This repository contains a hands-on PCB training project based on the TPS5450 non-synchronous buck converter, originally developed for the HKU ROBOCON TEAM (The University of Hong Kong).
The goal of this project is to let trainees experience the full PCB workflow:
- Schematic design
- PCB layout
- PCB fabrication (ordering boards)
- Component purchasing
- Soldering and assembly
- Basic testing and measurements
Others are welcome to use, modify, and adapt this project under the terms of the MIT License.
Typical contents of this repository include:
altium/TPS5450-Template/– Altium project template for the main converter boardTPS5450-Template.PrjPcb– Altium project filesch.SchDoc– Schematic document (starting template)pcb.PcbDoc– PCB document with board outline and design rules
TPS5450-TEST/– Altium project for the test kit PCBTPS5450-TEST.PrjPcb– Altium project file for test kit PCBsch.SchDoc– Schematic document for test kitpcb.PcbDoc– PCB document for test kit
LICENSE– MIT LicenseREADME.md– This file
Important: Component libraries (symbols & footprints) are not provided.
Trainees are expected to create or import their own TPS5450 symbol/footprint and other components using datasheets or existing libraries.
hint : altium library loader is a useful tool for this purpose. see https://www.samacsys.com/altium-designer-library-instructions/
Each trainee designs and builds a TPS5450-based non-synchronous DC-DC buck converter PCB.
The main learning objectives are:
- Understand the operation of a non-synchronous buck converter
- Learn basic TPS5450 application and feedback network design
- Practice Altium schematic and PCB design (including creating libraries)
- Experience the complete hardware flow:
design → fabrication → assembly → testing - Gain confidence working with real power electronics hardware
On the main board template, one 2-pin 2.54 mm header and three 3-pin 2.54 mm headers are already placed.
These headers are used to interface with the test kit PCB.
Do not move or rotate these connector footprints, otherwise the boards will no longer mate mechanically/electrically as intended.
Each trainee is assigned a unique target output voltage based on the last three digits of their student ID.
Let the last three digits be A B C (each 0–9):
- Target output voltage: A.BC V
Examples:
- Student ID ends with
123→ Vout = 1.23 V - Student ID ends with
457→ Vout = 4.57 V
If the first of the last three digits is 0, ignore this leading zero and fix the last digit to 5:
- Target output voltage: B.C5 V
Examples:
- Student ID ends with
058→ Vout = 5.85 V - Student ID ends with
032→ Vout = 3.25 V
In general, a ±2.5% error from the assigned target output voltage is acceptable under the specified test conditions.
Since it is impossible to achieve exact voltages due to standard resistor values, the acceptable output voltage range can be calculated as:
- Example: Target = 5.00 V → acceptable range ≈ 4.88 V – 5.13 V
Students must design the TPS5450 feedback network so that the measured output voltage stays within this tolerance.
- Altium Designer (version as used in your lab/course)
- Altium starter project/template for the TPS5450 buck converter
- Main board
.PcbDocwith:- Board size
- Basic design rules
- Pre-placed connector footprints:
- one 2-pin 2.54 mm header
- three 3-pin 2.54 mm headers
used to plug into the test kit PCB (positions must not be changed)
- Test kit
.PcbDoc:- Helper PCB used for:
- Power input / output connections
- Load connections
- Convenient test points for oscilloscope probes and multimeter leads
- Helper PCB used for:
Component libraries (TPS5450 and other parts) are intentionally not included.
Creating or importing symbols and footprints is part of the training.
To understand what you are designing, you are encouraged to review non-synchronous buck converters:
-
YouTube: “Non-synchronous DC-DC Buck Converter Basics”
https://www.youtube.com/watch?v=rfChSvb8FX0 -
Texas Instruments: “TPS5450 Datasheet”
https://www.ti.com/lit/ds/symlink/tps5450.pdf
This is the intended student workflow when using this project as a training exercise:
-
Design
- Clone or download this repository.
- Open the provided Altium project template.
- Create or import the TPS5450 symbol and footprint (and other required components) using datasheets or existing libraries.
