From: "Saved by Internet Explorer 11" Subject: New Page 1 Date: Mon, 20 Jan 2014 09:48:18 -0800 MIME-Version: 1.0 Content-Type: multipart/related; type="text/html"; boundary="----=_NextPart_000_0000_01CF15C4.BF0E9150" X-MimeOLE: Produced By Microsoft MimeOLE V6.1.7601.17609 This is a multi-part message in MIME format. ------=_NextPart_000_0000_01CF15C4.BF0E9150 Content-Type: text/html; charset="Windows-1252" Content-Transfer-Encoding: quoted-printable Content-Location: file://C:\Users\R&D 1\Documents\Research\Power Amplifiers\Class D Design Info\New Page 1.htm New Page 1=20 =20 =20 =20 =20 =20 =20 =20 =20

=20 =20 =20

Do = It Yourself=20 Car Amplifier

This = article is for=20 those who wants to make their own car amplifier. The basics of = calculation will=20 be discussed below. If you have understand it you will be able to make = car=20 amplifier yourself.

THE DESIGN OF = CAR POWER=20 AMPLIFIER

There=20 are many designs of good amplifier published, =20 solid state (SS) or tube designs. But few have written the design of = car power=20 amplifier

Actually=20 the difficulty of designing the car power amplifier does not lies with = the=20 audio power amplifier, but it is more to providing the switching power = supply.=20

As=20 we knows, the output power of any audio power amplifier is approached = by=20 formula :

P = =3D Vpp²/(8*Rl)

where=20 Vpp=3D peak to peak supply voltage, Rl is the speaker impedance load. = For car=20 voltage of 12Vdc, if we connect it to 4 Ohm speakers we will only have = power of=20 144/32 =3D 4,5 Watt. Bridging the amplifier will double the power, but = will never=20 be more than 40 W.

If=20 we want to make more powerful amplifier, lets say 170 watt at 4 ohm = speaker=20 load, we will need supply voltage of 74Vpp, or +/- 37 Vdc. The way to = have this=20 voltage from car supply of 12VDC is to make DC-DC=20 converter.

In=20 this article, I will discussed the car power amplifier in 3 steps = : =

1. =20 The design of audio power amplifier

2. =20 The design of DC-DC converter

3. Miscellenous =20 tips for making car power amplifier.

1. THE=20 DESIGN OF AUDIO POWER = AMPLIFIER =20

In = fig1=20 we can see that audio power amplifier can be splitted into 3 main = functions,=20 that is:

- =20 First stage / input stage

- =20 Second stage / voltage amplifier stage

- =20 Third stage / output stage

First = stage is the stage = that receives=20 the input audio signal and Negative Feedback =20 (NFB) signal from the output of the amp. Feedback is the back = signal=20 used to stabilized the audio amplifier, like the gain factor. For first = stage=20 built by discrete transistors, both signals is fed to basis of the = transistor,=20 like in = fig1.=20 Both basis of the transistors is the Non- Inverting input and Inverting = Input,=20 like those in the op-amp.

Second=20 stage is=20 the stage that responsibles for the Voltage Gain in the power=20 amplifier.

Third=20 stage is the Current Gain.

We can explain = those stages=20 in a simple way like this : Input signal, like from car = radio or=20 CD player have low voltage, about 1Vpp with few milliampere current. To = produce=20 power of 170 Watt at 4 ohm speaker load, than the signal has to have = maginitude=20 of 28Vpp and current of 6.5A (from the equation of P=3DI²*R = =3D=20 V²/R)

The = first=20 stage receives this signal in the non-inverting input and the inverting = input=20 receives NFB signal to make sure the voltage gain that the amplifier = produces=20 has a constant number, lets say 28 x. The output signal from the first = stage=20 has not reach 28Vpp, it tends to have the magnitude similiar to the = input=20 voltage. Second stage amplifies the voltage that the first stage = generates.=20 Second stage will amplifies the voltage to produce a signal that is = enlarge=20 28x for the amplifier to have a 28Vpp signal from 1Vpp signal, = but this=20 28Vpp signal still have small current , only a few mA and cannot drive = the=20 speaker load. The third stage amplifies the current from few mA to 6.5 = A.

