Stepup/stepdown regulator module (now generator)

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#1
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I'm in the middle of trying to fix up someone else problem. frown

 

I need a small regulator module with (was 1.5V) 3-5V minimum to 12V (or higher) input and a fixed 5V@ ~1A out.

 

Pololu has a few of them and I can get them from a local distributor but if anyone has any other ones, preferably available in Australia, it would be handy. Oh they have to be small.

 

It's job is to regulate the output of a small, custom made, wind turbine generator.

 

Doing more test tomorrow but that's the rough figures I could get from some early tests.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

Last Edited: Fri. Jul 7, 2017 - 04:35 AM
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js wrote:
regulate the output of a small, custom made, wind turbine generator

then you probably want something with Maximum Power Point Tracking (MPPT) ...

 

 

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Wind turbines need a constant load in order to not over rev in windy conditions, your regulator will need to dump excess power, usually in to a resistor (heater) bank of some sort. 

 

Jim

 

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Guys let's not complicate this wink, as you can see from the regulator specs it's only5W. There is a constant 5W load on the regulator. That's it.

 

I believe there is a mechanical speed regulator to the generator for maximum speed but I need to make sure of this possibly today.

 

We are not building a power station.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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That low end voltage is a killer.  Most can go down to about three volts to be able to get 5V/1A out.

 

Tough spec.  Is this a replacement, or a new design?

 

JIm

If you want a career with a known path - become an undertaker. Dead people don't sue! - Kartman

Please Read: Code-of-Conduct

Atmel Studio6.2/AS7, DipTrace, Quartus, MPLAB user

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Pololu has 0ne that goes down to 1.5V but I can see a lot of them at around 2.7V-3V in and up to 30V in max, one of those may do.

 

This is for something that 2 other people have had a go at fixing, maybe 3rd time lucky?

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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cheeky

You could always build a Joule Thief that starts at 35millivolts...

 

Ross McKenzie ValuSoft Melbourne Australia

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Yeah but I need about 5W (happy with 2.5W) and following tests I'm not getting anything near that from the generator. crying

 

I only get about 1.9W (7.9V into 33R) at 850 RPM (gale force wind??), at "low speed" of about 150RPM I only get 35mW.

 

In other words the regulator would be useless here, back to the drawing board!

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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So is this some kind of wind powered battery charger (5v 1A)  for a phone project? 

 

 

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Maybe... or maybe he is putting in an alternative bid to Elon Musk's...

 

http://www.abc.net.au/lateline/c...

 

Read the whole page to understand the issue.

 

Ross McKenzie ValuSoft Melbourne Australia

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js wrote:
at "low speed" of about 150RPM I only get 35mW.

Missouri Wind and Solar

7 Magnet Permanent Magnet Alternator for Wind Turbines

http://mwands.com/store/wind-turbine-products/wind-turbine-motor/7-magnet-permanent-magnet-alternator

...

  • Reaches over 12 Volts below 150 RPM
  • Good for 24 and 12 Volt battery Charging
  • Bi-Rotational - Will Produce Power in Both Directions
  • ...
  • Ideal For Low Wind Start-up
  • ...

Couldn't locate its current.

 

"Dare to be naïve." - Buckminster Fuller

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Thanks for the good read.

From the URL in your post :

Lateline - 14/03/2017: SA government unveils $500 million energy plan

by John Stewart

http://www.abc.net.au/lateline/content/2016/s4636135.htm

...

JAY WEATHERILL, SOUTH AUSTRALIAN PREMIER: Fundamentally here we've got market failure. The private sector is either not investing in new generation or not investing in maintaing existing generation. That's why governments need to step up.

...

ACTOR 2: (Reads Tweet) "Tesla will get the system installed and working 100 days from contract signature or it is free. That serious enough for you?"

...

A part of the private sector is the consumer who is sinking the current and sourcing the currency (a different form of current)

That's starting to flip here with consumers sourcing the current and sinking the currency cheeky

One very recent PV installation in the neighborhood with more nearby.

Some consumers are investing even with disincentives (removal of tax reductions for renewable energy)

The consumer's pressure is not yet great in Texas due to the large amount of natural gas infrastructure and methane-powered electricity generators.

There's greater consumer pressure in southern California :

TreeHugger

Tesla kills the duck with big batteries

by Lloyd Alter

January 31, 2017

http://www.treehugger.com/energy-policy/tesla-kills-duck-big-batteries.html

Tesla Motors, Southern California, battery stacks

...

What is really astonishing is that in just three months, Tesla has delivered a giant battery farm with 396 stacks of batteries that can provide enough electricity to power 15,000 houses for four hours, about how long it takes to shave the peaks, to kill the duck.

...

“There were teams working out there 24 hours a day, living in construction trailers and doing the commissioning work at two in the morning,” J.B. Straubel (Tesla Motors CTO) said. “It feels like the kind of pace that we need to change the world.”

...

 

"Dare to be naïve." - Buckminster Fuller

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is this some kind of wind powered battery charger

 No, "public art" project with lots of LEDs hanging on the generator.

Couldn't locate its current.

Or it's dimensions....

 

 

There is a lot of machined stainless steel where things are mounted and it will not fit.

 

So I'm pretty much stuck with what's there and need to fix somehow or it will cost a fortune to redo.

