A minimalistic hi-efficiently regulated DC/DC Step-up Converter

using a single 555 timer as the controller.

The purpose of this reference design is to give us an inexpensive, easy to uild s!itching Step-
up regulator, ut !ith no compromises on po!er conversion efficiency. "ere is the proposed
reference schematic.
The 555 is connected in #$ulse $osition %odulation& topology, acting as the controller of the
Step-up modulator. 'n this topology the 555 is self-timed !hile in parallel modulates its output T
"
and T
(
times depending on the control voltage pin. The relatively high current output of the 555 can
easily directly drive the gate of a po!er mosfet !ith hi sle! rate. The operation voltage range of
555 is also ideal. Such a !ell-driven po!er mosfet is the ideal s!itch for a hi-efficiency s!itching
Step-up regulator. The Step-)p topology is something classic. 't *ust consists of the po!er mosfet, a
hi-current inductor, an Schott+y diode and some output capacitors.
,inally !e should generate a proper signal on the control voltage pin of the 555. ,or this
purpose the feedac+ circuit is used. 't consists of the minimum possile parts and it acts as a
regulated -through the variale resistor ./0A.1 output voltage limiter y giving a negative
feedac+ ac+ to the 555. 2es a single nmos is enough to do the *o as the #control voltage pin& is
internally connected to a resistor net that drives this pin to 3/40CC. So the voltage on that pin !ith
the nmos feedac+ goes from 5 to 3/40CC. 6iven the values on resistors .A, .7, that actually
ma+es the output of the 555 to s!eep from 58 duty circle to 9::.;8. That is a safe maximum duty
circle for the setp-up converter. Someone could possile increase it y incising the value of the .A
resistor. That !ay you !ill get more output po!er, ut caution is advised.
List of materials:
1x Timer 555
1x IRF540*
1x BS170
1x 1n5822*
1x Hi-current inductor ~100uH
1x Elec !"# 1000u$1%&
1x Elec !"# 470u$50&
1x !er !"# 1u
1x !er !"# 10#
2x Re'i'tor 1(
1x Re'i'tor 10(
1x Re'i'tor 2(**
1x &"r")le Re' **(**
* B"'ic"ll+ " l"r,e li't o- "ltern"ti.e' c"n )e u'ed /ere
0de#endin, on t/e "##lic"tion1
** T/e'e ."lue' '/ould )e "ltered de#endin, on t/e m"ximum "nd
minimum de'ired out#ut .olt",e'
The implemented reference design.
Specs of the proposed reference design<
'nput voltage range< 5-=50
%aximum output regulated voltage< >50
%aximum output po!er< =5?att
%aximum oscillator fre@uency< ;5-A5+hB -depending on 0in1
Cfficiency A5-D58 -tested over a !ide range of scenarios1
Static consumption< 35ma -at =30 0in E 95.4?1
Futput noise -ripple1< G=55m0 -at =55ma load1
Output of the 555/ Mosfet Gate
Ripple on the Output (~105ma load)
.
$erformance analysis / $ossile modifications.
This circuit actually performed etter than ' expected. 't has over A58 efficiency even under
strange scenarios -such as 0inH5v 0outH3501. The circuit also remained cool even at the maximum
output -=5?1. Asolutely no cooler is needed for the %osfet. The only component that some!hat
got !arm !as the inductor -so most of the lost energy !as there1. ?ell, the only inductor ' had
availale !as one #stolen& from a ATI po!er supply. 't had 95.Dmm diameter !iring. This fact
cost me a little.
'n general y using a etter inductor -thic+er !iring / more Amps1, increasing the value of .
A
resistor and output capacitor, plus charging the =n5A33 Schott+y diode !ith something more hard
duty li+e %7.=5>5CT, more output po!er can e archived !ith etter efficiency and ripple. Fn
the other hand, if someone needs more maximum output voltage -more than >501 then he should
change the Schott+y diode !ith a regular one -ect =n5>II1 and possily for real high voltages even
change the mosfet. %aximum output voltages of A50J are achievale for lo! currents even at lo!
0in.
The only real dra!ac+ ' found on this circuit during the test !as the staility of the Futput
0oltage proportional to the 0in value and the Futput current. ,or 0in form 5 to =5 it shifted aout
=0 up. Same thing happened !ith a variation to the load from =5ma to 355ma at 350out. ?ell for
many applications 0in and 'out !ill not shift that much, so that could proaly e earale. 'f that
is not the case, then maye a more sophisticated/strong feedac+ or a etter inductor ect could
decrease the prolem.
.eal life / practical use scenarios of reference design<
Driving your regular =30 $C fans from 50 using the Step-up regulation to drive
them from 50 to =:0 -overvoltage1
http<//!!!.youtue.com/!atchKvHLov+?,67gsA
Driving a hard duty server fan ->A01 from the =30 of your $C -!ith fan speed
control1.
http<//!!!.youtue.com/!atchKvH6g@fL%TD:gC
Contact info:
Lostas 6alanopoulos
$hd. Candidate at Mational Technical )niversity of Athens.
Cmail< gus/galanopoulosNhotmail.com