Cheap Power Supplies With Fake Chips Might Not Be That Bad

November 10, 2023 by Dan Maloney 33 Comments

We all know the old maxim: if it’s too good to be true, it’s probably made with fake components. OK, maybe that’s not exactly how it goes, but in our world gone a little crazy, there’s good reason to be skeptical of pretty much everything you buy. And when you pay the equivalent of less than a buck for a DC-DC converter, you get what you pay for.

Or do you? It’s not so clear after watching [Denki Otaku]’s video on a bargain bag of buck converters he got from Amazon — ¥1,290 for a lot of ten, or $0.85 a piece. The thing that got [Denki]’s Spidey senses tingling is the chip around which these boards were built: the LM2596. These aren’t especially cheap chips; Mouser lists them for about $5.00 each in a reel of 500.

Initial testing showed the converters, which are rated at 3 to 42 VDC in and 1.25 to 35 VDC out, actually seem to do a decent job. At least with output voltage, which stays at the set point over a wide range of input voltages. The ripple voltage, though, is an astonishing 400 mV — almost 10% of the desired 5.0 V output. What’s more, the ripple frequency is 18 kHz, which is far below the 150 kHz oscillator that’s supposed to be in the LM2596. Other modules from the batch tested at 53 kHz ripple, so better, but still not good. There were more telltales of chip fakery, such as dodgy-looking lettering on the package, incorrect lead forming, and finger-scorching heat under the rated 3 A maximum load. Counterfeit? Almost definitely. Useless? Surprisingly, probably not. Depending on your application, these might do the job just fine, especially if you slap a bigger cap on the output to smooth that ripple and keep the draw low. And keep your fingers away, of course.

Worried that your chips are counterfeits? Here’s a field guide for fake chip spotters. And what do you do if you get something fake? A refund might just be possible.

Continue reading “Cheap Power Supplies With Fake Chips Might Not Be That Bad” →

A Simple Soft Power Switch Using Common Modules

July 21, 2020 by Tom Nardi 28 Comments

If you want to easily control the power in a circuit, you’ll probably reach for the classic toggle switch. While there’s certainly nothing wrong with that, physical toggles are a bit dated at this point. A soft power switch that turns your gadget on and off at the tap of a finger is far more 21st century. You might think this kind of modern trickery is too difficult to implement on a DIY project, but as [Sasa Karanovic] shows, it’s actually a lot easier than you might think.

Now to be fair, that wasn’t actually his goal. All [Sasa] was trying to do was come up with a slick way to control the LED lighting in his 3D printer enclosure. Which, as you can see in the video below, he accomplished. But the hacked together circuit he used to do it could easily be adapted for other electronic projects. If you’re using a LM2596 DC-DC converter module to power your gadget, you can add a touch sensitive soft switch for literally pennies.

The trick is utilizing the enable pin on the LM2596. The common buck converter modules tie this pin to ground so the regulator is always enabled, but if you lift the pin off the PCB and connect it to the output of a TTP223 capacitive touch sensor, you can simply tap the pad to control the regulator. Power for the touch sensor itself is pulled from the input side of the regulator, so even when the power is cut off downstream, the sensor is still awake and can kick the chip back into gear when you need it.

If you’re not interested in touch control, you could try connecting the enable pin on the regulator to an ESP8266 and making a cheap Internet-controlled DC power supply. Continue reading “A Simple Soft Power Switch Using Common Modules” →

Bench Power Supply Packs A Lot Into A DIN-Rail Package

August 18, 2018 by Dan Maloney 8 Comments

We’re not sure why we’ve got a thing for DIN-rail mounted projects, but we do. Perhaps it’s because we’ve seen so many cool industrial control cabinets, or maybe the forced neatness of DIN-mounted components resonates on some deep level. Whatever it is, if it’s DIN-rail mounted, chances are good that we’ll like it.

Take this DIN-mounted bench power supply, for instance. On the face of it, [TD-er]’s project is yet another bench supply built around those ubiquitous DPS switching power supply modules, the ones with the colorful displays. Simply throwing one of those in a DIN-mount enclosure isn’t much to write home about, but there’s more to this project than that. [TD-er] needed some fixed voltages in addition to the adjustable output, so a multi-voltage DC-DC converter board was included inside the case as well. The supply has 3.3, 5, and 12 volt fixed outputs along with the adjustable supply, and thanks to an enclosed Bluetooth module, the whole thing can be controlled from his phone. Plus it fits nicely in a compact work area, which is a nice feature.

We haven’t seen a lot of DIN-rail love around these pages — just this recent rotary phase converter with very tidy DIN-mounted controls. That’s a shame, we’d love to see more.

DIY Power Supply And TS100 Outlet Combo Shows Off Great Layout

March 19, 2018 by Donald Papp 18 Comments

Here’s a combination of two important electronics workbench tools into a single, cleanly-assembled unit. [uGen] created a DC power supply complete with a plug for the popular TS100 soldering iron, and it looks great! Most of the main components are familiar offerings, like a LM2596 DC to DC buck converter board and a DPS3003 adjustable DC power supply unit (we previously covered a DIY power supply based around the similar DPS5005.) The enclosure is an economical, featureless desktop instrument case whose panels were carefully cut to fit the necessary components. There’s one limitation to the combo: the unit uses a switch to either power an attached TS100 iron, or act as a general DC power supply. It cannot do both at once. So long as one doesn’t mind that limitation, it’s a nice bundle made from very affordable components.

It’s easy for something to look like a hack job, but to look clean and professional involves thoughtful measurement, planning, and assembly. Fortunately, [uGen] has supplied all the drawings and bill of materials for the project so there’s no need to start from scratch. Also, don’t forget that if the capabilities of the DPS power supply units leave you wanting a bit more, there is alternative firmware in the form of OpenDPS; it even offers a remote control feature by adding an ESP8266.

A low cost power supply unit with displays

A Low Cost Bench Supply

January 23, 2015 by Eric Evenchick 27 Comments

Everyone needs a power supply on their bench, but a standard lab supply isn’t cheap. [ludzinc]’s PSU Console is a cheap alternative, which provides the basic features you’d expect in a lab supply.

The basis of this PSU is a DC/DC module based on the LM2596 step down switching regulator. These modules cost less than a single LM2596, but have all the required components for a buck DC/DC converter. Sure, they might not last forever, and they’re not the most efficient regulators, but the price is right.

The front panel has four displays for voltage and current, which are just low cost voltmeter displays. The potentiometers are used for adjusting the voltage of the DC/DC, and controlling the current limiter. This limiter monitors current through a shunt, and shuts off a MOSFET when the limit is exceeded.

The final product looks like something that’s ready for daily use, and was much cheaper than most supplies with these features. These low cost DC/DC modules are worth a look if you’re considering a similar build.