Hey Guys,
After much research, testing, and money spent. I am back to one of Mikes suggestions about installing a Battery in the loop to handle the peak load requirements. Now I'm looking into what sort of circuit I would need to use to charge the battery during operation. I will refer to the battery inside the PSU as the PSU Batt and the main batteries as the Main Batt to reduce confusion in this little idea I have. Here goes.
Charging of the PSU Batt - Could be performed from the Main Batt when its voltage is high isolating the PSU Batt from the Main Batt using a diode, this will prevent the PSU BAtt from disscharging should the Main Batt lose voltage.
Charging of the PSU Batt while under 240V mode/operation - This is my biggest question, do I need some sort of Charging circuit for the battery while 240v is running and the system is operating on batteries? This could potentially be 90% of the time in some situations so I'm concerned about simply putting a switchmode PSU across the battery terminals and expecting it to last? And suggestions on this would be great!
Isolating the PSU BAtt from the Main Batt during 240v operation - I suppose another relay or NC FET? here could be used to simply cut connection between the PSU Batt and Main Batt during 240v PSU powered operation?
Any other ideas I haven't thought of?
As the main load of my device is ~300mA but clearly peaking high enough to cause a SMPS to struggle starting without having an error the Battery will fix the issue like a CAP has failed to do.
Here is hoping!
Looking forward to your responses, I feel confident this will fix the issue I have now and I might be able to start getting some sleep again
Thanks guys!