Cosel Launches High-Efficiency AC/DC Power Supply

Designing an efficient, compact, high-power AC/DC supply poses myriad engineering challenges. For example, the process requires balancing high power output with energy efficiency, minimizing heat generation, and ensuring durability under harsh conditions. Additionally, the power supply must also accommodate varying power demands and provide stable operation, necessitating accurate sensing components and precise control mechanisms. 

Cosel has introduced a low-profile 3-phase, 3-wire AC/DC power supply designed specifically for industrial equipment like semiconductor manufacturing, laser processing machines, and robotics. 

AC/DC power supply. Image used courtesy of Cosel

Technical Specifications

Supplying energy to industrial equipment requires careful engineering. For example, powering a laser is challenging due to its extreme sensitivity and susceptibility to damage. Even a single pulse of excessive current, lasting only a few microseconds, can overheat and harm the semiconductor structure that generates light in a laser diode. 

An AC/DC power supply transforms alternating current (AC) from a power outlet to a direct current (DC) most electronic devices utilize. DC power supplies rely on several technical parameters to ensure optimal performance and reliability. In most respects, the most important metric is the power supply unit’s (PSU) power conversion efficiency, which the semiconductor technology predominantly defines. To this end, the industry has recently shifted from conventional silicon semiconductors to wide bandgap semiconductors made with silicon carbide and gallium nitride. With larger bandgaps (> 2 eV), these semiconductors can operate at higher temperatures, voltages, and frequencies. These characteristics result in superior efficiency, faster switching speeds, and smaller device footprints than silicon counterparts.

Three-phase power. Image used courtesy of Wikimedia Commons

The input phase number is another important technical specification because it influences the power supply's complexity and efficiency. Three-phase power supplies offer smoother power delivery, reduced ripple, and higher efficiency than single-phase counterparts. This is because three-phase systems distribute power more evenly, reducing the load on individual phases and minimizing fluctuations. Consequently, they can handle higher power loads more effectively, making them ideal for industrial applications. Additionally, three-phase power supplies often result in smaller and lighter designs due to more efficient electrical components use, ultimately enhancing the overall system performance and reliability.

Enabling Industrial Revolution

Recently, Cosel launched the HFA3500TF, a low-profile, high-efficiency 3-phase AC/DC power supply optimized for industrial equipment. Delivering up to 3.5 kW of power, this power supply operates over a 180 to 528 VAC input range and accommodates 3-phase Delta and Star configurations.

HFA3500TF block diagram. Image used courtesy of Cosel

Designed for efficiency, the HFA3500TF achieves 94% efficiency at 400 VAC input and 65 VDC output by utilizing advanced digitally controlled switching topology and wide bandgap semiconductors. For flexibility, the device offers two adjustable output voltage options: 48VDC, adjustable from 24.00 to 55.20 VDC, and 65 VDC, adjustable from 32.50 to 74.75 VDC. Its low profile, measuring just 41 mm in height, allows for integration into 1U racks, while two variable-speed cooling fans, inrush current limiting, and comprehensive overcurrent, overvoltage, and thermal protection add to the solution’s reliability over differing operating conditions.  

Cosel states this PSU is well-suited for applications where space is limited but high power output is essential, such as automation systems, industrial machinery, and test equipment. 

Powering Progress

The demand for robust, efficient, and compact power solutions will only grow as industries evolve toward automation and more sophisticated machinery. In this respect, Cosel’s power supply, integrating wide bandgap semiconductors and advanced digital controls, hopes to set a new standard for performance and reliability.