EEVblog #102 - DIY Constant Current Dummy Load for Power Supply and Battery Testing
EEVblog
19 min, 9 sec
Dave Jones from EEVblog demonstrates how to build and use a DIY electronic load for characterizing and testing power supplies.
Summary
- Dave Jones introduces the concept of an electronic load for testing the performance of DC to DC converters over the entire load range.
- He uses junk box components to build an adjustable constant current load and demonstrates its operation.
- The electronic load consists of an N-Channel MOSFET, an LM324 opamp, and a 10-turn potentiometer for fine current adjustment.
- A panel meter is included to display the set current without the need for an external multimeter.
- Dave provides an example calculation for heat sink thermal management when using the electronic load.
Chapter 1
Dave Jones discusses the need for electronic loads in power supply testing and the basics of building one.
- Dave Jones highlights the frequent need to design switch mode power supplies for projects.
- He emphasizes the importance of characterizing power supply performance across the load range.
- An electronic load is introduced as a tool to simulate different load conditions for testing.
Chapter 2
Dave constructs a simple electronic load using junk box components and explains the design choices.
- Dave decides to build an electronic load using available components such as an N-Channel MOSFET and an LM324 opamp.
- The load functions as a constant current sink with a 10-turn potentiometer for precise control.
- The design includes a panel meter for direct current readout, eliminating the need for an external multimeter.
Chapter 3
Dave elaborates on the electronic load design, including the MOSFET characteristics and the voltage follower circuit.
- Dave selects a logic level MOSFET (MTP 305) and uses an LM324 opamp as a series pass transistor in the design.
- The MOSFET's characteristic curve is examined to understand the voltages required for different load currents.
- Dave explains the use of a voltage follower opamp and voltage divider to manage the input voltage for the load.
Chapter 4
Additional design aspects, such as fine-tuning and adding a panel meter to the load, are covered.
- A 10-turn potentiometer allows for fine control of load current from 1mA to 1A.
- The panel meter is introduced, which can display the set current up to 2A, simplifying power supply testing.
- Precision resistors are used in the input of the panel meter for accurate current measurement.
Chapter 5
Discussion on heat sink selection and power dissipation calculations for the electronic load.
- Dave calculates the power dissipation in the heat sink based on the input voltage and the load current.
- He provides a real-world example to check the temperature rise of the heat sink using a temperature probe.
- The results confirm the back of the envelope calculations for heat sink performance.
Chapter 6
Dave concludes with final thoughts on the electronic load's capabilities and potential applications.
- The electronic load is capable of handling a range of currents, limited by the specifications of the MOSFET and heat sink.
- Dave demonstrates the load's performance by showing it can handle currents from 1.5mA to 1.35A.
- The versatility of the load is highlighted, showing its potential for creating efficiency graphs for power supplies.
Chapter 7
Exploring how a microcontroller can extend the functionality of the electronic load.
- Adding a microcontroller can turn the simple load into an intelligent system capable of various load simulations.
- The microcontroller enables constant current, constant power, constant resistance, and pulse load testing.
- Such an advanced system can be used to generate detailed performance graphs for batteries and other devices.