Good afternoon, folks.
I had no idea there was a Phase Linear community online! I got a Facebook message asking about this thread and the work I did on the Pink Floyd amplifiers. I was the engineer for Britannia Row in Long Island, when the Floyd first set their sound company up in the United States. That was in the mid to late 1970s.
When we got the amps they had already been ruggedized by a process that was briefly described earlier in the thread. The Brits had made cubes of angle iron with trays to hold two amps. The power transformers were removed from the chassis and mounted to the heavy trays. That made the remaining amplifiers light enough that they did not flex and break apart on the road. Then the inputs and outputs were hardwired to the standard connectors we used for input and speakers. Power was supplied through one twist lock and fans were fitted to the backs of each heat sink, and the back of the whole enclosure, which was itself slid into an anvil road case.
The amps had various custom faceplates, some of which have been shown in stories on my blog over the years (it's at
http://jerobison.blogspot.com )
However, they still were not reliable and I attacked that problem here in the USA with some success. These are some of the things I did (there were others I don't remember; it's been 35+ years)
1 - We changed to higher speed Super Boxer fans and had two speeds for them. The higher speed was noisy but moved a lot of air. I fitted front panel warning lights that illuminated when the fans stepped up to high speed in response to sustained high temps.
2 - We experimented with different output transistors, modified driver circuits, and used heavier resistors on the driver boards.
3 - We combined the power supplies of the two amps and doubled the filter capacitor bank. I used a relay bridging a resistor bank to bring the capacitor banks online in steps so as not to overload the rectifiers. What that did was increase the peak power output because the supply voltage no longer sagged under load. That change made a significant difference in potential peak power.
4 - I also added MOV and diode transient suppression and I added clamps on the output lines for the same purpose. It turned out that poor quality power and cable induced transients had been responsible for some failures and that helped with that problem.
5 - I developed a limiter circuit that used a comparator to detect audio levels approaching the clip level as defined by power supply level at that moment and lowered output in advance. A companion circuit used a preset, time variable signal level limiter to prevent clipping and resultant destruction. The first circuit addressed the problem of driving amps to destruction when they clipped because the mains voltage had sagged and not enough power was available. The second circuit would allow maximum power at first but cut back to about 90% of potential after about 1 second to keep the outputs from overloading. With those circuits running the amps would be almost immune to clipping, even on powerful bass passages.
6 - Earlier in this thread someone wrote about three-way amplification, but by 1978 I had build Pink Floyd five-way crossovers so we had separate low bass, bass, low mid, high mid, and high amps and speakers. The great thing was, when the limiters were engaged for the low bass the mids and highs were generally still running free and you did not even hear the limiter effect except that the sound stayed clear.
After my time there I worked on many other high power amplifier designs, many of which were used in government and commercial power applications. My interest in transients and how they destroyed circuits led me to design the power conditioning for the ground zero test gear for our country's last big underground nuclear tests in the 1980s Some of those things were shown on the Discovery Science Channel's Ingenious Minds show a couple years ago. You can find that online I believe.
I never wrote much about my audio designs because I moved on to other things but I still loved that work.
John Elder Robison