How to design a high-reliability power supply module and conduct a high-reliability power supply module test?

The power module is a power supply that can be directly mounted on a printed circuit board. Its characteristics are that it can be an application-specific integrated circuit (ASIC), digital signal processor (DSP), microprocessor, memory, field programmable gate array (FPGA) ) And other digital or analog loads to provide power.

Switching power supplies can be divided into two categories: AC/DC and DC/DC. The DC/DC converter has now been modularized, and the design technology and production process have been mature and standardized at home and abroad, and have been recognized by users, but The modularization of AC/DC, due to its own characteristics, makes it encounter more complicated technical and process manufacturing problems in the process of modularization.

Power modules generally refer to AC/DC and DC/DC converters. The most commonly used in circuits is the DC power conversion module. As the power supply part of modern technology products, it has become one of the key components. First, power modules are widely used in switching equipment, access equipment, mobile communications, microwave communications, optical transmission, routers and other communications fields, as well as automotive electronics, aerospace, etc. The reliability of the power module will affect the reliability of the equipment to a large extent, so the reliability of the power module has become a prerequisite for guaranteeing all parameters and performance. The main factors affecting the reliability of the power supply module are: design ideas, product technology, test methods, materials, improper use and other factors.

Design ideas, product technology, test methods, and materials are controlled by the power module manufacturer. Therefore, the manufacturer’s engineers should optimize as many indicators as possible during product development and design to ensure high product reliability. EMC testing and certification

Product craftsmanship means that the quality of the product is not affected when the product is manufactured and stored. For example, if the power supply is not paid attention to electrostatic protection when it is produced, it may cause the damage rate of the components to increase, thereby affecting the life and reliability of the power supply. When storing, it should be protected from moisture, high and low temperature, static electricity, etc.

Carrying out some related system test work, you can check out the power supply before there is any problem, and prevent the influence on the equipment caused by the use process. Because the power supply is an integrated circuit, the choice of material quality has also become a problem. Good materials naturally result in good quality.

1. Reliability test method of power supply module:

1. Short circuit test

No-load short-circuit test (let the power supply repeat the test from no-load to short-circuit), full-load short-circuit test (let the power supply continue to work from full load to short-circuit test), short-circuit startup (let the power supply repeat the test from short-circuit to power-on).

2. Power on and off test

Input mains, over-input voltage points, under-input voltage points, power module z large load, 15 seconds off and 5 seconds to continue working.

3. Input transient high voltage test

Rated voltage input, use an oscilloscope to record the number of cycles of high voltage, the power supply runs at full load, and the superimposed voltage jumps continuously.

4. Output dynamic load test with unstable input power

The input voltage is adjusted to unstable jump, the output is adjusted to z large load and no-load jump, and continue to run.

5. Power waveform test

Simulate voltage input such as spikes, burrs, and harmonics, test the performance and parameters of the power supply, and check the components and other questions and answers.

6. Voltage test

Test a variety of operating overvoltages, and see what are the effects of overvoltages on the equipment.

7. High and low temperature test

Because the performance parameters of the components are abnormal under high and low temperature conditions, long-term testing can expose the hidden dangers of the product.

8. Insulation strength test

Increase the value on the basis of the insulation strength of the product, continue to test, and get the limit value and abnormal situation.

9. Anti-interference test

Using EFT, the anti-interference voltage can be set to different levels of voltage, and the impact anti-interference test can be continued.

10. Input low voltage test

Test the continuous low-voltage input of the power supply module, long-term undervoltage situation, whether it affects the performance parameters of the power supply, etc.

2. Different designs and different uses will have an impact on the reliability of the module. In addition to fully doing various quality inspections and tests, the manufacturing of high-reliability power modules should pay attention to the design points of the following 4 parts when designing :

4 elements of high-reliability power supply module design:

1. Anti-surge protection circuit design

How to design the anti-surge protection circuit? For different applications, perhaps adjusting the position of the resistance, inductance, and TVS tube may result in better applications and proper application circuits for the system to better improve EMC performance. Pay attention to the design of the two-stage anti-surge protection circuit. If used improperly, it will be counterproductive. Safety inspection

2. Reduce quota design

Properly control the components to the specified value in use, and reduce their quota to delay the degradation, improve the reliability of the components and enhance the reliability of the power supply.

3. Design of dual power supply module

Pay attention to the load balance for the two outputs of the dual power supply module, and pay attention to the uniform voltage output of the main and auxiliary circuits when designing.

4. Selection of components

The application of different components will cause the performance of the module to be different. For example, ceramic or electrolytic capacitors are generally used in the selection of capacitors. Although tantalum capacitors have long life, high temperature resistance and good performance, they are easy to break down the circuit. It should be noted that different products are used differently. Third-party testing agency

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