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Not just "performance" and "cost"! Power module selection, you must be worried about these problems!
The advent of power modules has freed embedded engineers from the tedious task of designing power supplies. However, with so many types of power modules available, how do we select the right one in our everyday circuit designs? In today's highly competitive market, rapid product design and development have become essential for staying ahead and seizing business opportunities. Modular development, platform-based development, and program-driven development are now widely embraced by system designers and hardware engineers, especially under tight project deadlines and pressure.
Take, for instance, the modular design of mobile phones. The development of any electronic product cannot bypass the design of the power supply. If a product is like a human body, then the power supply is akin to the heart—its health directly impacts survival. Similarly, the quality of the power supply design determines the performance of the entire product and ultimately influences the success or failure of the project. Power supply design is known for its professional complexity, long debugging cycles, and challenging troubleshooting, making it a daunting task for engineers.
In this context, modular power supplies emerged as a solution, providing relief to engineers. Among these, DC/DC power modules are extensively used in communication, networking, industrial control, rail transport, and other fields due to their compact size, superior performance, ease of use, and cost-effectiveness.
When choosing among the myriad options of power modules with varying models and brands, how do we find those that are both suitable and cost-effective? While the general selection criteria are well-known, let’s delve into some common dilemmas encountered during embedded system design.
Firstly, should we opt for an isolated or non-isolated DC/DC power module? This is a question most embedded system engineers ponder. Isolation serves two purposes: safety and noise reduction. As embedded systems are deployed in diverse environments, they often face challenges like mixed voltage supplies, digital-analog hybrid circuits, and high-speed-low-speed signal coexistence on the same board. Improper handling can lead to interference, degraded performance, and even system crashes. Using isolated power modules to power different sections of the PCB minimizes noise and enhances system stability.
Moreover, in industrial bus systems, harsh conditions such as surges, arc discharges, and lightning strikes are common. Isolation not only prevents ground loops but also protects the core system from adverse external factors entering via the bus, ensuring system safety.
Secondly, balancing performance and cost is always a challenge. Engineers often struggle with whether to prioritize performance at any cost or compromise on performance for budgetary reasons. For DC/DC power modules with identical input and output voltages, output power and operating temperature range are key factors influencing cost. Temperature grades typically range from commercial (0°C to 70°C) to military (−55°C to 125°C), each requiring different materials and manufacturing processes, thus affecting cost significantly.
If the actual power usage nears the module’s rated power, the chosen module must meet or exceed the required temperature range with some margin. Opting for a lower-cost module with a narrower temperature range may lead to overheating if the operating temperature approaches the limit. Derating, or selecting a higher-rated module, can mitigate this issue by reducing temperature rise and maintaining reliability.
In summary, while wider temperature ranges offer better performance and smaller packaging at a higher cost, cheaper options with broader margins and larger packages are also viable. The choice depends on the specific project requirements.
Thirdly, how much power margin should be reserved? A 20% buffer is generally recommended to ensure stability and reliability without excessive resource wastage. Fluctuating loads present additional challenges, necessitating careful calculation based on peak currents and load variation frequencies.
Lastly, does a higher isolation voltage always mean better performance? Not necessarily. Isolation voltage levels, ranging from 1000VDC to 6000VDC, refer to the maximum voltage the module can withstand between input and output. Higher isolation voltage means better safety, lower leakage current, and enhanced electromagnetic compatibility (EMC). However, higher isolation voltage also increases cost due to stricter design and material requirements.
While technology evolves rapidly, embedding systems demand swift development cycles. Proper selection of DC/DC power modules can streamline design processes, improve system reliability, and expedite product launches. Hence, understanding these nuances ensures not only efficiency but also innovation in embedded system design.