Power conversion is a critical component in almost every electronic product, from small consumer items to industrial robots. Power supply modules supply the electrical power that electronic circuit needs by converting a voltage from an input to one that is suitable for the end part. Factors to consider when choosing a power supply module include input voltage, output voltage, current, efficiency, Isolation, temperature range and size of the space for installation. Campus Component offers components for engineers, equipment makers, students and product developers in prototyping, product development and production.
All electronic devices require a reliable power source to function as intended. Your device's microcontroller, sensors, display, communication modules and integrated circuits all may need different voltage levels. If you do not select an appropriate power source, the circuit may behave in an unstable way, generating unwanted heat, rebooting or damaging components. An appropriate power supply enables you to satisfy the electrical needs of your system.
Power supply modules come in various formats to suit multiple application needs. AC to DC modules convert power from an AC source into direct current. DC to DC power converters convert one DC voltage into another. Isolated converters introduce an electrical separator between the input and output power circuits, a feature that might be important for your design to implement an established isolation barrier. Non-isolated power converters might be more suitable for many applications in which an isolation barrier isn't needed and efficiency, size, or cost is a priority.
When sourcing components for a project, knowledgeable electronics components suppliers enable purchasing department to locate items that fit the technical specifications. Campus Component offers online catalogue which buyers use to browse different electronic component groupings for various uses. Prior to placing orders, verify the specific part number, data sheets, availability and commercial information, to make sure that they are appropriate for the designed application.
Calculating the load is often the first consideration in selecting a power module. Design engineers must determine the load voltage and current demands of all the circuits involved and analyze how these demands may fluctuate in actual operation. The power requirements for meters, monitors, switching circuits, and machinery with power motors or displays, etc. can vary, so appropriate capacity and startup conditions should be calculated to avoid overstressing the power source.
Efficiency Another factor to keep in mind is the efficiency of the power converter. A more efficient power converter loses less energy as heat and so it can better handle the temperature conditions. In addition, a more efficient power converter might burn a little less power overall. The efficiency of the power converter depends on its input voltage, output load, switching conditions and the design of the converter.
Electrical and thermal performance should be evaluated together. No matter how efficient the converter, some heat will be generated, and the power loss can grow as the load increases or airflow is impeded. The enclosure, PCB copper area, venting, and other high-power components in the vicinity all influence operating temperature. Engineers must adhere to the thermal guidelines of the manufacturer and test the finished product in actual use before committing to the design.
The isolation needs are application specific and safety architecture. In isolated systems, a separated converter is used to break the isolation between the high and low power circuits. Note that the isolation levels are not an indicator of product safety. Systems designers also need to take into account insulation coordination, creepage/clearance distances, protective components, enclosure design and applicable product standards for safety relevant applications –tandem technical documentation and testing.
Power modules are used across a wide range of applications including industrial control, instrumentation, communication equipment, smart devices and embedded electronics. An industrial controller may require a dedicated voltage rail to power a processor and external sensors, whereas a communication device may need separate digital and radio-frequency (RF) voltage rails. By choosing modules to meet the needs of each circuit, power distribution can be made simple and the design can be easier to maintain.
IoT devices bring other power challenges. Battery based sensors require low standby power and connected devices have a transient increase in power demand when transmitting wirelessly. The engineer should consider startup behaviour, sleep states, load transients, and the power consumption of each individual subsystem. For mains powered devices, input protection, efficiency, thermal characteristics and standards compliance may be more important.
Physical assembly is also significant. The module needs to match the PCB space it needs to occupy and to support the necessary connection into the surrounding circuitry. Package dimensions, pin pitch, mounting information, PCB layout recommendations, and restrictions around the sensitive components need to be studied. The layout recommendation from the manufacturer reduces noise, enhances thermal performance, and support reliable operation.
Cost must be balanced against performance and longevity. A cheap module may not be the best choice if it adds additional filtering, produces thermal problems or does not operate as specified in the application. The buyer should compare the full technical specifications of the module in question and factor in the cost of supporting components, integration work, testing and redesign to balance purchase price against finished product needs.
Procurement planning takes on a whole new level of significance when transitioning a product design from prototype to production. It's vital to review stock status, lead times and product life cycle data; packaging details; and any compatible substitutes. Having an approved list of part numbers and current bill of materials can lower chance of procurement mistakes; and for production orders, it's best to establish supply relationships ahead of production planning.
Part selection is a key part of quality assurance Engineers should seek datasheets, application notes, recommended operating conditions and certification, as appropriate. Examine the datasheets and application notes of the component before ordering to give the engineering team an understanding of the operating environments and conditions of the device. Store and use the components as per the manufacturer's recommendations, including eletrostatic discharge precautions if necessary. Test the module you selected as part of the final circuit.
Campus Component provides categories of electronic components that can help developers working on power conversion and embedded electronics. A full design may require microcontrollers, sensors, connectors, display, communication modules and protection devices, among others, in addition to components on a project-specific list. Combining relevant components on a project list can assist your team in arranging your procurement needs and determining what elements are still required to complete a design.
When deciding on a power solution, reference the electric, thermal, mechanical and safety data. Studying the application's specs, carrying out real-life tests, and selecting availability in the long term will also help minimize unnecessary sourcing and engineering issues. The ideal module is one that will work for the design requirements – not the one with the lowest first cost.
Reliable power conversion is a crucial starting point when designing an industrial controller, connected device, instrumentation system, or other new electronic product. Browse the component categories available at Campus Component, review product specifications, and ensure the compatibility of the item for your application prior to making a purchase. Call Campus Component today to learn more about the component options that are right for your application.
