In this project, we will design a boost converter using the XL6019E chip, capable of stepping up input voltage to as high as 48V with a maximum current output of 2A. A boost converter is essential for various applications, including LED lighting, battery management systems, and high-power electronics. We will walk through designing and fabricating a custom PCB for this boost converter, with JLCPCB as our trusted PCB manufacturer. Their top-notch service ensures precise and high-quality PCBs for our DIY projects.
Get your PCB made with JLCPCB: https://jlcpcb.com/HAR
Supplies- Inductor: 68µH, rated for at least 2A
- Schottky Diode: SS34 or equivalent
- Capacitors:
- Input: 470µF, 25V electrolytic
- Output: 470µF, 50V electrolytic
- Ceramic: 0.1µF
- Resistors:
- Feedback voltage divider (see Step 3 for calculation)
- Connectors: Screw terminals or pin headers
- PCB (custom-designed, ordered from JLCPCB
The XL6019E operates as a boost converter by switching rapidly, transferring energy to an inductor, and stepping up the voltage. Below is the basic schematic:
- Input Power Supply: Provide 5V to 36V as input. Ensure the input capacitor can handle the ripple current.
- Inductor: The inductor’s value (68µH) determines the energy storage capability. Select one rated for at least 2A to avoid saturation.
- Diode: The Schottky diode ensures current flow during the off-switching phase. A low forward voltage drop diode is essential to maximize efficiency.
- Feedback Network: Two resistors form a voltage divider to set the output voltage.
- Output Capacitor: A higher voltage capacitor ensures smooth output.
Design your circuit in a PCB CAD software like KiCAD or EasyEDA.
Step 2: Calculating Feedback ResistorsThe XL6019E regulates output voltage using a feedback pin. The formula to set the output voltage is shown in the datasheet. Calculate R1 and R2 accordingly for 48V or higher
Step 3: PCB DesignDesign a compact PCB layout, ensuring:
- Wide traces for high current paths.
- Proper placement of input/output capacitors close to the XL6019E.
- Thermal vias under the IC for heat dissipation.
Upload your design to https://jlcpcb.com/HAR for fabrication. JLCPCB offers competitive pricing, quick turnaround, and exceptional quality.
Step 4: AssemblyOnce your PCB arrives, solder the components in the following order:
- SMD components, starting with the XL6019E.
- Through-hole components, such as the inductor and capacitors.
- Connectors for input and output.
Applications
- Powering LED strips.
- Charging high-voltage batteries.
- Laboratory experiments.
Building a boost converter with the XL6019E is an excellent way to learn about DC-DC power conversion. Ordering PCBs from JLCPCB ensures high reliability and precision. Show your support by sharing this project with others and trying out JLCPCB’s service for your next design.
Check out JLCPCB for your PCB needs: https://jlcpcb.com/HAR
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