Efficient and Dense: 2024 Power Supplies

As electrification transforms industries from transportation to medical technologies, engineers are pushing the boundaries of power conversion efficiency, density, and reliability at the same time. Semiconductor advancements, particularly wide-bandgap (WBG) technologies, have unlocked more compact and energy-efficient solutions that can operate in increasingly demanding environments.

What are some of the most notable power supply advances in 2024?

Power supplies. Image used courtesy of Adobe Stock

Advanced Energy’s Next-Gen Power Converters

A major challenge in AC-DC power conversion is optimizing scalability while minimizing power losses. Advanced Energy addressed this with the Evergreen modular platform, an AC-DC solution featuring air-cooled, high-power modules and innovative design.

With an impressive power density of 38 W/in³ and 0.98 power factor, the platform achieves over 95% efficiency and supports scaling up to 30 kW per shelf. Its 528 VAC input, 60 VDC output, and modularity, enabled by hot-swappable 10 kW modules, make the solution extremely versatile and capable of fighting the needs of various industries. Advanced Energy sees opportunities in the medical, defense, and computing markets.

Advanced Energy’s AC-DC power converter. Image used courtesy of Advanced Energy

Cosel’s 3.5kW High-Efficiency Power Supply

Power supply design becomes even more complicated when brought into the industrial world, where reliable operation is expected under uniquely harsh conditions. In 2024, Cosel addressed these issues with the HFA3500TF low-profile 3.5kW, 3-phase AC/DC power supply.

With a low profile of 41 mm (1.61 inches), it meets 1U rack height requirements, offers an input voltage from 180 to 528 VAC (3-phase), and provides dual output voltage options of 48 V at 73 A or 65 V at 54 A for up to 3510 W of power. The power supply also achieves efficiency ratings of up to 94% at 400 VAC input and 65 V output.

Cosel’s AC-DC power supply. Image used courtesy of Cosel

The HFA3500TF power supply offers a strong combination of performance and reliability. It complies with SEMI F47 and various EMI/EMS standards, including EN55032-A and FCC Part 15-A, and safety certifications, including UL62368-1 and EN62368-1.

OmniOn’s Smart DC-DC Converters

OmniOn Power brought new power density levels to the market in 2024 with its FPLX-series DC/DC converters. These non-isolated modules achieved densities of up to 194 A/in² in a compact 10 mm x 10 mm footprint and up to 88% efficiency. Operating with input ranges of 6-14 V and outputs from 0.45-3.6 V, they featured mode-switching for optimization and PMBus compatibility for monitoring.

TDK’s Efficient Industrial Converter

For harsh environments, TDK-Lambda introduced its RGB series of non-isolated DC-DC buck converters. These converters offer adjustable outputs up to 24 V, with efficiencies reaching 98.5%. Designed to operate from -40°C to +115°C, they feature a rugged encapsulated aluminum case for EMI reduction and conduction cooling. Compliant with MIL-STD-810G and global safety standards, the series incorporates advanced features like remote sensing and protection that guarantee reliability for industrial, medical, and battery-powered applications.

TDK Lambda’s RGB series. Image used courtesy of TDK-Lambda

Vox Power’s EIRE300 Series

The challenge of achieving compact and high-power-density designs for medical and industrial equipment led Voxpower to develop the EIRE300 series in 2024. This AC-DC power supply delivers continuous 300 W and peak 375 W output within a 4” x 2” footprint and 1” profile, resulting in a power density of over 37.5 W/in³. Operating at up to 95% efficiency, it supports fan-cooled and convection-cooled setups, while its advanced protections against over-voltage, over-current, and over-temperature position it as a versatile and efficient solution for demanding applications in space-constrained environments.

Vox Power's EIRE300. Image used courtesy of Vox Power

A Year in Review

It’s clear from 2024’s power supply advancements that a plethora of challenges face the industry at any given time. From modular scalability to rugged designs for harsh environments, 2024’s breakthroughs have pushed frontiers further yet again. These advances in power electronics could unlock new applications across vital fields like industrial, medical, and computing.