I am basically applying the
Infinite Monkeys Theroem to power supply design.
I agree that providing +/9 Volts and + 5 Volts from a Lithium Ion battery source is not complex these days; However, I have a few constraints:
1. I am not using a microprocessor to do the battery management, as is done in most devices such as the Real Monster GO DJ, a mobile phone, or this tablet I am using right now.
2. I am not making custom PC boards, or purchasing individual components. I am limited to available modules/circuit boards.
3. The high power requirements of the 2 player modules.
I have basically returned to the original design with the following changes:
1. I am using the 2A battery management board instead of the original Portable Battery Pack board.
2. I am using a Digital Panel Meter (DPM) for battery monitoring instead of a 0-100% meter, or the LED's on the battery management board.
3. I have added a small heat sink to the same adjustable boost module that I was using before.
Here is a current schematic of the Poor Man's GO DJ power system:
Note that +5 VDC for the DPM is provided by the Battery Management Board. This allows me to check the battery voltage while the rest of the unit is fully off -- In other words, I can check both the no-load voltage and the loaded voltage of the battery pack. I can also monitor the voltage during charging with the unit off.
Another big improvement was basically to make a low-resistance USB A - to - micro charge cable. I cut a 10' cable, which used slightly heavier guage wire, down to about 4 ft. With this cable, the PM GO DJ will now charge at 1.2A (up from 900mA using a regular USB cable.)
This arrangement seems to work adequately. I have run the PM GO DJ for several hours without drain on the batteries. The boost board still gets warm, but the heat sink is definitely helping.
Why not run the +/-9 VDC Boost either directly from the Battery Management board, or from the battery -- thus reducing load on the 5V board? As mentioned in a previous post, when the Battery Management board is simultaneously charging and supplying power, the output drops below 4.75VDC, but it also seems unstable. To prevent any noise, I did not want to chance running anything from this output. Also, the +/-9 VDC Boost will not function when the input drops much below 5V.
Remaining problems -- There is still no real under volt protection. If the unit is left on, the boost converter will stall someplace around 3.3V. At first that sounds good, but when it stalls, it does not present an open or high resistance. Boost modules of this design present a straight-through path when they stall. This could continue to discharge the battery to a level where damage will occur. The mitigation is the user's ability to monitor the battery voltage, and turn the unit off when the battery voltage is too low, or the players start to behave erratically.
I'm confident the PM GO DJ will make it through my next DJ Job, which is important, as I have a full-paying gig on December 3rd.