Offcourse the explenation for three stages = above is not=20 that simple in the real amplifier. We should take the nature's law for = a=20 transistor gain, that is G=3DRC/RE. This principles must be applied in = each=20 transistor in those 3 amplifier stages.

FIRST=20 STAGE

First stage designs have main component, that = is Constant=20 Current Source (CCS) which can be seen in = fig2.=20 One of the basic of electronic law that works on every circuit is that = the=20 voltage drop of Basis and Emitor (Vbe) equals the drop voltage of one = dioda =3D=20 0.67V. It can be seen in = fig2=20 that the voltage drop of 2 dioda IN4148 =3D 2 x 0.67V =3D 1,34V. We can = see in RE=20 and Q1, then V=3D0,67 is substracted by Vbe of Q1 and the other = 0,67V =20 will be the drop of RE. So we will have a Constant Current Source of = 0,67/RE.=20 In = fig2=20 the Ic is =3D 4,4mA. CCS first stage varies between 1-4mA.

In = fig1=20 first stage, each component will be explained like this:

- =20 R1 is the impedance of the audio amplifier, the range is 10 Kohm = =96 =20 47Kohm

- =20 C1 is the highpass filter from the equation : Fhp =3D 1/(2 = x pi x R1=20 x C1)

- =20 RED1 and RED2 is between 50-150 ohm

- =20 RM1 and RM2 is picked up so the voltage drop will be 50mV = =96 =20 150mV

- =20 Q3 and Q4 is the Current Mirror that ensures the current in RM1 = and RM2=20 will have the same magnitude.

- =20 RF and CF will be discussed later.

Before we discuss Second Stage and Third stage, = first we=20 will discuss the amplifying effect of a transistor. In fig3a=20 we will see a circuit of Common Emitor Mode (CEM). This circuit = will=20 amplifies the voltage. In fig3b=20 we see a Common Colector Mode (CCM). This circuit is the current = amplifier=20 without voltage amplifier. So if we want to amplifies voltage we use = CEM=20 circuit and to amplifies current we use CCM circuit.

SECOND=20 STAGE

The Second stage responsibles for all voltage = gain=20 (Maximum Voltage Swing) in an audio power amplifier. This is why the = Second=20 stage is generally known as VAS or Voltage Amplifier Stage. This = stage=20 consist of a voltage amplifier/CEM transistor(Q5 in = fig1)=20 in the bottom, Constant Current Source in the top, and a bias control = circuit=20 in the middle. Second stage CCS has current magnitude between 4-8mA

In the second stage there is an important = capacitor for=20 an audio power amplifier , that is Miller Capacitor (CC in = fig1).=20 CC defines the pole of the frequency response for an audio amplifier = and the=20 magnitude usually in small order (severalpF).

Bias control circuit consist of a transistor, = resistor=20 and a VR like in = fig5.=20 This circuit uses a transistor that is placed in the heatsink, because = the=20 transistor have good heat compensation factor (for bipolar = transistors). =20 For the amplifier that uses mosfet transistor for the final device, the = bias=20 circuit only needs potentio or dioda only because mosfets have = different heat=20 characteristic than bipolar transistors. The bias voltage magnitude = depends on=20 the type of the third stage used, which will be discussed later.

THIRD=20 STAGE

Third stage / Output Stage is the current = amplifier.=20 Third stage and the bias circuit will defines whether an amplifier = works in=20 class A, class AB or class B.

It can be said that almost 90 % of car audio = power=20 amplifier works in class B. Operation in class B does not mean that the = sound=20 produced is not good or corrupted. With good design, we will have good = audio=20 results, both from class A or class B. The choice of class B in car = audio power=20 amplifier is conected to efficiency and the heat generated. Heat=20 generated is a very important factor, because if not considered = carefully, it=20 will lead to amplifier breakdown.

