Peak Current of PWM

high-currentpwm

I am designing a controller for a hotwire cutter. As measured, the resistance measured is 1 \$\Omega\$. The power is switched on and off with a 555 astable mode to produce a pwm of \$V_{on}=12\$ V and \$V_{off}=0\$ V.

Although I can adjust the duty cycle so that the average current is 4 A or less (at which the power supply is rated), I am drawing 12 A during each \$V_{on}\$ period. By adding a capacitor, the instantaneous current shall stabilize but the initial current is still enormous and worrying. Any possible remedies?

schematic

simulate this circuit – Schematic created using CircuitLab

Best Answer

schematic

simulate this circuit – Schematic created using CircuitLab

You could greatly increase the PWM frequency and place a power inductor in series with the wire. Say you switch at 50kHz and you want 1A of ripple, the inductor would have to be a few hundred uH, and must be rated to not saturate at something like 5A. You also need a Schottky diode. No capacitor is required -- unless you care about EMI.. but it could be a pretty good broadband RF jammer without it if the loop area of the wire is large.