Ready-made module or DIY solution for switching regulator circuits?

Many electronics companies today do not have the deep knowledge needed to build switching regulators, not least because the technologies involved can be highly specialised and processes such as the moulding of ferrite materials often may simply not be available. Product life cycles are also considerably shorter, and development costs, delays in the design process, and EMC tests all influence the return on investment.

Although developing a custom design may seem straightforward thanks to the comprehensive application information and design tools provided by control IC manufacturers, it is often impossible to predict the actual circuit requirements.

The proposed output capacity is often far too low for real dynamic loads. These can fluctuate between the active and standby states by a factor of one million, potentially causing unacceptable voltage peaks. (Fig. 2)

The new generations of modular voltage converters achieve high performance over a wide range of operating conditions. The RPMH series from RECOM, for example, is a 0.5A component with input voltage up to 65V and an output trimmable between 2.5V and 28V, all in a 12.19 x 12.19 x 3.75 mm EMI-shielded package. The series can be operated at up to 105°C without forced air cooling. An identically packaged component, in the RPM series, can provide output current as high as 6A.

• Low production costs for adding comprehensive control and monitoring functions.
• They frequently incorporate functions to minimise low-load power consumption while maximising efficiency, with techniques such as phase shedding in multi-phase converter topologies, because applications may be operated under different standby, low-load or full-load conditions.
• They employ advanced production techniques for very high power density, such as flip-chip on leadframe technology with over-moulding. Example: the RECOM RPX series, which achieves rated power of 2.5A in a QFN package (4.5 x 4 x 2 mm), with some in the series rated for ambient temperatures up to 95°C at full load without forced air cooling.
• With their degree of integration, modular converters can implement a different topology at low cost, e.g. a buck-boost circuit with four switches. This is effectively an array of MOSFETs which can be configured as switches or diodes to switch seamlessly between buck and boost modes. Example: The RECOM RBB series features up to a 3A rating in an LGA package and even offers a 3kW version in half-brick format with 9V to 60V input and 0V to 60V output. Typical applications include 48V to 24V or 12V to 24V battery power conversion, electric vehicles, battery voltage stabilisers or high-power laboratory DC power supplies.

If users and developers choose a switching regulator module that enables all of the processes and design techniques necessary for optimum performance, they save time and money. Added to this are the savings in supplier and inventory management – procurement, storage and handling is required for just one component compared with many parts from disparate suppliers for an in-house build. SMD placement time is reduced, and savings also accrue in testing and for agency approvals. With modules increasingly meeting industry standards for functionality and pinning, e.g. DOSA, second-sourcing concerns are also minimised. Taking total cost of ownership into account, a modular solution can now provide a clear advantage.

At Schukat electronic we offer a wide range of switching regulator modules from various series from our long-time partner and power supply manufacturer RECOM, offering a variety of features. In addition, our technical sales team will advise you on any power supply questions you may have.