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How to Choose Modular Power Supply in Automotive Electronics and Other Fields？

Article Source：Kinri Energy | Author：Kinri Energy | Issuing Time：2024.03.07
Module power supply is a power supply that can be directly mounted on printed circuit boards, providing power for specialized integrated circuits (ASICs), digital signal processors (DSPs), microprocessors, memory, field programmable gate arrays (FPGAs), and other digital or analog loads.

Generally speaking, these types of modules are referred to as load (POL) power supply systems or point of use power supply systems (PUPS). Due to the obvious advantages of modular structure, modular power supplies are widely used in communication fields such as switching devices, access devices, mobile communication, microwave communication, optical transmission, routers, and automotive electronics, aerospace, etc.

The selection of module power supply should consider the following points:

1. Consider the output power of the product:

1-60W, it is generally recommended that the actual power used is 30-80% of the rated power of the module power supply (the specific proportion is also related to other factors). Within this power range, the performance of the module power supply in all aspects is relatively sufficient and stable and reliable. A light load causes resource waste, while a heavy load is detrimental to temperature rise, reliability, and other factors. All module power supplies have a certain overload capacity.

2. What is the input voltage and output voltage

And it is necessary to consider whether the output voltage is single output or dual output.

3. Is there a requirement for isolation voltage

In general, there is not a high requirement for the isolation voltage of the module power supply, but a higher isolation voltage can ensure that the module power supply has smaller leakage current, higher safety and reliability, and better EMC characteristics. Therefore, the commonly used isolation voltage level in the industry is above 1500VDC.

4. Working temperature and derating usage

-40-85 degrees, -25-75 degrees. Generally, module power supplies from manufacturers have several temperature range products to choose from: commercial grade, industrial grade, military grade, etc. When selecting a module power supply, it is important to consider the actual operating temperature range required, as different temperature levels, materials, and manufacturing processes can result in significant price differences. Improper selection can also affect usage, so careful consideration is necessary.

There are two ways to choose:

One is to choose based on the usage power and packaging form. If the actual usage power is close to the rated power under certain conditions of volume (packaging form), then the nominal temperature range of the module must strictly meet the actual needs or even have a slight margin.

The second is to choose based on the temperature range. If a product with a smaller temperature range is chosen due to cost considerations, but sometimes the temperature approaches the limit, what should be done? Reduced usage. Choosing products with higher power or packaging can alleviate this contradiction to a certain extent by reducing the temperature rise of the "big horse pulling the small car". The reduction ratio varies with different power levels, generally ranging from 3 to 10W/℃ for power levels above 50W. In short, either choose products with a wide temperature range for better power utilization and smaller packaging, but at a higher price; Either choose products with a general temperature range, lower prices, and larger power margins and packaging forms. A compromise should be considered.

5. Are there any requirements for packaging and size

There are various packaging forms for modular power supplies, including those that comply with international standards and non-standard ones. For the same company's products, the same power product has different packaging, and the same packaging has different power. So how to choose the packaging form?

There are mainly three aspects:

① Under certain power conditions, the volume should be as small as possible in order to provide more space and functionality for other parts of the system;

② Try to choose products that comply with international standard packaging, as they have good compatibility and are not limited to one or two suppliers;

③ It should have scalability to facilitate system expansion and upgrading.

Choose a packaging method. Due to the increased power requirements for the system due to functional upgrades, the power module packaging remains unchanged, and the system circuit board design does not need to be modified, greatly simplifying product upgrades and saving time.

6. Fault protection function

According to statistical data, the main reason for the failure of module power supply within the expected effective time is damage under external fault conditions. The probability of failure during normal use is very low. Therefore, an important part of extending the lifespan of module power supplies and improving system reliability is to choose products with complete protection functions. That is, when the external circuit of the module power supply fails, the module power supply can automatically enter the protection state without permanent failure. After the external fault disappears, it should be able to automatically restore normal operation.

The protection function of the module power supply should at least include input overvoltage, undervoltage, and soft start protection; Output overvoltage, overcurrent, short circuit protection, and high-power products should also have over temperature protection.

7. Power consumption and efficiency

Under certain output power conditions, the smaller the module loss P, the higher the efficiency, lower the temperature rise, and longer the lifespan. In addition to normal losses at full load, there are also two losses worth noting: no-load losses and short-circuit losses (module power loss during output short-circuit), because the smaller these two losses, the higher the efficiency of the module, especially in cases where short-circuit measures are not taken in a timely manner, which may last for a longer time. The smaller the short-circuit losses, the greater the probability of failure. Of course, the smaller the loss, the more in line with energy-saving requirements.

8. Working frequency

Generally speaking, the higher the operating frequency, the smaller the output ripple noise and the better the dynamic response of the power supply. However, the higher the requirements for components, especially magnetic materials, will increase the cost, making it difficult to meet the requirements of dynamic response under load changing conditions. Therefore, high switching frequency products should be considered for high demand field applications. On the other hand, when the switching frequency of the module power supply is close to the signal operating frequency, it is easy to cause beat oscillation, and this should also be considered when selecting.

In short, module power supplies, like other components, can only be maximized in performance and reliability through careful selection and reasonable application, and module power supplies will be more widely adopted.
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