Many configurations of the output stage can be = seen in = fig4.=20 Each configuration has different optimum bias voltage. It depends on = how many=20 Vbe's that have to be passed. Example : In = fig4(a) =20 the signal has to pass 4 Vbe's, which is Vbe Q1, Q3, Q4 and Q2. So the = optimum=20 bias =3D 4 x 0.67V =3D 2.8V.

Both 3 stages that we have discussed above, if = we connect=20 the together will be a circuit that can be seen in = fig5.=20 Parts of this circuit can be explained like this:

- =20 The value of Negative Feedback (NFB) resistor is determined by=20 determining the gain factor with the equation : Gain =3D = 1+(R10/R8) =3D=20 1+10k/500 =3D 21 x. The value of R10 =3D value of R1 to balance input. = R20 and C7=20 are the pole and slope compensator.

- =20 C2 limits the DC gain factor, value ranging from 47-220 uF, = usually using=20 a nonpolar capacitor.

- =20 R21, R22 and C11 will stabilize CCS. Here we use CCS with 2 = transistor=20 system,but the equation used still the same, that is Ic =3D = 0,67/RE .

- =20 The output of differential pair tapped from collector of T10 and = send to=20 VAS which is built by T12 and T4. This configuration is called = Darlington VAS=20 and the value of R8 is standard.

- =20 C3 is the Miller capacitor with value of 100pF.

- =20 C5 is called Speed Up Capacitor. Several designs do not use this=20 capacitor

- =20 R18, C6,L1 and R19 are output power stabilisator. If there is any = oscilation occur in the audio power amplifier, the first tobe effected = is R18=20 besides the final transistors.

Car Power amplifier usually loaded by low = impedance=20 speakers, usually 4 ohms and can reach =BD ohm on bridge mode. = Here we know=20 the term =93High Current Amplifier=94. The difference is the number of = final=20 transistors, or in = fig5=20 it is the number of pairs of T7 and T8. As a rule of thumb, the number = of=20 transistor needed first has tobe calculated by equations above, and = then we=20 determine the number of final transistor needed with assumption that 1=20 transistor can handle 50 Watt output. A pair of bipolar transistor can = handle=20 100 Watt. The power is raised by parrarelling several output = transistors, so=20 the currrent flowing will be larger. For large number of final = transistors, we=20 change the predriver stage with darlington configuration.

Several designs uses symetrical design, like = those used=20 in AXL and Crescendo schematic. this design is developed from the = basic=20 principal above, but the signal handling for + and - part is handled by = complementary circuits.

I have an example about another kind of power = amplifier,=20 that is a non-feedback amplifier. You can view the principles of the = "millenium=20 power amplifier" in the http://www.lcaudio.com/ . This = amplifier has=20 a certain gain factor in first and second stage, while the third stage = is only=20 current amplifier.

2.THE DESIGN=20 OF DC-DC CONVERTER

For building car power amplifier, we need = symmetrical=20 power supply (+, 0, -) by building DC-DC converter. The converter = system=20 discussed below will be the SMPS(Switch Mode Power Supply) type PWM = (Pulse=20 Width Modulation). This system will deliver stable output voltage, = regardless=20 of the input voltage (usually the car electrical system will range in=20 9-15Vdc).

