hyperboost preview

[georges80]

I've been working on a new high voltage current regulated boost converter and finally got time to assemble a prototype yesterday. More work to do to decide on dimming/pwm input control, but the basic driver is performing well with the multiturn trimpot.

The hyperboost can run from a nominal 6V to 50V input. Output voltage is up to 70V and open circuit protected (maxes out to 70V).

Board diameter is 1.4" with components only on the top side. Heatsink attachment is the same well proven scheme as for hipCC and hipFlex, a piece of thermal pad material. Running at >60W input, and 28C ambient the hottest area on the driver (via IR thermal gun) was 50C. So the driver is very temperature stable with the thermal path I've provided. The poor LEDs though were getting sizzling hot...

I've set max output current to 1.3A and as implemented is dimmable via a trimpot (much like CCHIPO). I plan to provide a PWM input so it can work with d2Flex. I "may" also do a Flex version - but that will come later if I decide there's a market for it.

Efficiency is around 88 - 92% for the tests I performed.

Here's a picture of the prototype driver:

Some efficiency readings here:

It was amusing to set up a load. I had 7 series connected Luxeon3's, a K2, an old Lamina white array and Lamina Red array and some other Red array. All that to get around 50Volts worth of Vf to test with. I had to cover the LEDs to stop from getting blinded by all the light

cheers,
george.

 

[marcopolo]

Perfect for large strings of power LED's in the home. Or light up your bicycle like a Christmas tree!!

16up XP-G for downhillers/trail riders? (Troutie/Znomit/Piesoup or any other hardcore builders!)

LOADS of possibilites with this! Flex it!

Marco

 

[trout]

Sounds like a beast but a likeable beast . seconded on the Hyperflex suggestion.

Will it be able to handle the messy electric from a car of motorbike

 

[georges80]

Sounds like a beast but a likeable beast . seconded on the Hyperflex suggestion.

Will it be able to handle the messy electric from a car of motorbike

Should be able to since it can handle up to 50V input... I need to add in polarity protection still.

If I "flexed" it then I'd have to look at some high voltage regulator for the uController and also add it power control circuitry for 'sleeping' the switcher core. Anyhow, it's something I'll think about and research.

I'll focus on the 'dumb' version first and get that into production. What I learn from the dumb version I'll roll into the flex version later.

cheers,
george.

 

[dom]

Looks great George
What market are you targeting for these?
Or where do you think they'd work best?

Would have been great when i had my 48V e-bike!

Cheers
Dom

 

[StevelKnievel]

This is great George! I've been wanting a big boost driver (but not CCHIPO big) for some automotive and motorcycle projects that have been on the back burner.

Cheers!

 

[piesoup]

Perfect for large strings of power LED's in the home. Or light up your bicycle like a Christmas tree!!

16up XP-G for downhillers/trail riders? (Troutie/Znomit/Piesoup or any other hardcore builders!)

LOADS of possibilites with this! Flex it!

Marco

This is what I need for my 24x XP-G Firestarter! Gonna ask for a beta one to try out.
Also keen to see a hyperFlex in the future

 

[georges80]

Well, I ordered production boards yesterday, so in about 2 - 3 weeks I should have some hyperboost drivers available for sale.

I've added polarity protection to the design and in doing so found a nice schottky diode that I'll use also for the boost converter section. That will allow me to raise the max output voltage (open circuit protected) to 80V.

cheers,
george.

 

[herulach]

George, is this suitable for use as a boost driver for more modest output voltages (I'm thinking 4 LEDs)? The design makes it much easier to heatsink than Maxflex.

If it isn't is there a chance of a maxflex/fatman with a similar form factor?

 

[georges80]

George, is this suitable for use as a boost driver for more modest output voltages (I'm thinking 4 LEDs)? The design makes it much easier to heatsink than Maxflex.

If it isn't is there a chance of a maxflex/fatman with a similar form factor?

