EEVblog #102 - DIY Constant Current Dummy Load for Power Supply and Battery Testing

EEVblog

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

Introduction to Electronic Loads

0:00 - 1 min, 0 sec

Dave Jones discusses the need for electronic loads in power supply testing and the basics of building one.

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

Building an Electronic Load

1:00 - 1 min, 5 sec

Dave constructs a simple electronic load using junk box components and explains the design choices.

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

Design Details of the Electronic Load

2:05 - 1 min, 53 sec

Dave elaborates on the electronic load design, including the MOSFET characteristics and the voltage follower circuit.

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

Fine-Tuning and Panel Meter Integration

3:58 - 1 min, 20 sec

Additional design aspects, such as fine-tuning and adding a panel meter to the load, are covered.

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

Heat Sink and Power Dissipation

5:18 - 1 min, 47 sec

Discussion on heat sink selection and power dissipation calculations for the electronic load.

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

Final Thoughts and Use Cases

7:05 - 1 min, 54 sec

Dave concludes with final thoughts on the electronic load's capabilities and potential applications.

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

Advanced Electronic Load with Microcontroller

8:59 - 8 min, 58 sec

Exploring how a microcontroller can extend the functionality of the electronic load.

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.