Push-Pull Driver with Lossless Clamps

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  • Last Post 12 December 2020
Munny posted this 02 December 2020

Push-Pull Driver Powering SFT

Finally got this bugger designed, built and tested.

Been wanting a rock solid push-pull driver with integrated lossless clamps for over five years now.  I can say with confidence, "It has arrived."

 

My first test was to try it against Bill Alek's Split Flux Transformer (SFT) and it drives it just fine, only the SFT is not an AboveUnity device as far as I can tell.  But hey, the guy got a patent (US9620280B2) on it, so it must be wonderful to somebody.

 

Anyway, if someone out there is interested, I can send you all the DipTrace files or just the OSH Park board link and the bill of materials.  It's nothing all that fancy, but it does have a lot of best practices implemented in the design.  If you need something as a basis for any sort of power inverter, this will do the job.  And by the way, it's fully isolated so using it with oscilloscopes that have a common ground is not an issue.

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Munny posted this 02 December 2020

Here's a couple more images:

Push-Pull Driver Image #1

Push-Pull Driver Image #2

Munny posted this 10 December 2020

This board is based off the SG3525AN push-pull PWM chip which gives you analog control of frequency, duty cycle and dead-time.  Sync and oscillator pins have been brought out for more flexibility.  For drive boost and isolation it uses a pair of Infineon IceDrivers.  The final drive are not MOSFETs; instead there is a pair of UnitedSiC power JFETs which act like true high-speed bidirectional switches.  You can think of a JFET as a voltage controlled resistor, where current can flow through it in either direction.  They have no body diode like a MOSFET does.  Unlike a MOSFET, JFETs are normally-on devices and the gate has to be pushed negative roughly 15 volts to turn them off.  The IceDrivers coupled with a small three watt DC to DC converter makes this possible.

Also included on this board is a lossless clamp circuit preventing any inductive kick from destroying the JFETs.  Thanks goes to Verpies over at overunity.com for posting this:

Looking at just the lossless clamp portion, you have a relatively simple circuit, though genius in its function:

Which can be retrofitted to any push-pull drive device with or without some sort of clamping circuitry.  A common anode diode package such as this works nicely.

This board is designed for push-pull operation, but can also be used as a simple pulser as long as the duty cycle does not need to exceed 50%, which would prove very bad in actual push-pull configuration.

Here's a 20 second flyby of the board:

I haven't fully pushed the limits of this board, but so far everything I have done using my bench power supply as an input source has worked flawlessly with all the components running at ambient temperature.  I'm fairly certain one could run a 500 watt power inverter with no trouble at all.

Munny posted this 11 December 2020

And boy oh boy, it works better than I thought.  With no changes to the scope or the amperage and voltage probes, I get the following:

Input power:

 

Output power:

Just kidding.  It's not an AboveUnity device, but the numbers don't lie right?

Let this be a lesson as to why you trust your instincts and not your measuring equipment.

I will say with confidence, this board runs very efficiently; it just doesn't make something from nothing.

When you can clearly disconnect the power source and the device keeps running while holding amperage and voltage levels without any phase change, then you have something to write home about.  Until then, keep experimenting, learning and trying to understand how this universe is put together.

Vidura posted this 11 December 2020

Hello Munny, Nice device, if I may comment: RMS measurements are only valid for pure sine wave AC. For complex waveforms it should be average or mean power. Regards Vidura.

raivope posted this 11 December 2020

Hi,
I also own the Siglent scope and use it for power measurement. You must use mean(math) instead of rms(math) to have proper power. It is actually quite exact device provided that your probes are ok.

Raivo

Munny posted this 12 December 2020

Hi,
I also own the Siglent scope and use it for power measurement. You must use mean(math) instead of rms(math) to have proper power. It is actually quite exact device provided that your probes are ok.

Raivo

With different firmware, I have seen variations in these values, so I have been avoiding putting any trust in them.

From the above:

   IN:  12.87W

   OUT:  11.96W

Seems quite reasonable and believable.  I may begin to put a little more stock in those readings from here on out.  Thanks Raivo for the heads up.

Not real certain why I cannot get Cycle Mean to lock--may have to do some more fiddling with it.

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Chris posted this 12 December 2020

Hi Munny,

We have covered this in great detail in the Measurements Thread.

I believe it may be worth a very thorough read, as what you're posting, is very confusing for others that do not know better. I am not a fan of Confusion at all. I like things Clear and as Precise as possible.

Measurements are Extremely Easy if one is to follow the very basic Measurement Protocols We Here at Aboveunity.com have laid out.

Best Wishes,

   Chris

 

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Munny posted this 12 December 2020

There we go.