To explain the SMPS type PWM, it can be = analogued=20 by the next example. Look at fig6.=20 There is a voltage pulse V1 on-off with 50% wide. These pulses if = passed =20 through suitable L and C filter will be transformated into = straight=20 voltage of V2 which is V2 =3D =BD V1. (noticed the marked area below = pulsed V1 is=20 the same total area of the marked straight V2 ). With the same = logic, if=20 the pulse width of V1 is narrowed, we will have a lower V2 and if we = enlarge=20 the width of V1 pulse, we will have higher V2. Some may ask, how can we = get=20 30VDC from the car's 12VDC? The answer is simple. If we get the V1 = voltage to=20 60VDC, then in the 50% duty cycle, we will get 30VDC straight. This is = the part=20 where the power switching transformer takes control, to make the 60VDC = from=20 12VDC, and then chopped by the PWM. This is the princip of PWM. = (Like the=20 principal of class D digital power amplifier). In this design, we use=20 regulating PWM IC's, like TL494, TL594, SG3524, SG3525. These IC's will = compare=20 the output of DC-DC converter with a reference voltage. If the output = of DC-DC=20 converter is smaller than reference voltage, then the IC will enlarge = the pulse=20 width so the voltage will raise equally to to reach determined voltage. = So as=20 if the output of DC-DC converter is higher than the reference voltage, = the IC=20 will narrow the pulse width so the output voltage will be lowered to = the=20 determined voltage.

Generally SMPS used in car audio = amplifier is the=20 push-pull system with switching frequency between 20-70Khz. In push = pull sytem=20 like in = fig7,=20 Q1 and Q2 gives alternating switched current pulses so the = transformator will=20 be objected to maximum flux swing change without saturating the core. =

In this design we will use PWM IC with SG3524 = from SGS=20 Thompson. Specifications can be seen in SGS Thompson's website. = = Fig8=20 shows the configuration of 16 pins on this IC. To make is simpler, lets = design a=20 SMPS by explaining the function of each pin.

For the stereo power amplifier in = fig5,=20 we will need a SMPS 12Vdc input and summetrical output of = +/- 37Vdc=20 with 8A rating.

1. =20 First we make the Remote Turn On circuit , which is connected from the = car=20 radio / CD player. The circuit can be seen in fig9a.=20 This circuit will turn on the SMPS by giving 12Vdc to pin 12, pin 13 = and pin=20 15.

2. The=20 SMPS switching frequency is determined 50Khz. For this, the clock = inside IC=20 SG3524 is adjusted 2 x 50 Khz =3D 100Khz. This clock is built up = by pin=20 7(Ct) and pin 6(Rt). The approach can be done with equation Fclk = =3D 1 /(Rt=20 x Ct). Here we use Ct =3D 1nF and Rt =3D 10Kohm like in fig9b

3. =20 Pin 2(Non Inv In). In pin 2 we put stable reverence output for = the SMPS.=20 Here we use reference voltage of =BD from reference pin 16.

4. =20 Pin 1(Inv In) is the output voltage detector . Pin 1 is = connected to the=20 optoisolator type 4N35 like in fig9b.=20 Optoisolator is an important component in making this SMPS so we can = have =20 Floating Secondary Ground which will prevent noises (especially = whine/storing)=20 if the power amplifier is placed in car. The value of zener diode = is 2 x=20 37V =3D 74V. If it is difficult to have zener voltage of 74 V, then we = can series=20 several zener values until we have total of 74 V.

5. =20 Pin (4) and =20 pin(5) are not used and connected to ground, pin(8) and pin(10)=20 connected directly with ground.

6. =20 Pin no 9(Comp) = determines=20 slope and pole of feedback from the whole SMPS system. In this design = we use=20 only 1 capacitor of 100nF.

7. =20 Pin no 16(Vref) gives reverence voltage of 5,1 Vdc . This pin is = placed=20 with 10nF as a voltage stabilisator.

8. =20 The output ripple (Vr) of the SMPS is determined by equation = :

= Vr =3D 8 x=20 10^-6 x I / Co. With I =3D 8A and Vr =3D 0,029V we will have = Co of=20 2.200uF in +37Vdc ->-37Vdc rail or 4400uF = each=20 in+37Vdc_0 =20 and 4.400uF in 0_-37Vdc.

9. =20 For output filter capacitor of 2.200uF, we will need = approximately =20 4x 2.200uF or 8.800uF in the SMPS's input 12Vdc . The larger the value = of this=20 capacitor, more energy stored for the SMPS.

