Dual Output DC-DC Converter Design

₹37500-75000 INR

Closed

Posted 7 days ago

₹37500-75000 INR

Paid on delivery

Project Title Design & Development of Wide Input Isolated Dual Output DC-DC Flyback Converter (20V–160VDC Input | 12V/1A & 5V/0.5A Outputs) Project Overview We are looking for an experienced Power Electronics Engineer with proven expertise in isolated SMPS and flyback converter design to develop a compact, industrial-grade DC-DC converter module. The converter will operate from a 20VDC to 160VDC input and provide two fully regulated isolated outputs: 12V DC @ 1A 5V DC @ 0.5A The product will be used in industrial control systems, battery-powered equipment, and EV-related applications. The design must emphasize high reliability, stable operation over the complete input voltage range, thermal performance, electrical isolation, and manufacturability. Only freelancers with prior experience in designing isolated flyback power supplies and custom high-frequency transformers should apply. Please include details of similar projects completed. Project Scope The selected freelancer will be responsible for complete hardware development from design to production-ready documentation. 1. Circuit Design [login to view URL] suitable Flyback Controller IC. [login to view URL] input stage for 20V–160VDC operation. [login to view URL] primary and secondary power stages. [login to view URL] isolated feedback regulation. [login to view URL] auxiliary power/start-up circuit. [login to view URL] output filtering for low ripple and noise. [login to view URL] EMI/EMC input filtering. [login to view URL] proper grounding and isolation techniques. 2. Transformer Design [login to view URL] custom high-frequency flyback transformer. [login to view URL] turns ratio, air gap, wire gauge, insulation, and core selection. [login to view URL] leakage inductance. [login to view URL] complete winding diagram and manufacturing drawing. [login to view URL] transformer material and insulation class. 3. Protection Features The design shall include: [login to view URL] polarity protection [login to view URL] surge protection 3.Over-voltage protection 4.Over-current protection 5.Short-circuit protection [login to view URL] overload protection [login to view URL] protection 8.Soft-start function [login to view URL] recovery after fault 4. Performance Requirements [login to view URL] Voltage: 20VDC to 160VDC [login to view URL] 1: 12VDC ±1%, 1A [login to view URL] 2: 5VDC ±2%, 100mA [login to view URL] Voltage: 3000VAC minimum [login to view URL]: ≥85% (Target) [login to view URL] Frequency: 100–200kHz [login to view URL] & Noise: 12V Output: <120mVp-p 5V Output: <80mVp-p [login to view URL] operation at full load. [login to view URL] operation throughout the complete input voltage range. [login to view URL] operating temperature: -40°C to +85°C 5. PCB Design 1.Two-layer or four-layer PCB (based on design requirement). [login to view URL] creepage and clearance for 3kVAC isolation. [login to view URL] layout for EMI reduction. [login to view URL] management using copper planes and thermal vias. 5.Manufacturing-ready PCB layout. [login to view URL] in KiCad (preferred). 6. Testing & Validation Provide test procedures for: 1.Start-up testing 2.Full-load testing [login to view URL] regulation [login to view URL] regulation [login to view URL] measurement [login to view URL] rise test [login to view URL] (Hi-Pot) test [login to view URL] ripple measurement 9.Short-circuit test [login to view URL] protection verification 7. Deliverables The final deliverables shall include: [login to view URL] schematic source files [login to view URL] layout source files [login to view URL] files [login to view URL] files [login to view URL] & Place files [login to view URL] of Materials (BOM) with manufacturer part numbers [login to view URL] design calculations [login to view URL] manufacturing drawing [login to view URL] calculations [login to view URL] drawings [login to view URL] procedure [login to view URL] support during bring-up [login to view URL] documentation for manufacturing Preferred Skills [login to view URL] Electronics Design [login to view URL] SMPS Design [login to view URL] Input DC-DC Converter Design [login to view URL] & Magnetic Design [login to view URL] Circuit Design [login to view URL] PCB Design [login to view URL] Compliance [login to view URL] Power Supply Design [login to view URL] Power Electronics [login to view URL] Experience Note: The selected freelancer may be required to provide online technical discussions during the design and prototype validation phase. Production-ready design quality is expected. Prototype Requirement: Preference will be given to freelancers who can manufacture, assemble, test, and validate at least one working prototype. Please specify whether your proposal includes PCB fabrication, transformer winding, assembly, and testing, along with the additional cost.

