I designed a simple 2-way passive audio crossover, consisting of 2 power inductors and 2 non polarized electrolytic or ceramic capacitors so this makes for a second-order design or 12 dB/octave. This order is commonly used in passive crossovers as it offers a reasonable balance between complexity and response. Higher order audio filters are harder to design, because components interact with each other.
I calculated the component values for the audio crossover based on the Linkwitz–Riley capacitor and inductor ratios. I chose the cutout frequency to be at 4000 Hz. This value was choosen to better protect the tweeter from lower frequencies.
The pcbs were provided by PCBWay who offer fast and reliable service. Packega came in fast, only taking 4 days to arrive. PCBs came well packaged. On the fist glance the PCBs looked good, the solder pads were nice and sharp. This was the first PCB that I ordered with a silkscreen and it also looked very nice. I was happy with the PCB service, mostly by the fast shipping and production time. You can order your own PCBs here: https://www.pcbway.com/project/shareproject/2_way_Audio_crossover.html
I designed a complete enclosure to house my previously designed tpa3116 2x50w amplifier board.
The design includes a 10A fuse to protect the amplifier board in case of a short-circiut or a reverse polarity of the power supply. I also fitted the amplifier ic with a heat sink which help the amplifier to achive the desired 2x50W of output power.
The enclosure is equipped whits several 5mm banana plugs for power transfer and 2 pairs of audio signal jacks.
I designed an audio power amplifier board based around the tpa3116d2. I chose the highest possible oscilator frequency of 1200khz. Many chinese designs feature no output LC filter which may result in power losses and lower efficiency. Because of that I chose higher grade components that are included in the output filter. My design also includes a large heat spreder, whitch may come in handy when dealing with a version of the IC that has a bottom mounted heat pad. My design also include loads of vias at the adge of the PCB which take care of high frequency interference.
The ampflifier is capable of delivering 50W to a singe channel load (4ohm).