10. =20 Output filter inductor Lo is determine by : Lo =3D 0,5 x Vout/ = (I x F).=20 With Vout =3D 2 x 37V =3D 74V, I =3D 8A dan F =3D 50Khz, we will have = Lo =3D 0,092mH or=20 Lo =3D 0,046mH on each supply rail + and =96 37Vdc.

11. =20 Pin 11 and pin 14 are output pins that will drive the primary = winding=20 switching mosfets. Inside IC SG3524 both pins have already opereated in = mode=20 push-pull. The circuit for driving power mosfets can be seen in = fig9b.=20 The number of power mosfet used is 3 in each transformator primary. So = total=20 there is 6 power mosfets type BUZ11.

12. =20 Transformator(trafo) for SMPS is selfwould from ferrite toroidal = core=20 (like donuts) like in fig10.=20 It is very important that for SMPS frequency above 20Khz, we cannot use = iron=20 core transformator like we use in homes. The ferite core transformator = will=20 have black color like in the speaker magnets, but do not have = magnetizing=20 force. The basic of equation for switching power supply with = 12Vdc input=20 is:

(1) =20 Np =3D 1,37 x 10⁵ / (F x Ae), where Np=3D = primary number=20 of turns, F =3D = switching frequency,=20 Ae =3D X x Y =3D window area of ferrite in cm². Look at fig10.=20 To make it easy to wound the transformator, we will have to choose the = toroid=20 core with minimal diameter of 2,5 cm and window area minimal of=20 0.75cm².This is necessary for the easyness of self = handwound.=20 Remember that in push-pull system there is 2 primary windings.

(2) Ns/Np =3D = Vo/8,8,=20 where Ns =3D secondary number of turns, Vo =3D secondary output = voltage

(3) Ap =3D = 0,004 x Vo x Io, =20 where Ap =3D window area of primary wire in mm², Vo = =3D output=20 voltage, Io =3D output current.

(4) As =3D = 0,13 x Io,=20 where As =3D window area of secondary wire in mm².

Example : =20 If we use toroidal ferrite core with window area of Ae =3D = 1=20 cm². then from equation no. 1 we will have number of primary = turn Np=20 =3D 1,37 x 10⁵ / (50Khz x 1 cm²) =3D 2,74 turns. = In practice,=20 number of minimal primary turns is 4 so the primary will cover the = whole=20 toroidal core. So we use 4 turns for Q1 and 4 turns for Q2.

From equation = (2) we have=20 that Ns/Np =3D 37/8.8 =3D 4,2. From here we can calculate that the = number of=20 secondary windings is =3D Np x Np/Ns =3D 4 x 4,2 =3D 16,8 or 17 = windings. Like the=20 primary, in secondary we use 2 x 17 turns, that is 17 turns for = +37V=20 =96> 0 and 17 turns for 0-> -37V

Equation (3) is = used tp=20 determine the number of primary winding wires. We have Ap =3D = 0,004 x 74 x=20 8 =3D 2,36mm². If we use a 1mm diameter magnet wire, we will = have=20 window area of 0,785mm² so we will need 3 wire magnets = for=20 each primary windings

Equation (4) is = used to=20 determine the number of wire needed for secondary windings. We have As = =3D 0,13 x=20 8 =3D 1mm² So if we use wire magnet with diameter of = 0,8mm(window area=20 =3D 0, 5mm²), then we will need 2 wires with diameter 0,8mm = for each=20 secondary windings.

13. =20 The secondary output voltage is rectified by full bridge = configuration=20 like in fig11.=20 Bridging diode must be the type of fast rectifier, usually looks like=20 transistor TO220 with plate heatsink. For SMPS we cannot use ordinary = 50/60Hz=20 rectifier diode. For this design we use diode type BYW29-150, = which have=20 rating of 8A, 150V. We can also use other diodes like with = prefixes=20 FE=85,MUR..., as long as it is a fast rectifier diode with minimal = specification=20 like above.

