48V 150A DC Converter Design
Budget: ₹600 – ₹1,500 INR
I need a straightforward, component-level design for a high-current buck/boost converter that can take 16 V – 60 V DC and deliver a stable 48 V output at up to 150 A for mixed industrial loads. A small tweak via a potentiometer must let me step the output down to 24 V when required.
Key points to cover
• Controller: TL494 for regulation and feedback
• Gate drive: IR2110 (or compatible) to drive the power stage
• Input range: 16 V–60 V DC
• Output settings: 48 V default, adjustable to 24 V via pot
• Continuous current: 150 A (with notes on heat-sinking, copper weight, and parallel MOSFET layout)
• Load type: mixed (both resistive and inductive) in an industrial environment
Deliverables I expect
1. Clear, annotated schematic (PDF or KiCad/Altium) showing TL494, IR2110, power devices, current-sense, protection, and pot-controlled voltage divider.
2. Concise Bill of Materials with part numbers that are realistically and widely available.
3. PCB layout guidelines or a basic PCB file highlighting track widths, copper pours, and thermal vias necessary for 150 A operation.
4. Brief design notes: gate-drive timing, current limiting method, efficiency estimate, and suggestions for cooling and EMI control.
A simple, workable blueprint that lets me prototype quickly is all I need with simulation or firmware if possible. Please keep the design as compact and cost-effective as possible while meeting the current requirement.
Key points to cover
• Controller: TL494 for regulation and feedback
• Gate drive: IR2110 (or compatible) to drive the power stage
• Input range: 16 V–60 V DC
• Output settings: 48 V default, adjustable to 24 V via pot
• Continuous current: 150 A (with notes on heat-sinking, copper weight, and parallel MOSFET layout)
• Load type: mixed (both resistive and inductive) in an industrial environment
Deliverables I expect
1. Clear, annotated schematic (PDF or KiCad/Altium) showing TL494, IR2110, power devices, current-sense, protection, and pot-controlled voltage divider.
2. Concise Bill of Materials with part numbers that are realistically and widely available.
3. PCB layout guidelines or a basic PCB file highlighting track widths, copper pours, and thermal vias necessary for 150 A operation.
4. Brief design notes: gate-drive timing, current limiting method, efficiency estimate, and suggestions for cooling and EMI control.
A simple, workable blueprint that lets me prototype quickly is all I need with simulation or firmware if possible. Please keep the design as compact and cost-effective as possible while meeting the current requirement.