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FOR BATTERY AND SUPERCAPACITOR-POWERED SYSTEMS
DC/DC Converters for Battery and Supercapacitor-Powered Systems: Efficiency for Longer Operating Times
Context and Background
Our cutting-edge DC/DC converters set the standard for battery and supercapacitor-powered electrical systems. With a focus on maximum efficiency, reliability, and compact size, our products offer tailored solutions for the complex challenges of modern energy storage and management systems.
Batteries provide high energy density and are excellent for applications that require long-term energy storage and continuous power supply. However, they respond slower to sudden power demands and have longer charging times.
Supercapacitors (supercaps), on the other hand, are characterized by their extremely high power density and fast charging and discharging capabilities. They are ideal for applications requiring short-term energy peaks or quick energy recovery. Our DC/DC converters are designed to optimally support both technologies, ensuring maximum efficiency and flexibility.
At the heart of our development is the optimization of energy efficiency. Our converters achieve very impressive efficiencies of up to 99%, which not only significantly extend battery life but also minimize heat loss. This makes them the ideal choice for a variety of applications, from electromobility and robotics to warehouse management systems.
DC/DC Converters for Extended Operating Times: Non-Stop Operation in Warehouse Management
Our customer, a global leader in robotics for the automated storage and retrieval of large goods, requires a compact DC/DC converter for their supercapacitor-powered transport systems. The key requirements are minimal size and maximum efficiency to meet stringent standards for energy conservation and space optimization. Our DC/DC converter, the 257LE-24-SD, delivers on both fronts with an efficiency of up to 98%, compact dimensions of 90x90x26 mm, and a lightweight design at just 355 grams. Its high efficiency enables transport robots to operate an average of 10 additional minutes per cycle—an important advantage, particularly in 24/7 warehouse automation systems. Even when the input voltage drops to 9VDC, as supercapacitors are near depletion, the converter reliably maintains a stable 24VDC output to ensure smooth operation.
Power Supply for Transport Systems in the Aviation Industry
A manufacturer of transport shuttles for the aviation industry requires a solution to power their electrical system. The input side provides 24VDC, which needs to be boosted and regulated to 28VDC, with the input voltage fluctuating between 20VDC and 30VDC. The output voltage must stay above 27VDC to prevent communication loss with the aircraft during high-power boot processes. This is accomplished using our DC/DC buck-boost converter 257E-28-SD.
Since the devices on the 28V side can consume more than 1kW of power, three converters are connected in parallel to supply the necessary current. In some systems, a backup battery also needs to be charged, ensuring the system stays operational even during unexpected stops when the supercapacitors are depleted and can't be recharged.
Portable, rechargeable devices: Lightweights for mobile applications
For our customer, who develops portable, battery-powered applications, the size and weight of the DC/DC converters are crucial for the mobility and user-friendliness of the end devices. Our DC/DC converters offer an optimal solution with a compact design and minimal weight without losing performance. Due to the required specifications, our galvanically isolated DC/DC converter 755-24-SD is used. Note that this is our biggest design in the portfolio. Compared to competitor products, we minimize the weight significantly and only require a minimal amount of space.
