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A buck converter is a step-down DC-DC converter that reduces input voltage to a desired lower output voltage with a high efficiency. It is commonly used in various applications where power conversion is necessary, such as power supplies, electric vehicles, and industrial controls.

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Buck Converter Design: En-Core 1.0

Introduction

This project involves designing a non-isolated buck converter that steps down a 24V input to a 5V output with an efficiency of at least 90%. The buck converter is essential in many power conversion applications, such as power supplies and electric vehicles.

Key Specifications:

  • Input Voltage (Vin): 24V (±2% tolerance)
  • Output Voltage (Vout): 5V (±0.01V)
  • Input Current: 1A max
  • Maximum Output Current: 4.32A
  • Efficiency: ≥ 90%
  • Form Factor: Max PCB size of 10 cm x 5 cm

Theoretical Background

A buck converter reduces the input voltage to a lower output voltage by switching a MOSFET on and off. The energy is stored in an inductor and smoothed out by a capacitor. The main components are:

  • Schottky Diode (1N5817): The diode is forward biased when the NMOS is open switch, hence it allows the flow of current through it. When NMOS is closed, it is reverse biased, hence inductor starts storing energy. It also minimizes energy losses as compared to conventional diodes.
  • PWM Source (NE555 Timer): Generates the switching signal of frequency 500kHz and Duty cycle(20.8%) to switch the circuit between input voltage and Schottky Diode.
  • Inductor and Capacitor: For storing energy in the form of magnetic field and powering the circuit when NMOS is open switch, an inductor is used with ripple current = 0.2 * I_maxout. The capacitor is used for output voltage smoothing.

Efficiency Calculation:

Efficiency depends on losses in the MOSFET (switching and conduction losses), inductor, and other components.


Simulation and Testing

The circuit was simulated to verify the design, focusing on:

  • Input voltage (24V DC)
  • PWM signal generated by the NE555 (duty cycle 20.8%)
  • Output voltage (5V with 0.02V ripple)

6316340018767052681

Simulation Graphs:

  • Green: 24V input voltage
  • Blue: PWM signal from the NE555 timer
  • Red: 5V output DC voltage

6316340018767052683


Schematic and PCB Design

  • Schematic: Designed using KiCad, featuring a PWM generator (NE555), MOSFET, Schottky diode, inductor, and output capacitor.
  • PCB Design: A dual-layer design to ensure proper thermal management, minimized noise, and correct trace width for current handling.

Schematic

Kicad pcb

Kicad pcb2

6316340018767052651


Conclusion

The buck converter successfully steps down 24V to 5V with over 90% efficiency, meeting all design and dimensional constraints.


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About

A buck converter is a step-down DC-DC converter that reduces input voltage to a desired lower output voltage with a high efficiency. It is commonly used in various applications where power conversion is necessary, such as power supplies, electric vehicles, and industrial controls.

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