Topology Reconfiguration and Heat Dissipation Practice for Industrial Switching Power supplies to Achieve over 96% Efficiency

Topology Reconfiguration and Heat Dissipation Practice for Industrial Switching Power Supplies to Achieve over 96% Efficiency

Abstract

In the era of rapid industrial automation and intelligence, an efficient and stable power supply is the cornerstone of smooth industrial operations. This paper delves into the strategies of topology reconfiguration and heat dissipation design to elevate the efficiency of industrial switching power supplies to over 96%. By dissecting and enhancing existing power modules and integrating EBYTE's high - efficiency power solutions, we aim to achieve a power supply that is both efficient and reliable.

Keywords

Industrial switching power supply; Topology reconfiguration; Heat dissipation design; EBYTE power module

Main Body

1. Introduction

Industrial switching power supplies are the unsung heroes of modern industry, powering a vast array of equipment. However, traditional switching power supplies are shackled by their topology and heat dissipation design limitations. Their efficiency rarely crosses the 90% threshold, which not only leads to energy waste but also poses challenges in high - performance industrial applications. This paper presents a comprehensive approach to push the efficiency of these power supplies beyond 96% through topology reconfiguration and optimized heat dissipation design.

2. Topology Reconfiguration

Traditional topologies like flyback, forward, and half - bridge have served their purpose but fall short in the face of today's high - efficiency demands. Newer topologies offer a way forward.

LLC Resonant Converter

The LLC resonant converter is a game - changer. It operates on the principle of zero - voltage switching (ZVS) and zero - current switching (ZCS) via a resonant circuit. This means that during the switching process, there is little to no voltage or current across the switches, drastically reducing switching losses. For example, in high - frequency applications, the reduction in switching losses can lead to a significant boost in efficiency. Moreover, its low electromagnetic interference (EMI) makes it suitable for industrial environments where sensitive electronic equipment is present. The good load regulation ensures a stable output voltage even when the load varies, which is crucial for maintaining the performance of industrial machinery.

Synchronous Rectification Technology

In high - power applications, synchronous rectification technology shines. By replacing traditional diodes with MOSFETs on the secondary side, it slashes rectification losses. Diodes have a forward voltage drop, which results in power dissipation. MOSFETs, on the other hand, have a much lower on - resistance, reducing the power lost during rectification. This technology can be particularly effective in power supplies for large - scale industrial motors or heavy - duty machinery.

3. Heat Dissipation Design

Efficient heat dissipation is non - negotiable for power modules operating under high load.

Heat Sink and Fan

Installing a heat sink on the power module's surface increases the surface area for heat transfer. The fan then forces air over the heat sink, enhancing the convective heat transfer process. This combination is a tried - and - true method. For instance, in a large - scale industrial power supply cabinet, multiple power modules with heat sinks and fans can work in tandem to maintain a safe operating temperature.

Heat Pipe Technology

Heat pipe technology takes heat dissipation to the next level. It uses a working fluid inside a sealed pipe. When heat is applied at one end, the fluid evaporates, carrying the heat to the other end where it condenses and releases the heat. This phase - change process is extremely efficient at transferring heat quickly to the heat sink, ensuring that the power module remains cool even under heavy load.

4. Application of EBYTE Power Modules

EBYTE's power modules are a key component in this high - efficiency solution.

High Efficiency

EBYTE power modules, such as AM11 - 12W12V and DM41 - 20W2412B1, are designed with advanced topologies and optimized circuits. This enables them to achieve high conversion efficiency, meeting the stringent requirements of industrial applications.

Wide Voltage Input

The ability to support a wide voltage input range is a significant advantage. In industrial settings where the power grid may be unstable, these modules can adapt and provide a stable output voltage, ensuring the continuous operation of equipment.

Multiple Protection Functions

With built - in over - voltage, over - current, short - circuit, and over - temperature protection, EBYTE power modules can automatically recover from abnormal conditions. This not only protects the power module itself but also the connected industrial equipment, improving the overall system reliability.

Small Volume

The compact size of EBYTE power modules makes them easy to integrate into various devices. In industrial control cabinets or small - scale automation systems where space is at a premium, these modules can be installed without taking up excessive room.

5. Practical Case

In a real - world industrial application, the combination of EBYTE's AM11 - 12W12V power module with LLC resonant converters and synchronous rectification technology has been a success. The power supply efficiency has soared to over 96%. The optimized heat dissipation design, including heat sinks, fans, and heat pipe technology, has ensured that the power module operates stably even during long - term, high - load operations.

Through topology reconfiguration and optimized heat dissipation design, and with the integration of EBYTE's high - efficiency power modules, the efficiency of industrial switching power supplies can be significantly improved. This not only enhances the power supply's conversion efficiency but also boosts the reliability and stability of the entire industrial system, opening up new possibilities for industrial automation and intelligence. The application of these technologies has broad prospects in various industrial sectors, from manufacturing to energy production.