Power Supply - How Hard Can It Be? -- Episode 542
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  • Author Author: tariq.ahmad
  • Date Created: 10 Mar 2022 5:22 PM Date Created
  • Last Updated Last Updated: 18 Mar 2022 8:24 AM
  • Views 11845 views
  • Likes 12 likes
  • Comments 14 comments

A Noise-Free DIY Switching Power Supply - How Hard Can It Be? -- Episode 542

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Switch Mode Power Supplies (SMPS) need a printed circuit board (PCB). To see why check out this video. We look at how hard could it be to get a PCB design right! Hint: You need copper zones to get a low-noise SMPS design.

 

Supplemental Content:

  • Free Routing
  • Workbench Wednesdays Measuring SMPS Ripple
  • Resources

 

Bill of Material:

Product Name Manufacturer Quantity Buy Kit
DC/DC CONV, BUCK/BOOST/INVERT, 85DEG C On-Semi 1 Buy Now
Small Signal Schottky Diode, Single, 45 V, 8 A, 570 mV, 120 A, 150 °C Vishay 1 Buy Now
Power Inductor (SMD), 180 uH, 1.9 A, Shielded, 1.6 A, SRR1210 Series, 12mm x 12mm x 10mm Bourns 1 Buy Now
CAP, 4700uF, 16V, RADIAL, SMD PANASONIC 1 Buy Now
SMD Multilayer Ceramic Capacitor, 0.47 µF, 25 V, 0805 [2012 Metric], ± 10%, X7R, -55 °C SAMSUNG ELECTRO-MECHANICS 1 Buy Now
Surface Mount Thick Film Resistor, CRG Series, 68 kohm, 330 mW, - 5%, 150 V RoHS Compliant: Yes TE CONNECTIVITY 1 Buy Now
SMD Aluminum Electrolytic Capacitor, Radial Can - SMD, 330 µF, 25 V, 0.8 ohm, 2000 hours @ 85°C NIC COMPONENTS 1 Buy Now
 

Additional Parts:

PCBs: Auto-Routed, 6mil no pour, 6mil with ground pour, and Copper Zones

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Top Comments

  • dougw
    dougw over 3 years ago in reply to kmikemoo +1
    I had an instructor that used the same phrase - I think in connection to report writing objectives. It seems to me the more I know the less obvious it becomes.
  • dougw
    dougw over 3 years ago +1
    Interesting episode, although designing for failure rubs me the wrong way. I would like to see to see if there is a difference between realistic attempts - I doubt anyone would design with a 6 mil trace…
  • mayermakes
    mayermakes over 3 years ago in reply to dougw +1
    I agree, a follow up episode showing how to impedance match traces and compare them to filled zones would be interesting!
  • baldengineer
    baldengineer over 2 years ago in reply to koudelad

    That is what I had to do on the Mega IIe project’s power supply! The noise went down significantly by going to four layers.

    Going forward, I will probably always use 4 layers on (standalone) SMPS designs. But as you said, pre-made modules are often a better option. 

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  • koudelad
    koudelad over 2 years ago in reply to koudelad

    I also just remembered an experiment of a teaching assistant on EE university. Instead of using a 2 layer PCB, using 4 layers with ground layer and a power layer. Even a sloppy designed PCB that produced a high amount of EMI got under control using this thick.

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  • koudelad
    koudelad over 2 years ago

    Great episode. I got to it a year after releasing, but glad I found it.

    I guess one solution for less skilled HW designers might be that there will be ready made modules that would be connected to a target PCB via castellated edges or just pin headers, just like use processing power (e.g. Raspberry Pi Pico) / communication modules (many GSM / BT / GPS modules).

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  • baldengineer
    baldengineer over 3 years ago in reply to dougw

    I'm with you. Even with good simulation tools, predicting how the passives actually work is a huge challenge.

    Pre-2020 supply shortage, I would stick to a couple of switch controllers.

    Any time I use a new one, I always build a separate power supply module (similar to the boards I did in this video) so I can test them a bit before incorporating them into a final design.

    The upside is you get lots of design practice and a handful of modules. The downside to the shortage situation is that I am not building experience with any particular parts.

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  • dougw
    dougw over 3 years ago

    The biggest issue I have with designing switching power supplies is that I am unable to predict performance. Noise performance, thermal performance, efficiency and even current capacity. I need my prototypes to work well on the first spin. Cloning a reference design might be a way to reduce risk, but I usually find it very hard to procure the exact BoM used in the reference design, and the PCB layout is often wasteful of space. It is also common that the reference design doesn't meet all the requirements of the application. Maybe if I invested the time and money in perfecting my own reference designs I could get to a comfortable place, but I'm not there yet.

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  • baldengineer
    baldengineer over 3 years ago in reply to dougw

    Yeah. There's been a couple of other variations I've considered. These were four I did a single night based on the common ones I see around the interwebs.

    EMI differences is another angle I'd like to approach. This is where I think fat trace vs. pour might be more interesting.

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  • kmikemoo
    kmikemoo over 3 years ago in reply to dougw

    I gotta say... I appreciate the illustration.  I do have a bad tendency to say "Aw, it'll be fine."     And it's not. Frowning2    Being able to see the consequences of the shortcuts that I can see me taking... a least some of them...very valuable.  Still learning. Slight smile

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  • mayermakes
    mayermakes over 3 years ago in reply to dougw

    I agree, a follow up episode showing how to impedance match traces and compare them to filled zones would be interesting!

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  • dougw
    dougw over 3 years ago

    Interesting episode, although designing for failure rubs me the wrong way. I would like to see to see if there is a difference between realistic attempts - I doubt anyone would design with a 6 mil trace meant to carry 4 amps, even though I know it was done just for illustration. It would have been interesting to see differences between heavy traces and poured interconnects. Heavy traces are easier to edit and their impedance can actually be calculated.

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  • dougw
    dougw over 3 years ago in reply to kmikemoo

    I had an instructor that used the same phrase - I think in connection to report writing objectives.

    It seems to me the more I know the less obvious it becomes.

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