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Old 12-28-2009, 12:21 AM   #13 (permalink)
NiHaoMike
Master EcoModder
 
Join Date: Sep 2008
Location: Texas
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The DC/DC converter for my PC worked great. I have not started work on the booster since I don't have a use for it now.

I did do a lot of research for constructing power supply transformers. For low voltages, high currents, windings are often made from copper strips instead of wire. Copper tape is commonly available as copper flashing if you don't mind buying a bulk supply of it. High temperature insulation is commonly available in the form of oven bags. The form and core can be obtained from the main transformer in an old PC power supply. How to take it apart without breaking the core is a little tricky. I have had limited success putting the transformer on a stove and slowly ramping up the temperature until a gentle pry with a screwdriver gets it apart. I found out that my cousin disassembles electronic devices for a living (failure and design analysis), so I'm going to ask him for tips on disassembling a transformer.

Basically, rewind the transformer with a few turns of high current center tap winding in the center and continue that with lower current windings (about 3-4 times as many turns as the center winding) at the ends. The center connects to the input, the ends of the high current winding connect to the output rectifier, and the ends of the low current windings connect to two MOSFETs going to ground. The MOSFETs are driven alternatively in current mode like all push pull supplies.
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If America manages to eliminate obesity, we would save as much fuel as if every American were to stop driving for three days every year. To be slender like Tiffany Yep is to be a real hypermiler...

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