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I’ve been running into this problem too, my solution has been to use parts and reference designs originally created for PoE applications. Inductor selection is also more finicky. When assembling a buck circuit to take 12v down to 5v, I can be pretty cavalier about the inductor, so long as it supports my max current x1.5 (my minimum derating value), but once you get to covert 48v down to 12, 5, or 3.3, ripple becomes a huge concern, but also the inductor behaves like a gigantic flywheel, plowing current down regardless of upstream switches and in general doing its own thing. I tend to over-protect my circuits with camping diodes and zeners to dump excess voltage to ground - something you don’t usually do when you’re controlling the voltage source, but I lack the knowledge on how to make a minimum design possible here.


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