 

And why do they all insist on using DELTA wiring of the coils? That takes 6 diodes instead of 3 in the rectifier, in my case I could have gained 0.7V by having a STAR topology.

But what do I know?

 

The original design, from what I understand, has a geared DC motor as the generator, but because of the gearing the blades did not turn or did extremely slowly.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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Can you hide some distributed solar panels in the structure to feed a 6V @ ~15Ah battery ?
Some solar panels are mounted on semi-flexable substrates.

Last Edited: Wed. Mar 15, 2017 - 10:09 PM
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I have room for a skeleton of a new born mouse. sad

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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A pair of wires, leading to an more-accessible and spacious location, where a 5V supply is hidden ?

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Remember this is a wind turbine that spins around with the direction of the wind, maybe 3m high.

 

Also it is an ART form, one messes with artist and their art at their own peril. surprise

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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defn: Art: A disconnect from the real world

Ross McKenzie ValuSoft Melbourne Australia

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Slip-rings ? (with DC filtering on the consuming side).
Depending on how the rotating structure is supported you might be able to hide the slip-ring(s) inside the support.

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Isn't there a problem that the low-voltage condition is also a low-current condition?  To keep constant power out, the current available at the input would have to go up (or at least stay the same) for the low-voltage case...

 

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The MoWind device is the size of an auto alternator, as that is the basis from which it is built.

 

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js wrote:
Also it is an ART form, one messes with artist and their art at their own peril. surprise
Instead of messing with an artist's art consider attempting to entrain the artist's thought with your thought (art and physics)

Downsize (1KW at 36km/hr) the following from ones in Iceland :

IceWind

Wind Power

http://icewind.is/en/wind-power/

...

(mid-page)

IceWind CW – For residential applications

...

 

"Dare to be naïve." - Buckminster Fuller

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The MoWind device is the size of an auto alternator,

And I have a 20mm thick space to fit it. wink

 

Also remember that this thing is already built and installed for several months, just not working, that's why they call me, and me name aint even MacGyver.

And I also need 5W max.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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js wrote:
this thing is already built and installed for several months, just not working

 

Reminds me of the Tin Man from the Wiz of Oz, perhaps it just needs some oil.

 

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Back to this again....

 

Anyone used either one of these? They are either based on the XL6009 or LM2577 but they seem to be lying on the specs. I guess they are cheap enough to get one in and try for myself.

 

http://www.ebay.com.au/itm/DC-DC...

 

http://www.ebay.com.au/itm/Boost...

 

this one from Pololu seems a bit more believable somehow https://www.pololu.com/product/2574

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

Last Edited: Sat. Jun 24, 2017 - 11:59 PM
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TI says minimum of 3.5V input for the LM2577 and the XL6009's maker says 5 volts. Pololu say 2.9 volts. No one near your original 1.5 volts. Did this same artist also conceptualise the sky hook but fail to find a maker with the lighter than air hook?

Ross McKenzie ValuSoft Melbourne Australia

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Edited the original Vin in OP.

 

Well I now have a new generator prototype and I'm expecting around 6Vdc at 50rpm so the 3-5V in minimum should be ok. I will do final tests on Thursday before getting the coil's PCB done.

 

Don't know who to believe surprise Pololu seems to be using the TPS55340 from TI but if I enter any parameters (as they show on their charts) in webench is has a heart attack and it says that the design cannot be made with that chip! Maybe webench has been designed by the same people that made this forum? devil

 

I would be very happy to get the 5V out at even 700mA rather than the 1.2A with 3.3V in. (or the 2A with 5V or more in)

 

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

Last Edited: Sun. Jun 25, 2017 - 01:11 AM
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Maybe it's a case of webench not knowing about the TPS55340 chip yet?? It comes up with a few alternatives but using LMxxx type regulators.

 

I learned a new type of regulator type, uncoupled inductors SEPIC! That would be the type the eBay boards (LM2577 or XL6009) use as they have 2 inductors.

 

That makes me feel a bit more comfortable with the eBay boards.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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I use the one with the LM2596 and it performs as the Datasheet for it says.  Cheaper than the unit you call out as well.

 

Jim

If you want a career with a known path - become an undertaker. Dead people don't sue! - Kartman

Please Read: Code-of-Conduct

Atmel Studio6.2/AS7, DipTrace, Quartus, MPLAB user

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I use the one with the LM2596

Link please. I think you posted it a while ago in another thread but can't remember.

 

The LM2596 seems to be a buck only version rather than a buck/boost type.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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There is a link to the one I use in your first link.  But yes you are correct that it is a step down regulator.

 

http://www.ebay.com.au/itm/HOT-P...

 

JIm

If you want a career with a known path - become an undertaker. Dead people don't sue! - Kartman

Please Read: Code-of-Conduct

Atmel Studio6.2/AS7, DipTrace, Quartus, MPLAB user

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Getting a Pololu S18V20F5 as I'm be able to get it "locally" (From Perth surprise) and in stock, should be here tomorrow. This unit seems just right if it works as advertised.

John Samperi

Ampertronics Pty. Ltd.

www.ampertronics.com.au

* Electronic Design * Custom Products * Contract Assembly

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Well I now have a new generator prototype

And for the curios this is what the stator looks like, the diodes at the back are not fully soldered as I'm expecting the correct ones on Tuesday.

The coils are just glued on for the initial tests, then they will be epoxy-ed in place. The PCB will be mounted on a support disk (some form of plastic).