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View Full Version : Idea 1A or better switch-mode BEC with only 7 components!


KreAture
Apr 23, 2004, 07:30 AM
I finally got it to work, but ended up with something a bit different than the topic I started with. So I decided to repost it here with a better thread-name.

Basically it's a regulator using a LM circuit (linear regulator) as a stabelizer instead of as the actual regulator. It basically does the job of a zener voltage reference and error amplifier/fet-driving circuitry with feedback filter. In essence it thus reduces partscount to 7.

The schematic looks like this:
(see attached image)

Depending on if one needs more current, or low input voltage capability one can use a lov threashold FET or a high current capable bipolar transistor.

There are now two different layouts. One for non-passthrough and another for passthrough of the RXchannel. You'll see wich is wich.

The two green pads are for the coil wich is mounted on the back of the board.

Parts-list is as follows:

Part Value
C1 47u (30v capable)
C2 470u (minimum 5v capable)
D1 SM6T30A (30 V capable transient diode)
FET1 IRF7404 (0.7v threshold 20v capable. This limits max V-in to 20v.)
L1 Coil. Preferably toroid, atleast 5-600 uH, mounted on back of board.
R1 30 to 100 Ohm, 0805 size
REG LM340MP-5,0 (Or any pin-compatible 5v linear reg.)


I will be posting the PCB mask when I get home.

Some tests I've done with this setup include 750 mA continous load with both FET and bipolar transistor. The FET only resulted in 60-65% eff possibly due to the fact that it has max eff at a much higher current. (Only body-temp at 750 mA) The bipolar version achieved 73% eff at 750 mA and should be capable of 1 amp continous. For smaller planes the bipolar is thus best suited. For large planes, I'd reccommend using a FET.

Another side-note:
The Bipolar seems to keep the oscillations going at lower voltages while the FET stops. This can be very bad for flights... I suggest testing the BEC thouroughly to find what pont it will become unreliable with your parts. The oscillations dissappear when it reaches a too low input voltage. This is best checked with a scope, but I suppose one can measure the frequency over the coil with a DVM...

Trikky
Apr 23, 2004, 07:53 AM
looking good KreAture
I was just about to start work on something like this using a LM2576 but no need to now

Chris

KreAture
Apr 23, 2004, 02:34 PM
I chose the LM340M because of the small package it comes in. It has a bit high drop but it's current-rating becomes irrelevant with this switching circuit.

The SO8 size FET actually takes less space than it's DPAK and D2PAK counterparts and also has same height as the SO223 pack for the reg, allowing a shared heatsink more easily.

I'm still looking for a transient-diode that would be same height to complete the design though. It would allow a single plate-sink over the entire circuit.

KreAture
Apr 25, 2004, 11:52 AM
I had my first flights today with the KBEC !
No problems of any kind. Lovely flight. I played with my 1500 mAh 3s Kokam pack and brushless Axi motor for 36 minutes consisting of mostly takeoffs, low-passes, touch & go's and landings. Trying to nail the ultimate landing :)

simingx
Apr 26, 2004, 12:49 AM
Would this be able to handle 3A or so? I'm looking to replace a LM1084 regulator... :D
What's the dropout voltage for this circuit?

KreAture
Apr 26, 2004, 06:47 AM
With a bipolar transistor for switching it can go as low as 7.5v on 1 amp.
With a 0.7v threshold FET it can only go to approx 8.5v.

This circuit is made for those occations when a linear regulator becomes impractical. Such as 3 and 4-cell LiPo use.

KreAture
Apr 27, 2004, 10:54 AM
Here's the latest version... I decided the functionality was good enough to warrant a even better layout. I added a pin-header for the ESC and changed the placements a lot to allow both caps to be on one side together with all wire-exits.

http://www.unixcore.com/~kreature/images/kbec/kbec_2.3_01.gif

The scale on image is in mm, but can be translated to inches by dividing with 25.4 :p

KreAture
Apr 27, 2004, 05:11 PM
I made a bipolar version too as I wanted the best eff and lowest input voltage for my fest test version...

It works well :)
I have 74% eff at both a 240mA and a 700mA load :)

KreAture
Apr 27, 2004, 06:39 PM
Some images:

Electronics side...
http://www.unixcore.com/~kreature/images/kbec/kbec_2.3_02.jpg

And coil side...
http://www.unixcore.com/~kreature/images/kbec/kbec_2.3_03.jpg

The inductance of the coil adjusts switching frequency and should really be quite bulky... The circuit as shown on images with wires weigh 16g or 0.6 oz.

KreAture
Apr 29, 2004, 10:35 AM
I've flown the version 2.3 and am very happy with it ;)
I did have some glitching, but are not sure if this is caused by the BEC. Will look at supply line with a scope to see. It might be as simple as stuffing a larger output-cap on there.

On the development side I have one last feature I wish to add. A way for the BEC to sense that the ESC is turned on (supplying 5v via it's BEC) and thus turning itself on. This would allow the BEC to be used in a plane where only the ESC's on/off switch is accessible so that no plugging and unplugging of battery will be needed.

vintage1
Apr 30, 2004, 06:21 AM
People who leave batteries in planes that are only off as far as the receiver and servos are concerned end up with a high battery replacment bill. The average ESC draws a few mA even when the switch is off.

10 mA will drain a 4A/h pack in 400 hours. Just over two weeks.

I'll take my packs out if its all the same to you :D

KreAture
Apr 30, 2004, 07:43 AM
NO vintage1, I am not talking aobout storage...
I am talking about when you install battery, attach wing and are ready for some flying.

Flick the switch and it all comes to life...
Switch off and fix the control-surfaces or whatever, maby replace prop ? Then switch on again and fly more.

When your done, ofcource you disconnect battery.
I just want my BEC to be controlled by the switch in the ESC so that one doesn't have to fiddle with disconnecting battery every time one wants to disable the electronics in the plane for a brief period.