- Implement the schematic for a TPS5450-based buck converter.
- Set the feedback network according to your assigned output voltage.
- Complete the PCB layout following the constraints and good layout practice for switching regulators.
- Do not change the position of the pre-placed 2-pin and 3-pin 2.54 mm headers, as they must align with the test kit PCB.
-
PCB Fabrication
- Generate Gerber / production files in Altium. Reference : https://jlcpcb.com/help/article/How-to-export-Altium-PCB-to-gerber-files
- Order PCBs from a manufacturer on your own (according to course or team guidelines).
- Use the board parameters defined in the provided
.PcbDocunless told otherwise.
-
Components
- Prepare a BOM (Bill of Materials).
- Purchase TPS5450 and all required passive components & connectors yourself. suggect suppliers : lcsc, mouser or youxin-electronic.taobao.com, if you know how to use taobao.
-
Assembly
- Solder components onto your PCB.
- Optionally assemble the test kit PCB for easier testing.
- Inspect for solder bridges, wrong orientations, missing/incorrect parts, etc.
-
Testing
- Check for shorts between VIN, VOUT, GND before powering up.
- Power up using a bench power supply with current limit.
- Measure:
- Output voltage and compare with your assigned target (±2.5%).
- Basic load performance (under specified loads).
- If available, use an oscilloscope to:
- Observe the SW node waveform.
- Measure output ripple.
The repository includes a test kit PCB that implements a selectable resistive load bank for your converter output.
The test kit is designed as a simple, robust load for your TPS5450 board:
- It uses five 5 Ω / 10 W cement resistors as load elements.
- Each resistor is connected to VOUT through its own switch / control channel.
- A 5-position DIP switch (SW1) allows you to enable 1 to 5 load resistors independently.
- This lets you easily test how your converter behaves under different load currents.
For example, if your TPS5450 board outputs 5 V:
- Each 5 Ω resistor draws approximately 1.0 A and dissipates about 5 W.
- Enabling 1 / 2 / 3 / 4 / 5 resistors in parallel corresponds roughly to:
- 1 A / 2 A / 3 A / 4 A / 5 A total load current
(assuming your design and test limits allow these current levels).
- 1 A / 2 A / 3 A / 4 A / 5 A total load current
Since each resistor is rated at 10 W and used at around 5 W in this example, there is some power margin, but:
- The resistors will still become very hot at higher load settings.
- Long-duration tests at high current should be done with care and good ventilation.
Additional features:
- Indicator LEDs near each channel show which load channels are currently enabled.
- Matching 2.54 mm headers on the test kit and main board allow the two PCBs to plug together directly, so that:
- Power and load connections are clean and repeatable
- Students can focus on measurement instead of wiring
- Large VIN / GND / VOUT pads make it easy to:
- Connect a bench power supply and your TPS5450 board
- Attach crocodile clips
- Probe the circuit with an oscilloscope or multimeter without stressing the main PCB
Even if you are not part of HKU ROBOCON TEAM, you can:
- Use this project as a teaching example for:
- Power electronics
- PCB design
- Practical lab training
- Adapt the materials to your own:
- University course
- Student team training
- Internal hardware bootcamp
- Modify the design to use:
- Different output voltages
- Different input voltage ranges
- Alternative test setups
If you adapt this project, a short attribution such as the following is appreciated (but not legally required):
Based on the TPS5450 Buck Converter Training Project by HKU ROBOCON TEAM (The University of Hong Kong).
This project is released under the MIT License.
- Copyright (c) 2025 HKU ROBOCON TEAM
You are free to use, copy, modify, merge, publish, distribute, sublicense, and/or sell copies of this project, subject to the conditions in the LICENSE file.
See the LICENSE file for full details.
- HKU ROBOCON TEAM – Original author and maintainer of this training project.
- The teaching staff and mentors who contributed to:
- Circuit design
- PCB layout
- Test procedures
- Documentation
If you have questions, suggestions, or improvements, feel free to open an issue or submit a pull request.