Challenges Engineers Face during DC-DC Power Supply Design

Electronic system designers, program managers, engineers, and original equipment manufacturers must address numerous challenges in the selection or development of an appropriate power supply for their systems. These challenges include a multitude of aspects related to the product development cycle, time-to-market, reliability and warranty, parts availability, and life cycle costs. In some cases, an existing power supply can be readily adapted from a different application. In other cases, it may be necessary to develop a new or custom power supply. Let’s examine the major challenges faced in the design of DC-DC power supplies and determine the solution.

Top Challenges Faced by Engineers during DC-DC Power Supply

1.   Physical Size: Much as Moore’s law observes an increase in the number of components in a decreasing amount of available space, so too have advances in miniaturization technologies had a dramatic impact on the DC-DC power supply industry. Electronic systems, such as computers, cell phones and televisions – which once occupied large volumes – can now fit in the palm of a hand. The trend in miniaturization requires the shrinking of the power components that keep them running. Older systems that have not been updated for several years tend to use older generation DC-DC power supply technology with larger form factors. Depending on the physical requirements of an application, DC-DC power supply designers have had to become increasingly creative to adapt to changing space demands. We have reached a point where off-the-shelf supplies might not be enough. Take health care industry for example, they need new sets of power demands for bedside care and personal monitoring devices.

2.     Non-Standard DC Inputs: Today’s world is increasingly being run by small microprocessors that are sensitive to even small voltage fluctuations. Many power problems originate in the commercial power grid, which, with its thousands of miles of transmission lines, is subject to numerous power disturbances related to weather conditions, equipment failure, traffic accidents, and switching problems. Some of these problems include transients, interruptions, voltage fluctuations and frequency variations. A robust DC-DC power supply must reliably operate through input power disturbances in order to ensure the reliable operation of the systems it supports. While most applications require the typical 115 or 230V, new applications call for more unique DC input voltages, and power supply companies are adapting to meet these changing requirements.

3.   Non-Standard Output Voltages: Electronic components and systems that operate at standard or generic voltages (e.g. 5V, 12V, 24V, and 48V) may be inefficient, since the power that is not used produces extra heat in the system, which must be removed if it is to remain within its operating temperature range. Modern electronic components may need to operate at non-standard voltages in an effort to maintain high system efficiency in a reduced size. This poses problems to electronic system designers since it may not be feasible to use an off-the-shelf DC-DC power supply. This increased demand for non-standard voltages is calling for DC-DC power supply provides to adjust product offerings to meet custom voltage requirements.

Besides these three top challenges, there are two more such as ruggedization and component obsolescence where engineers also face challenges to design DC-DCpower supply. Though many industry sectors face fast development cycles and feel they need to forego the customization process, at many times, it is inevitable. At least now you can achieve “power your way” with E-Star Development Co. Ltd.