Every Engineer needs at least one bench power supply in his house.I agree one can get the power supply directly from the store,but they are costly and some are ugly in terms of design too.
We all need to make sure that the power supply represent that person who is using it whether it is a student or an engineer or an hobbyist , this is my personal thought.
Lets make the Power supply case Creative with the features that of high end bench power supply and modularise so that in future we can modify it. This power Supply is a single channel power supply.
Input: 220-240V AC
Output: 1.3v to 19.2v 3Amps with three leds to indicate constant current,full charge indicator,charging indicator .Two binding post and One usb connector as O/p
/!\ The SMPS that i am using provides 24v /10 Amps but 10 Amps is lot more and i do not need that much current ,because of that i have limit the current till 3 amps with a fuse that can be replaced in future if more current is needed.
- Smps 11.25$
- DC DC Buck 4.69$
- V/I display 2.38$
- Connectors and other stuff 2$
- laser cutting 4.69$
- vinyl cutting 2.5$
This can be further reduce by selecting smps with lower specifications
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Step 1: Story
I was frustrated of using so many power adapter's like 9v 2A ,12V 1A and so on....This created the mess of connections. I would need dc dc buck regulator and always constantly checking voltage before powering any circuit this wasted my time.
There are many types of buck regulators available in market and hooking up wires every now and then took precious time and most importantly this thing made my table really messy.With esp8266 wifi module ,things got worst .As Esp8266 needed 3.3v with Current more then arduino it was no good to power it from arduino.
IT took me some time to come up with the design of the power supply and what material to be used.
In past i worked only on acrylic laser cutting so that's why i choose acrylic. But aluminium would be better choice to make the power supply case.It was a risk to choose acrylic but i went for it.
i thought of aluminium as top part and add curves in it.but was not having experience what so ever in cnc and how to achieve this shape in the end i needed to satisfy with this only.
Step 2: Materials and Tools
1)Smps 24v 10A X 1
4)4mm banana binding post X 2
9)3 pin AC power plug connector with wire that has ratting of at least 10A X 1
11 )Soldering wire
12)Screws and nut
- Glue Gun
- Wire stripper
- Soldering iron
Step 3: Case Design and Build
- I have used two software's to make that case one is corel draw and another is makercase that is online to make Finger slots.
- You will need to check the usb A dimensions and Ac power connector i was not having vernier calibre to do it accurately.My friend in laser cutting made two to three cuts for perfect fit.
You will need to make holes for Ac power connector too with drill machine or you can modify corel draw file and align holes perfectly.
- For top panel sticker i choose carbon fibre material instead of that image and with vinyl cutting i cut out that pattern
- You will need to use araldite to stick all sides. Don't stick the top panel, make sure it is open ,just in case in future, to modify your power supply.
Step 4: Connections for Bench Power Supply
Verify all the wires thrice and check the connections as you will be using AC mains . Also use heat shrink insulation tube to cover all wires.so that no two wires comes into connect because of soldering.
This is very important step ensure you do it and then move to other steps
You will see three leds on the Dc DC buck .Desolder the smd leds and solder the wires for Three leds that are placed on the case.
Desolder the potentiometer on the buck and solder the wires to the pot on the case.if the shaft of pot is too big cut with dremel if necessary .
Step 5: Conclusion
You did it!! Now you have successfully build your own lab bench power supply that has constant voltage and constant current mode ,no more use of adapter's and buck buck regulator.
Be safe and modify the bench power supply if you need more current .use 10 Amps dc dc buck and use 10 Amps fuse with it.