Circuit Design

PCB Layout

Electrical Engineering

Project ID: 40578469

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Active 7 days ago

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7 freelancers are bidding on average ₹120,893 INR for this job

@macroenergy

As an electrical engineer deeply committed to your project's success, I believe I bring a unique set of skills to the table. My extensive experience in circuit design, electronic design, and PCB layout make me the ideal fit for your dual output DC-DC converter project. But what sets me further apart from other candidates is my specialization in PowerElectronics and Embedded Systems. To give you a taste of my capabilities, let me highlight some of my most relevant work: I have successfully implemented various AC/DC and DC/DC converters, battery chargers, and solar inverters as part of my work in renewable energy. Notably, I have also designed customized power supplies with precise voltage outputs similar to what your project demands-working in line with your requirements is not just familiar territory for me, it's where I excel. Additionally, my proficiency in using advanced simulation tools such as OrCAD and MATLAB ensures that the designs I create perform excellently even before they are manufactured. Moreover, supported by a deep understanding of EMC compliance through my work on Bluetooth and RF projects, I can assure you that your product will meet all necessary safety standards. Overall, my breadth of knowledge and prior experience promise an efficient solution for you backed up by thorough testing protocols offering a high-quality deliverable.

₹70,000 INR in 20 days

4.8

(157 reviews)

7.4

@shadabkhan92

As an experienced Electrical Engineer specializing in Circuit Design and PCB Layout, I'm excited to offer my services on your Dual Output DC-DC Converter Design project. My skill sets are vast and focused on this particular area of power electronics where I have significant expertise and knowledge. Specifically, my experience designing isolated flyback power supplies and custom high-frequency transformers aligns precisely with the demands of your project. Over the years, I have consistently designed and delivered high-performing hardware that emphasizes reliability, stability, thermal performance, isolation, and manufacturability - all crucial aspects you value in your project. Moreover, I have a proven track record working with end-to-end ERP integrations, which resonates perfectly with the stack you intend to pair AI systems with. Not only will I be able to develop a compact, industrial-grade DC-DC converter module as per your specifications but also ensure smooth interaction within your existing workflows. In addition to meeting the performance requirements outlined by for full functionality of your Smart Control System I'll provide detailed test procedures for validating performance while offering continuous technical support throughout the process.

₹56,250 INR in 7 days

5.0

(2 reviews)

3.4

@Ryan15222

Hi, I'm very interested in your wide-input isolated flyback converter project. I have extensive experience in power electronics, isolated DC-DC converters, transformer design, PCB development, and prototype validation, and I can deliver a production-ready design from concept through prototype support. My scope includes: Complete flyback converter design (20–160VDC input, dual isolated outputs) Custom high-frequency transformer design with manufacturing documentation Schematic capture and PCB layout in KiCad EMI/EMC-aware layout, thermal optimization, and isolation compliance Full design calculations, BOM, Gerber, assembly files, and manufacturing documentation Test procedures and prototype bring-up support I can also support PCB fabrication, transformer winding, assembly, and functional testing of the first prototype. These manufacturing costs will be quoted separately based on the final BOM and fabrication requirements. Before we begin, I have a few questions: Is reinforced isolation required, or is basic 3kVAC isolation sufficient? Do you have preferred controller ICs or key components, or should I select the most suitable ones? Are there target PCB dimensions or enclosure constraints? Will the design require CE/UL/IEC pre-compliance considerations? I'm available to start immediately and look forward to helping you develop a reliable, production-ready power supply. Best regards,

₹250,000 INR in 15 days