It can run from a minimum of 7V. So, yes, it could boost to just 4 LEDs. Basically it's a boost converter that can run from 7V to 50V and boost up to 80V (input voltage < output voltage, i.e. typical boost converter limitation).

It is intended to replace CCHIPO - since it is much smaller, but can obviously be used in place of Fatman (note again the 7V min input voltage).

Regarding a flex version, that will have to wait. Getting hyperboost into production and shipping is my first priority and feedback from its use will then allow me to put the appropriate hardware features into the hyperflex version. The main issue is that the hyperflex would be a relatively large board to deal with the additional uController circuitry. I'm guessing 1.8" diameter would be likely (keeping it single sided again) - so it needs to be seen if such a large board makes sense - and that's something you folk can provide opinions/thoughts on...

cheers,
george.

 

[Wok]

Hi George,

? Is it open-cit safe? [output i.e]

eng hoe

 

[georges80]

Hi George,

? Is it open-cit safe? [output i.e]

eng hoe

You did read the 1st post right? - all of it ??? Short answer, yes

cheers,
george.

 

[herulach]

It can run from a minimum of 7V. So, yes, it could boost to just 4 LEDs. Basically it's a boost converter that can run from 7V to 50V and boost up to 80V (input voltage < output voltage, i.e. typical boost converter limitation).

It is intended to replace CCHIPO - since it is much smaller, but can obviously be used in place of Fatman (note again the 7V min input voltage).

Regarding a flex version, that will have to wait. Getting hyperboost into production and shipping is my first priority and feedback from its use will then allow me to put the appropriate hardware features into the hyperflex version. The main issue is that the hyperflex would be a relatively large board to deal with the additional uController circuitry. I'm guessing 1.8" diameter would be likely (keeping it single sided again) - so it needs to be seen if such a large board makes sense - and that's something you folk can provide opinions/thoughts on...

cheers,
george.

Thanks for that george, MCE from 3 LiOn cells is what I'm envisaging. Is the production board 1.4" or the prototype? If it could get down to maybe 1.2 it would probably fit nicely into even an mr11 housing.

 

[georges80]

Thanks for that george, MCE from 3 LiOn cells is what I'm envisaging. Is the production board 1.4" or the prototype? If it could get down to maybe 1.2 it would probably fit nicely into even an mr11 housing.

1.4" is the prototype size and the production boards will be the same. There's no room to shrink it down less than that, especially with the added polarity protection - the new schottky diodes are relatively large. Remember, we are talking about a driver than can handle >60W

cheers,
george.

 

[georges80]

First production boards are nearly ready to ship. Here's a top & bottom view of a production board that will be under going testing over the next few days.

cheers,
george.

 

[wquiles]

First production boards are nearly ready to ship. Here's a top & bottom view of a production board that will be under going testing over the next few days.

(snip pics)

cheers,
george.

Nice looking George

Will

 

[georges80]

Been doing some testing and the results look good. I'm finalizing the resistance value table to allow users to just measure the trimpot resistance and they adjust it (with no power applied) to see their target current.

I've tested 4 boards and the resistance table is consistent within a couple of percent so I'm very happy.

I'll be updating my website later today with resistance values and be releasing the driver for sale tomorrow.

Hope some of you crazy "MORE LIGHT" folk will find some good uses for this driver

cheers,
george.

 

[cytoe]

George, when's the HyperFlex coming out? Could the uController stuff go on another board?

 

[fyrstormer]

Please tell me the PWM will be smoothed out with a capacitor. The last thing I need is blinky headlights as cars go over bumps trying to give me seizures. I get bad enough headaches from the stupid blue HID lights everybody under 18 puts in their cars nowadays.

 

[georges80]

Please tell me the PWM will be smoothed out with a capacitor. The last thing I need is blinky headlights as cars go over bumps trying to give me seizures. I get bad enough headaches from the stupid blue HID lights everybody under 18 puts in their cars nowadays.

PWM?? This is a fully current regulated boost driver, it is not a PWM driver. There is no "flicker"...

cheers,
george.