Designing a Switched Mode Regulator for 48V 40A Battery ROV Applications

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#1 21670162 20 Oct 2013 18:10

Amr Awny Amr Awny

Anonymous

Post #1
21670162 20 Oct 2013 18:10

I would like to design a switched mode regulator (48 volt 40 amp battery) for my rov but i don't know how to do it or how it look like if i purchase it
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#2 21670163 20 Oct 2013 20:01

Mark Harrington Mark Harrington

Anonymous

Post #2
21670163 20 Oct 2013 20:01

48 volts for a rov ?? What exactly is a Rov ?? do you mean Rover as in the vehicle ?
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#3 21670164 21 Oct 2013 17:30

Amr Awny Amr Awny

Anonymous

Post #3
21670164 21 Oct 2013 17:30

remotely operated under water vehicle ,, the competition oblige us to use a 48 volt battery 40 amp , and I am using motors which use about 25 amp
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#4 21670165 21 Oct 2013 18:36

Cody Gass Cody Gass

Anonymous

Post #4
21670165 21 Oct 2013 18:36

If you're using a battery, why do you need a regulator? Are you trying to change the output voltage to something other than 48V?
#5 21670166 22 Oct 2013 16:23

Amr Awny Amr Awny

Anonymous

Post #5
21670166 22 Oct 2013 16:23

the bilge pump operates @ 10 volts and 2 of them are working @ the same time
#6 21670167 22 Oct 2013 22:08

Mark Harrington Mark Harrington

Anonymous

Post #6
21670167 22 Oct 2013 22:08

So you looking at 50 amps combined total from the Battery if you have both motors going Thats a lot of current out of the battery Whats the amp hour on the Battery if you dont me asking
#7 21670168 23 Oct 2013 08:52

DAVID CUTHBERT DAVID CUTHBERT

Anonymous

Post #7
21670168 23 Oct 2013 08:52

Amr,

I recommend an off-the-shelf power supply. The reason is that a 2000 watt switching power supply is a major project and if you're like some of us you will go through a long and expensive learning process. And as reliability is probably paramount to your ROV, you don't want it failing.

If I understand, the input voltage is 48 volts. What voltage or voltages does the switching power supply need to deliver?
#8 21670169 23 Oct 2013 11:15

Cody Gass Cody Gass

Anonymous

Post #8
21670169 23 Oct 2013 11:15

So a 10 volt 50 amp SMPS? That's a pretty hefty project. I'd look into buying one. Building your first SMPS is tough and expensive. Building your first SMPS with it being capable of delivering 500+W and 10A is even tougher and more expensive.
#9 21670170 23 Oct 2013 12:48

Mark Harrington Mark Harrington

Anonymous

Post #9
21670170 23 Oct 2013 12:48

Id use nucluer power ( Only In marine subs I didnt say use as an energy souce on land did I , justin case lol ) If i was you

I can see you batteries going flat at about 300 below see level after about half an hour either that or once you open the ballast tanks you wont have enough air to blow them out to get to the surface again with that sort of current drain
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#10 21670171 20 Nov 2013 18:45

Amr Awny Amr Awny

Anonymous

Post #10
21670171 20 Nov 2013 18:45

I need to regulate the 48 input voltage to 12 output voltage plus , i want the motors will get 12 amp
#11 21670172 20 Nov 2013 20:12

DAVID CUTHBERT DAVID CUTHBERT

Anonymous

Post #11
21670172 20 Nov 2013 20:12

The Linear Technology LTM8027 uModule regulator operates to 60 volts and outputs 4 amps. These devices can be paralleled to supply the 12 amp motors.

To account for differences output voltage tolerance a series resistor of perhaps 0.1 ohms is placed in series with each regulator. This should be optimized using LTSpice at which time the number of devices can be determined to provide >12 amps under worse-case conditions.
#12 21670173 21 Nov 2013 07:17

DAVID CUTHBERT DAVID CUTHBERT

Anonymous

Post #12
21670173 21 Nov 2013 07:17

I think you would do best (save time and a steep learning curve) by going with an off-the-shelf solution. One solution I've used is the Vicor Maxi, Mini, Micro series of DC-DC converters.

For your 48-12 volt, 12 amp requirement the Vicor V48B12C250B will do the job. It will supply 12 volts at 21 amps and is $168 USD.

http://www.vicorpower.com/home/products.html?productType=cfg&productKey=V48B12C250B

To reduce EMI on the 48 volt bus a Vicor FIAM filter can be used.

http://www.vicorpower.com/documents/datasheets/ds_fiam.pdf
#13 21670174 06 Feb 2014 02:40

Garth Wilson Garth Wilson

Anonymous

Post #13
21670174 06 Feb 2014 02:40

I agree with the off-the-shelf path. SMPS design and construction is not for beginners. Even though the switching frequency may not seem that high, the di/dt's are astronomical, and good PCB layout and overall construction is imperative if you want decent behavior out of it.
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Topic summary

The discussion focuses on designing a switched mode power supply (SMPS) to regulate a 48V battery source for a remotely operated underwater vehicle (ROV) application, specifically stepping down to 12V at 12A to power motors and bilge pumps. The original poster needs a regulator to convert 48V input to 12V output with sufficient current capacity. Several contributors recommend using off-the-shelf DC-DC converters due to the complexity, cost, and reliability challenges of designing a high-current (up to 40A) SMPS from scratch. Suggested solutions include paralleling multiple Linear Technology LTM8027 uModule regulators (each rated for 60V input and 4A output) with series resistors to share load current, and using Vicor Maxi, Mini, or Micro series DC-DC converters, specifically the Vicor V48B12C250B model, which provides 12V at 21A output and includes options for EMI filtering with Vicor FIAM filters. The importance of proper PCB layout and design to handle high di/dt and EMI in SMPS is emphasized. Battery capacity and current draw considerations for underwater operation are also noted.
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Designing a Switched Mode Regulator for 48V 40A Battery ROV Applications

Designing a Switched Mode Regulator for 48V 40A Battery ROV Applications

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