Posts with «tip» label





In [Tom’s] specific example, he’s using a TIP120 to control a motor at 5 volts drawing 1 amp of current. [Tom’s] big problem with the TIP120 is that it’s inefficient when running the motor. That’s because the TIP120 isn’t a transistor. It’s two transistors configured as a Darlington pair. Like everything else in life, Darlington pairs have trade offs. To achieve high gain, you end up with higher voltage drop. In high current designs, that translates into heat. In this case, 2 watts of heat, which [Tom] claims will result in melted parts and fire. It turns out that the datasheet shows 2 watts is the upper limit for thermal dissipation on the TIP120’s TO-220 case. It will get very hot, but it will not catch fire. Want to be on the safe side? Add a heatsink, which is as easy as attaching a piece of metal using the convenient screw hole in the TO-220 case.

Just for fun, we created our own version of [Tom’s] example. We connected a TIP120 to a 12V lab supply. Rather than connect a motor, we grabbed our Re:Load Pro and set it for 1 amp. We use a 680 ohm base resistor to ensure the TIP120 was in saturation. The Re:Load Pro indicated that it was indeed seeing 1 amp of current flow, at 10.9 volts. This means that the TIP120 was only dropping 1.1V, rather than the 2V quoted on the datasheet. Were we just lucky? We tried a few TIP120s we had around the lab from a couple of manufacturers, and all of them were pretty close – well below the worst case 2V. Obviously you can’t design beyond the specs called on in the datasheet, but sometimes things work out in your favor. With the current set to 1 amp, the math is easy. The Re:Load Pro was converting 10.9 watts of power to heat. The TIP120 was dissipating 1.1 watts. The TIP120 did get hot – we measured up to 60°C. But it never went beyond that. A heatsink would have cooled things down, but we were shooting for worst case scenario.  We ran this setup for 2 hours and there was no smoke, fire, or failure.

Can you do better with a different part? Absolutely. [Tom] suggests a MOSFET such as the NTD4906N. FETs are great, we use them all the time. However, they come with a completely different set of rules and pitfalls compared to BJTs. Learning the rules, the design trade offs and pitfalls of both families of devices are key factors when learning electronics design. Every component a designer learns is a new color on their design palette. On the code side we worry about people becoming “cut and paste” coders. The same thing happens on the hardware side when a designer doesn’t learn how to use different types of parts.

So don’t throw away your old parts. Use them, learn from them, and become a better designer for it!

Filed under: classic hacks, misc hacks