How to Simplify Power Design of DC-DC Converter with Modular Architecture

 

DC-DC converters are essential components in electronic devices, responsible for converting one voltage level to another. They are widely used in applications ranging from portable electronics to industrial automation. Developing power systems for aerospace and military applications poses numerous challenges, particularly when dealing with complex, high-power DC-DC converter architectures.

Embedded Developers/Designers face the task of meeting these standards for input voltage, electromagnetic interference (EMI), environmental conditions, and Heat management. DC-DC converters play an important role in transforming and regulating electrical power in various applications. To process this power design, electronic engineers are increasingly turning to modular architectures.

In this blog, we'll explore the benefits and How you can Simplify the Power Design of DC-DC Converter with Modular Architecture design for a wide range of applications.

What is the Modular Architecture and Power Solution used in the Power Design of DC-DC Converter?

Modular Architecture

 Modular architecture involves breaking down complex systems into smaller, more manageable modules. When applied to DC-DC converters, this approach offers several advantages:

Scalability: Modular DC-DC converters allow for easy scalability. Engineers can mix and match modules to achieve the desired power output, adapting to the specific needs of each application. This flexibility is particularly beneficial for prototypes and evolving project requirements.

Reduced Development Time: Designing a power solution from scratch can be time-consuming. With modular architecture, embedded developers can use pre-designed modules which will reduce the development time significantly. This accelerated design process enables faster time-to-market for electronic products.

Ease of Maintenance: In case of circuit failure or your circuit needs an upgrade, using modular DC-DC converters simplifies the debugging and maintenance process. Engineers can simply replace or upgrade individual modules without disrupting the entire power system, minimizing downtime and associated costs.

Customization Options: Modular DC-DC converters provide a customization platform where engineers can build power solutions to meet specific application requirements. This customization ensures optimal performance and energy efficiency for diverse electronic devices.

Enhanced Reliability: The modular approach improves system reliability by isolating potential issues to specific modules. This isolation minimizes the impact of a failure, making it easier to identify and address problems quickly.

A modular approach achieves comparable or superior performance through a combination of modules. The structure of each modular solution varies based on the application's requirements, typically taking together multiple DC-DC converters to adjust the common bus voltage for specific load needs.

Process in Simplifying Power Design of DC-DC Converter with Modular Architecture

1) Identifying the system requirements and module options with a high-level definition of system operation.

 

2) Organize and classify the system inputs and outputs.

3) Developing system architecture and selecting power components and also reviewing available power components and modules.

4) Identifying necessary circuitry for interfacing modules and performing specialized functions.

5) Formulating a power delivery strategy using available modules and constructing a block diagram.

6) Implementation of modules and support circuitry.

7) Finalizing module configurations.

Four Stages of Design

Stage 1: Basic System Requirements

Gathering system requirements is the first step in simplifying the power design of DC-DC converter with Modular architecture. The main evaluation parameters at this stage are the power source, characteristics of the power source, types of load needed, and type of architecture needed to build.

Stage 2: System Architecture

Create a power distribution framework and build the process of choosing and solidifying the power components necessary to meet the requirements of the system conversion. Formulate a system block diagram and decide on a structure for delivering power seamlessly from the source to the load.

Stage 3: Implementation

In the current stage of the design phase, configurations for modules and the external circuitry essential for the ultimate system integration have been concluded. Initiate the exploration by inspecting an illustrative instance of supporting circuitry, presented for simplicity around a lone DC-DC module.

Figure: Supporting circuitry required to build a complete system with a DC-DC converter with Modular Architecture.

Stage 4: Module Control and Monitoring

In the final phase of the design process, customize the module behavior and oversee the control and monitoring interfaces.

Applications of DC-DC Converter with Modular Architecture

1. Military Applications

In military applications, a prevalent power supply is a predefined bus providing 24V DC or 28V DC, applicable to both airborne and ground scenarios. Wide input range DC-DC converters offer adaptability to 24V DC or 28V DC inputs, accommodating voltage fluctuations during abnormal or emergency operating conditions.

 

 

 

Additional modules like voltage limiters and EMI filters can be integrated. Modules such as GAIA's HUGD-300 address challenges related to capacitor size and inrush current during bus power absence, providing a more efficient solution.

2. Electromagnetic Interference(EMI/EMC)

Efficiency and size reduction in DC-DC converter modules often result from their switching nature, creating electrical noise.

GAIA's DC converters with synchronization pins offer a unique solution, allowing designers to shift the switching frequency away from sensitive frequencies. In multi-module systems, precise alignment of switching frequencies eliminates low-frequency "beat" noise caused by slight differences in individual module frequencies.

3. Operating in Different Environmental Conditions

Military/avionics systems face diverse and challenging environmental conditions, including extreme temperatures, humidity, shock, and vibration. A modular approach, utilizing pre-qualified modules, reduces design risks and simplifies the approval process.

4. Heat Management

Heat management is a critical aspect of any electrical system, especially in confined spaces like those found in military/avionics applications. GAIA converter modules are designed for a maximum case or floor temperature, providing a reliable thermal threshold. Thermal management strategies may include fan-forced air cooling, enhanced board metallization, heat sinking, or a combination of these techniques.

Conclusion

From the above blog we can conclude that a DC-DC converter with modular architecture can reduce design time and have multiple applications in the defense field, it can even work well in different environment conditions, providing good support for EMI/EMC issues and managing high-temperature. As this technology is evolving, developers must ensure that the chosen architecture and modules comply with the latest standards, which will ensure the long lifetime and effectiveness of their power system designs.

If you are looking to design a DC-DC converter with Modular Architecture and looking for electronic components for power solutions from trusted brands such as Mornsun, AIT, IK SEMICON and other components reach out to Campus Component- the best electronics suppliers today!