Electronic – Switching Regulator Current Conversion

In addtion to the concerns brought up in the comments (incorrect P-FET polarity, no catch diode/MOSFET), I have some at-a-quick-glance concerns:

• The microcontroller won't be able to drive the gate of Q1 very hard (usually GPIO pins can only source a few milliamps) so your turn-on and turn-off will be very slow. This will limit how well your high-side switch will behave.

• You don't have a gate-to-source resistor on Q1, so you're solely dependent on the GPIO keeping the MOSFET on or off. If the GPIO pin goes high-impedance, the MOSFET may turn itself on if the gate picks up a charge from the environment.

• If your 70R P-channel gate resistor is solidly on (if Q1 is saturated), it's going to burn

  \$ D \cdot \dfrac{(16V)^2}{70 \Omega} = D \cdot 3.65W\$

  which is crazy high power since D is going to be high (input is close to output). Also, the 225mA or so that will flow will also be burned in Q1, which isn't healthy since it's a relatively small device.

  (You need \$V_{GS}\$ of around 4V to draw ~400mA through Q1, and you need \$V_{GS}\$ of -7.5V for 40A in Q4).

  • Your purely resistive feedback network is a bad idea. You really need some compensation and/or filtering. Your comparator will be hyper-fast and could react to switching noise, pickup, ripple, etc. - since you don't seem to be using an error amplifier with compensation to control the gain and phase, you're going to need some cap across R5 (and some luck).

  • You don't have any current monitoring or over-current protection in your power train.

  • You don't have any over-voltage protection in your power train.

  • You don't have any over-temperature protection in your power train.

  • You don't have input reverse-polarity protection and an input fuse in your power train. Big no-no, especially when the source is battery-based (big short-circuit sourcing capability).

This is a simpler project if you use an off-the-shelf analog synchronous buck controller. I don't understand why you would want to use the ATtiny for this.

That being said, this isn't a simple project by any stretch. Your schematic is largely incomplete and lacks basic safety protection that any power supply (especially ones that run at high power levels like yours) will need.

Think about your requirements, calculate all the losses, design in some protections and come back with rev. 2.

It's odd what you say about the bootstrap circuit not performing well above D=0.5. I'm using the same driver chip for a hefty 200 watt power supply where the duty range is quite wide and I've never seen this happening.

I'm switching at 100 kHz - maybe you are using a switch frequency that is too low? Too low a frequency will cause bootstrap power to be a problem.

Another alternative is to use something like a little 2 watt Traco-Power or XP or Murata mini-power module to generate a floating 12 volt for your top FET.