(Topic ID: 293774)

Power Regulation and Rectification Explained.

By Bmad21

2 years ago



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    #1 2 years ago

    Hello

    I should start out with this and explain in detail important aspects in pinball electronics and starting off, Lets talk about Power Regulation and Rectification.
    (If you already know about this, let this be a guide for New People).
    Lets get started.

    Why do we need Regulation and Rectification?
    To simply convert between AC to DC and peel off certain voltages.

    Alternating Current that comes out of wall socket is 60hz (50 if you live in Europe) 120v (Something else in other countries).

    If you were to plot the power coming out of your socket it would look like waves, Sine wave to be precise but with logic needs, we need a straight line, AC does not give us a straight line of a current so we need to translate that to Flat line, this translation is Rectification.

    It does this in Three Stages.

    The first Stage is that the current is stepped down, by the use of transformers, I am going to boil it down. we have been told to us that their is a relationship between voltage and magnetism and the way we translate the two is through inductors.

    The more windings the bigger the field, the more power however, if that field collapses (down turn of the sine wave) in a coil with less turns (That is nearby), a lower voltage is induced, in that coil.

    In some cases we need to step up or down and that is accomplished by tapping off one side of the transformer, the less windings we tap off the lower the voltage the more windings we tap off from the higher the voltage in relationship to the coil that feeds the transformer.

    The Feeder coil, is called the primary winding. the coil that taps off from the transformer is called a Secondary.

    The magnetic field is carried around by the metal that the primary is wounded on and the secondary gets that field via that same metal or "Core"

    To calculate the ratio is to count the primary winding and divide it against the winding count off the secondary.

    We cannot step down DC with Transformers is because, that field does not collapse to induce another voltage in that secondary.

    Step Two
    After voltage stepping next is the real deal Rectification.

    The heart of it all is a full bridge rectifier and it has 4 diodes connected to each other in a ring.

    On the upswing of the current wave the rectifier will let it through. When the current reaches zero and proceed into and through the negative region the bridge will then conduct in away that what should be a valley in the wave is now deflected so that the current is back up into a new hill.

    Instead of
    Hill, Valley, Hill

    Its now
    Hill, Hill, Hill

    This current is not suitable for logic because, the current now fluctuates to 0 to what ever the orginal voltage coming in to the bridge.

    We fix this by inserting a capacitor that branches off the output leg.

    What this does is that is smooths it out it acts like a shock absorber and we get our DC current.

    That DC current is not pure DC current but the ripple has becomes small, really small.

    Dont think that the current is unsuitable it is suitable for our needs.

    Step three
    Now lets talk about regulation.

    Our new DC current and Voltage is unstable it fluctuates and we need steady.

    So what the regulator does is it regulates the voltage to a steady magnitude, its like a self adjusting variable resistor and it adjusts itself.

    I hope this information is useful and helpful for the next time you need it.

    Thoughts and or Questions?

    #2 2 years ago

    Good explanation!

    I think that for the pinball hobbyist it would be easier to to just say that the transformer is used to convert wall AC voltage to lower voltages needed by the pinball circuitry, and that the output voltage depends on number of transformer coil windings in primary/secondary. Anyway, for a given machine, that is a fixed ratio.

    More interesting part would be the rectification and filtering. How in the full wave rectification a voltage corresponding of two diode threshold voltages is lost, but the filter capacitor gets charged to transformer peak voltage - 2xVth, and how much filter capacitance is needed to keep the voltage always high enough for the regulator to do its work. (for example WPC games 5V subsystem BR2/C5), and what is the effect of increased contact resistance or capacitor ESR. And why does the 35 amp rectifier eventually fail even if it only has to serve for max 2 amp.

    #3 2 years ago

    i heard deeproot was hiring and they need this info.

    don't give it away for free when you can charge for it. i hear they pay well and produce nothing.

    #4 2 years ago

    This is interesting! Thanks for putting it together. Now how does this work for further stepping down? I know Stern has their 48V PSU. But then they step that down to various voltages that are needed for lights, logic, switches, etc. What is the process that does that? The same as above with the three steps? Or is it different to ramp down DC to lower DC?

    #5 2 years ago

    Stern has a 48V PSU, and uses local step-down switching power supplies on the node boards to make lower voltages for lamps/leds etc.

    #6 2 years ago
    Quoted from atum:

    This is interesting! Thanks for putting it together. Now how does this work for further stepping down? I know Stern has their 48V PSU. But then they step that down to various voltages that are needed for lights, logic, switches, etc. What is the process that does that? The same as above with the three steps? Or is it different to ramp down DC to lower DC?

    Resistors or a resistor divider circuit.

    Remember DC cannot be stepped up or down with transformers.

    #7 2 years ago
    Quoted from Tuukka:

    Stern has a 48V PSU, and uses local step-down switching power supplies on the node boards to make lower voltages for lamps/leds etc.

    So what exactly does that mean? They have the 48V in the back. So all lines into the board are 48V. Then the node send 48V to the coils, but then for switches and lights, there is just a little chip on there that functions like a resistor to drop the throughput voltage to the appropriate amount?

    #8 2 years ago
    Quoted from Tuukka:

    Good explanation!
    I think that for the pinball hobbyist it would be easier to to just say that the transformer is used to convert wall AC voltage to lower voltages needed by the pinball circuitry, and that the output voltage depends on number of transformer coil windings in primary/secondary. Anyway, for a given machine, that is a fixed ratio.
    More interesting part would be the rectification and filtering. How in the full wave rectification a voltage corresponding of two diode threshold voltages is lost, but the filter capacitor gets charged to transformer peak voltage - 2xVth, and how much filter capacitance is needed to keep the voltage always high enough for the regulator to do its work. (for example WPC games 5V subsystem BR2/C5), and what is the effect of increased contact resistance or capacitor ESR. And why does the 35 amp rectifier eventually fail even if it only has to serve for max 2 amp.

    Think of this as this way.

    You have a water line that the level flow is unstable, you add a piece of pipe that is perpendicular to the line.

    And what that does is it do is provides a extra water to keep that fluncuation to a minimum.

    Same with the capacitor in this case.

    Yes voltage is stepped down at transformer but thats a raw step down.

    That capacitor at the end of rectification is calculated to the design because, if we go too high if we are to turn off the load, capacitor discharges or could supply too much + what is rectified.

    The higher that capacitor the smaller the ripple but like I said you go too high danger awaits.

    #9 2 years ago
    Quoted from Bmad21:

    The first Stage is that the current is stepped down, by the use of transformers, I am going to boil it down. we have been told to us that their is a relationship between current and magnetism and the way we translate the two is through inductors.

    The transformer steps up or down voltage, that's why you see transformers rated with input and output voltages. The transformer does have power ratings also which is dependent upon the size of the xformer wire and the load placed upon it.

    Quoted from Bmad21:

    On the upswing of the current wave the rectifier will let it through when the current reaches zero from the downswing the bridge will then conduct in away that what should be a valley in the wave now deflects the current back up into a new hill.

    You should say on the upswing of the voltage, or downswing for the negative portion of the wave, the rectifier will pass thru the voltage. You could have the capability of 100 amps before the diodes but if you have insufficient voltage the rectifier will pass nothing.

    I'm not trying to bust your you know what, but the devil is in the details.

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