We have all experienced the situation where when we need to use an electronic device, we find that the battery of the device is dead. For many years, our portable electronic devices have been limited by battery life and size. As the cost of lithium-ion batteries continues to decline, as well as the increasing charge density, longer runtimes, more exciting electronic devices will emerge. As applications begin to move toward multi-cell battery packs, designers will face the problem of converting higher voltages into usable voltages for compact electronic circuits while overcoming battery voltage transients and changes.
Examples include drones, vacuum cleaner robots, power tools, and electric bicycles. Developers tend to use higher voltage battery packs to increase battery life between charges. Currently, the flight time of drones is limited to approximately 25 minutes, while the maximum mileage of electric bikes after a single charge can reach 50 miles. Battery life will increase with the use of smaller, higher voltage batteries.
A common feature of all of these applications is the motor, which can have detrimental transient effects on the supply voltage, such as motor kickback and inductor spikes that can be as high as twice the input voltage. If the input voltage rating is not set accordingly, these higher voltages can damage the system power solution, as well as other internal circuitry. If the motor suddenly stops or decelerates, a negative current is pumped into the power supply, causing the supply voltage to increase. In the figure below, channel 1 shows the supply current, channel 2 shows the supply voltage, and channel 3 shows the motor speed.
Figure 1: Power supply pumping due to motor deceleration.
When the motor decelerates, the power supply voltage drops significantly. If the battery's DC/DC converter is not rated to operate at a higher voltage, this will damage the system power solution and potentially damage downstream components.
When designing a system, choosing a DC/DC converter that supports a wide input voltage range minimizes the need for external transient protection circuitry. This not only simplifies the design, but also greatly reduces the solution size. Using a DC/DC converter, a system with a higher operating voltage can withstand the increase in supply voltage and maintain voltage regulation on the output. TI's LM5000 series devices are designed for input voltage ratings up to 42V/65V, making them ideal for handling transients in 12V/24V systems. For example, the LM5007 and LM25011 are well suited to protect systems from the short-term increase in supply voltage, a situation that often occurs in these systems. For higher voltage 24V/48V input buses, a 100V synchronous buck controller such as the LM5116 can handle the worst transient conditions in these systems. Controllers and converters with a wide input voltage range provide a great solution for high voltage battery pack applications and protect the system from transient effects to keep the device operating under these conditions.
A simplified block diagram of a battery pack power supply design is shown in FIG.
Figure 2: Block diagram of a high voltage battery pack.
When you're looking to create the latest, best portable or autonomous electronics, consider the worst-case transients that can occur and choose a wide VIN DC/DC device that protects downstream circuitry.
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