24V input, 48V output, 2000W DC-DC Converter design

Designing a 24V input, 48V output, 2000W power supply is crucial for maintaining stable operation and prolonging the lifespan of electronic equipment. This article will outline the power supply design and highlight the selected components.

1. Power Supply Design: The power supply is intended to deliver stable power to a high-power device. It operates with a 24V input voltage and provides a 48V output voltage while supporting a maximum power output of 2000W. To ensure high efficiency and reliability, the following design considerations have been incorporated:
2. Program Overview: (1) Dual-Channel PWM Control: Utilizing dual-channel PWM control technology enhances the power supply’s efficiency by regulating the switching frequency and duty cycle of the power stage.

(2) Capacitive Filtering and Voltage Stabilization: Capacitive filtering and voltage stabilization modules are integrated into the design. These components effectively reduce noise and fluctuations in the output voltage, ensuring stability.

(3) High-Efficiency Components: High-efficiency inductors and switching tubes have been carefully selected to minimize power loss and heat generation. These components contribute to overall efficiency improvement.

By implementing these design principles, an efficient and reliable power supply solution can be achieved for the specified 24V input, 48V output, and 2000W power requirements.

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Specific Implementation Plan: The implementation plan for designing a 24V input, 48V output, 2000W power supply includes the following key components and techniques:

1. Dual-channel PWM Control Technology: To achieve high efficiency, a dual-channel PWM control technology is employed. This technique converts the input voltage into high-frequency pulse signals. Two independent PWM controllers generate separate high-frequency pulse signals that amplify the current through switch tubes. This design enhances efficiency and stability while reducing size and weight.
2. Capacitor Filter and Voltage Regulator Module: A capacitor filter and voltage regulator module are utilized to ensure stable output voltage. Four capacitors are employed for low-pass filtering, effectively eliminating high-frequency noise and ripple. Additionally, an LM7812 voltage regulator module is employed to achieve precise voltage regulation, ensuring output voltage stability.
3. High-efficiency Inductors and Switches: To reduce power loss and heat generation, high-efficiency inductors and switches are incorporated into the power supply design. Ferrite core inductors with higher magnetic flux density are chosen to minimize leakage loss. Furthermore, IGBT switches with lower on-resistance and higher open-loop frequency are selected to decrease switching losses and elevate overall work efficiency.

By implementing these specific design elements, the power supply can efficiently provide stable power support, meeting the requirements of a 24V input, 48V output, and 2000W power output.

Specific Component Models: To ensure high efficiency and reliability, carefully selecting suitable component models is essential. Here are the specific models of the selected components:

1. Input Filter Capacitor: Utilize a polyester film capacitor with a recommended model of 47uF/50V.
2. Output Filter Capacitor: Choose a solid capacitor with a recommended model of 1000uF/48V to ensure effective filtering.
3. PWM Controller Chip: Implement TI’s TPS61082-Q2 PWM controller chip for efficient power supply control.
4. Switch Tube: Incorporate ABB company’s IRM630N40N MOSFET switch tube known for its reliable performance.
5. Inductor: Select a ferrite core inductor with a recommended model of 2A/H and a 40mm diameter to reduce losses and enhance efficiency.
6. Voltage Stabilizing Module: Implement an LM7812 voltage stabilizing module to achieve precise voltage regulation.

By utilizing these specific component models, the designed power supply will have enhanced efficiency, stability, and reliability, meeting the specified requirements effectively.