3. MISCELLENEUS TIPS FOR MAKING CAR POWER = AMPLIFIER=20 =20

Car power amplifier has specific accesories = like preamp=20 gain circuit, an inverting channel so that the power is bridgeable. = These=20 functions usually done with opamps. The circuit can be seen in fig12a=20 and the supply circuit can be seen in fig12b.=20 The circuit is placed before the audio amplifier circuit.

The transformator is handwound on toroidal = ferrite core.=20 The output filter inductor can be made with ferrite core material or = MPP core=20 material. It can be made with 1.2mm wire magnet, handwound and measured = until=20 we have 0,046mH

Handwound the transformator core can be done as = follow=20 (fig13b):

- =20 First we wound the secondary winding of 4 wires of 0.8mm magnet = wires at=20 once with 17 numbers of turn. The turn can be made in any direction as = long as=20 we consistent with the direction of the wound. If we have finished = wounding it,=20 the toroidal core will look like fig13a.=20 We named the wires with wireA,B,C, and D. If we start the wound = on top of=20 the core, the end will be at the bottom of the core. Make sure each = wire edges=20 with AVOmeter. Connect start edge of wire A and B to point S1 and the = end edge=20 of wire A and B to point G. The start edge of wire C and D is = connected=20 to point G and the end edge of wire C and D is connected to point = S2. =20 Point G will be the secondary ground of the power amplifier and point = S1 and S2=20 will be connected to bridging diode of BYW29.

- =20 After we finished with secondary winding, we start to wound = primary=20 winding. Edges of primary wires is placed diagonally to the edges of = the=20 secondary wires like in fig13c.=20 Like winding the secondary wires, we wound 6 wires of 1mm diameter at = once.=20 Name them wire A,B,C,D,E,and F. Connect the start edge of wire = A,B,C to=20 point P1 and the end edge of wire A,B,C to point P+. Connect the start = point of=20 wire D,E,F to point P+ and the end edge of wire D,E,F to point P2 (fig13d)

=20 If you have finished winding the primary and the secondary, the = whole=20 transformator will have the same wire directions like in fig12e.=20 Connect point P+ to the +12VDC of the car battery, point P1 to the = drain of=20 power mosfets Q1 and point P2 to the drain of the power mosfets Q2. =

It is important to remember that all tracks in = PCB layer=20 that is connected to the power transformer has to have sufficient width = due to=20 large current will be involved. Also it is better if we soldered those = tracks=20 to have more current transfer.

After finishing winding the transformator, = place all the=20 rest of the component and finish assembly of the SMPS. You can test it = by=20 connect it with 12VDC input from the battery. Don't forget to connect = the=20 remote turn on with 12VDC. There should be output voltage of = +37V, 0 and=20 =9637V without any large current draw in the 12VDC line. Check for any = mistakes,=20 if the output voltage do not present or if the SMPS draws large current = from=20 12VDC input.

In the assembly process of car audio power = amplifier, we=20 have to pay attention in mounting all transistors to the heatsink. We = must use=20 sufficient heatsink surface so the heat won't damage the amplifier. Use = mica=20 isolator and white silicon pasta to make sure the heat transfer. Firmly = tighten=20 all the bolts to press all the transistors. Car amplifier works in = vigorous=20 environment like in the trunk of a car. Placing an extra fan always a = good idea=20 in making car power amplifier.

After we connect the SMPS to the audio = amplifier, we are=20 ready to test the car power amplifier. First trim the bias = potentiometer fully=20 left side to have minimum bias. Turn on the SMPS and look for the = current draw=20 in 12VDC line with ampmeter. The ampmeter indicator will raise for a = moment to=20 fill all the capacitors. After a few moment, the ampmeter indicator = must turn=20 back to minimum indication of ampere. If not, there is some problem. = Then we=20 trim the bias to optimal point. Usually for car stereo power amplifier = total=20 quiscent ampere will not exceed 2A of 12VDC line.

=20

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