Completely integrated modules exist that contain a DC-DC converter plus everything else required to control it. These modules typically include a microcontroller, screen, buttons, and a rotary controller to configure the DC-DC converter and change its settings.
Overview
Integrated DC-DC converter modules can turn a simple power supply into a lab bench power supply, battery charger, or solar energy converter. They are available in pure buck (lower input voltage), boost (raise input voltage), or combined buck-and-boost configurations.
Buck-and-boost modules are the most versatile as they can be used with almost any readily available power supply or battery, while providing the full voltage range typically needed.
Protections
An internal microcontroller offers a range of protections that automatically cut power output when limits are exceeded:
- Over-Current Protection (OCP): Activates when current exceeds a specified limit. This protects both the power supply from overload and connected loads that are sensitive to excessive current (e.g., LED strips) or faulty (e.g., short circuits).
- Over-Power Protection (OPP): Triggered when power (voltage × current) exceeds a set limit. This is useful in situations with fluctuating voltage, and it protects both the power supply and sensitive loads.
- Under-Voltage Protection (LVP): Engages when voltage drops below a predefined threshold. This is particularly useful when using a battery as the power source, as it prevents over-discharge.
- Over-Voltage Protection (OVP): Activated when voltage exceeds a threshold. Essential when charging batteries, as it prevents overcharging. The flexibility to set a cut-off voltage allows for charging different battery chemistries and even charging to a specific state of charge (e.g., for long-term storage of Li-Ion/Li-Po batteries).
- Over-Temperature Protection (OTP): Engages when the internal or external temperature exceeds a threshold. This can protect the power supply from overheating (e.g., in hot environments or if a cooling fan fails) and helps monitor the load (e.g., to detect a catastrophic battery failure during charging).
- Over-Timeout Protection (OHP): Triggered when the device operates for a specified duration. This adds an extra layer of security during battery charging operations.
- Over-Capacity Protection (OAP): Activates when a set amount of energy has been supplied. This allows for precise energy delivery to a battery.
- Over-Energy Protection (OPH): Similar to OAP, but more precise when the voltage fluctuates (e.g., during battery charging), ensuring the correct amount of energy is delivered.
In addition to these microcontroller-managed protections, discrete components may offer additional reverse voltage and reverse polarity protection.
Always consult the specifications as support for these protections may vary across different modules.
Special Features
Some modules include external interfaces (e.g., serial, WiFi, Bluetooth, IR, remote controls, and more) for data export and/or device control. Certain models allow for configuring the duty cycle and support Maximum Power Point Tracking (MPPT) for efficient solar charging.
Use Cases
Plug-and-play DC-DC converter modules are simple to use and suitable for a variety of applications:
- Lab Bench Power Supply: Adjustable voltages with definable maximum currents, offering short circuit protection.
- Battery Charger: Fully configurable charger adaptable to multiple battery types and chemistries.
- Solar Converter: Efficiently harvests energy from solar panels to charge batteries.
- Battery Capacity Tester: Safely discharges a battery to a safe level while logging the total energy supplied.
- Power Meter: Logs the total power consumed by a device over time.
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(content created Jan 16, 2025)