Inspiration

While making a customized RGB LED set up at our home, basically it was a bunch of addressable 5v LEDs the WS2812, but unfortunately we didn't have a high current power source to light them up properly. Since there was a lot of them, it required around 9 Amps of current to lighten up at full brightness. This led us to design one Power Supply for this purpose, as well as the Gerbers are shared, so if one wants to make this power source they can do so easily.

What it does

It is a High Watt Power Supply Unit that converts 85V to 250V RMS AC to 5V DC rated at 60W which provides a current draw of 12 Amps, and that too in a small form factor, and isolated output with high efficiency.

How we built it

First, we tinkered with TI’s Webench Power Supply Design and found some really decent designs, as a perfect match for our requirements. After a while, by getting a balanced result from all ways, i.e a small size, high current draw (12A) ample to source our LEDs, high efficiency; we started making the schematic in EasyEDA. Next, we designed the PCB and rechecked every connection thoroughly for any disputes. Obviously, we don't want to get ourselves zapped.

Main Components Used

Bridge Rectifier

Coupled Transformer

CV CC UCC28740 flyback controller by TI

UCC24630 Synchronous Rectifier Controller by TI

Optocouplers

Power Mosfets

TL431 adjustable Zener

Schottky Diodes

Power Inductors

Complementary Passive components

Challenges we ran into

Orienting the PCB Layout was a bit challenging, Along with that routing and connecting the components was bit tricky.

Accomplishments that we're proud of

Making the PCB design and completing the project on time with video and presentation was our greatest achievement.

What we learned

It was a good experience, about learning about the fly-back controller, which not only provides isolation but also has great efficiency. How SMPS has been so efficient and small yet delivering such high power.

What's next for Zeus

Later this week we are thinking of fabricating this PCB along with component sourcing, to make it real.

Warning

This Circuit deals with AC mains (aka High Voltage that can kill you). Take High precautions before performing. You have been warned.