Input power:

 

Output power:

 

Cmean jumps about a little bit, probably within +/- 5%.  I would say with this technique, this scope and these probes, an output reading in excess of 15% of the input reading is something to take seriously.  Anything less and it's still in no-mans land.

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Munny posted this 12 December 2020

Hi Munny,

We have covered this in great detail in the Measurements Thread.

I believe it may be worth a very thorough read, as what you're posting, is very confusing for others that do not know better. I am not a fan of Confusion at all. I like things Clear and as Precise as possible.

Measurements are Extremely Easy if one is to follow the very basic Measurement Protocols We Here at Aboveunity.com have laid out.

There are two things important to me when taking measurements:

   1.  Never modify the test apparatus you are trying to measure.  In other words, no shunts for current measurement.  If you add a shunt, keep in mind this becomes a permanent part of your device.  I prefer using a current probe; mine happens to be fast enough that it is pretty unlikely my scope will see a current reading that is lagging the actual DUT, which would be an artificial phase delay.

   2.  Use a protocol such that you can measure input, then output without changing any variables.  This means do not alter the probe's calibration or the way you connect them.  Whatever error exists will exist for both measurements.  The two values you get will be relative to each other and nothing else.  Use this to make your comparison and decide what needs to be done next.

The protocol you use has to be sound for both input and output.  If you have DC input with some ripple or ramping and a pseudo square wave output, your choices become pretty limited.  From what I've seen so far, calculating instantaneous watts (V x A) using the math function of your scope is the most promising.  The next thing is defining a boundary such as a complete cycle to accumulate the data of interest.  We also have to look at polarity very carefully.  If you connect your current probe one way on the input and have it flipped on the output, you just broke rule number 2 and your power comparison is now bogus.  To fix this, you must properly define your signal and return.  If you got all this correct, only then can you look at the mean power over a complete cycle, which in most cases will give you a relative comparison of how your DUT is operating.  If you cannot define a complete cycle due to the DUT behaving chaotically, then you must average over a fairly long period of time and do it consistently on both input and output.  Consistency in how you acquire your two comparison values is the science and ensuring the protocol is valid for both samples is the method.

Jagau posted this 12 December 2020

hey Munny

For the first point, what Chris wanted to explain to you is that when you are not lucky enough to have a current probe, as you know they are very expensive and an approach with a shunt resistance of 0.01 ohm is justified. Unfortunately, we cannot all afford current probes which alone exceed the value of our oscilloscope, we manage with what we have in hand.


For the second point, it is of course certain that the skill of each one here can be different depending on the knowledge that one respects the protocols as much for the calibration as for the taking of measurements. We have to respect everyone's spirit here.

Just a precision, to have an average power you must take the column before mean, the Cmean that you have circled is for only one cycle, it is not the mean power.

Jagau

Munny posted this 12 December 2020

Just a precision, to have an average power you must take the column before mean, the Cmean that you have circled is for only one cycle, it is not the mean power.

It's my understanding, the reason one would "prefer" Cmean versus Mean is when there isn't an integer number of cycles presented on the oscilloscope's screen.  Averaging in a partial (non-complete) cycle will skew the value.  There is also the issue of how well your scope detects what an actual "cycle" is.  One can override the scope's determination of a "cycle" by capturing the data into a file and manually manipulating all the data points, setting a boundary for the start and end of one complete cycle.

The alternative is to have many cycles presented on the screen and use the Mean value instead.  Using this approach, the overwhelming number of samples will dwarf any small partial cycle.  The possible issue here is the number of samples gathered--the resolution.  Always keep in mind the images we see on the scope are actually just an array of data points linked together via graphics manipulation, either straight lines or curves.  Regardless, the data points are only an approximation of what the actual waveform looks like.  There could be all sorts of narrow spikes the scope does not detect due to its sampling resolution.

It's always good to have awareness about the tools we use.  Modern oscilloscopes do a pretty good job of giving us insights into the signals we create, but they are not perfect.  It would be nice if everyone had at their disposal a top-of-the-line Tektronix scope with high-end probes and calibration modules.  Unfortunately this is not the reality, so I do understand, we use what we have.

As for using shunts, it's not a matter of luck.  I saved my pennies for years to acquire a decent current probe.  I don't expect anyone else to do the same.  Just keep in mind when you use shunts, these components become a factor in their own right.  If you use a different shunt on the input then you use on the output, you break consistency.  If your scope does not have isolated grounds, you have to make absolutely certain the way you connect your probes does not introduce an artifact into your testing method.  If you use a large value shunt, you can change the behavior of your DUT considerably.  If you use a small value shunt, the voltage signal you measure across it can be right near the threshold of noise, rendering the values you obtain almost useless.  My point in saying this is:  It's always an engineering trade-off.  You get something, but lose something else.  You have to know what you can sacrifice and what you cannot.

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