Solving Acoustic Noise in Power Modules with IKP Electronics

High Power Density is a Trend — But Balance is the True Goal ⚡ In test power supplies, power density has become a major focus. Packing more kilowatts into fewer liters means better space utilization and efficiency — a clear advantage for R&D labs and system integration. But density alone is not enough. A truly robust solution must also balance performance and long-term reliability. Without this balance, higher density can quickly turn into higher risk. In practice, high-density designs must be supported by advanced capabilities, such as: 🔎 Four-quadrant operation → enabling bidirectional power flow for complex test scenarios 🔎 Programmable waveforms with feedback → simulating diverse conditions with high accuracy 🔎 Modular scalability → supporting multi-unit parallel connection and future expansion 🔎 Integrated AC source + load design → reducing system complexity, cabling, and cost 🔎 Fast dynamic response → ensuring precise performance in demanding applications An example is the ActionPower PRE20 Series, which integrates 22 kVA in just 3U (≈133 mm) — reaching nearly 950–1100 W/L, a level that stands among the industry’s best. Importantly, this density is achieved together with dynamic performance, functional integration, and stability, making it suitable for advanced applications like battery simulation, grid emulation, and high-end validation. 👉 In the end, high power density matters — but true engineering excellence lies in achieving density, performance, and reliability together. #HighPowerDensity #PowerTesting #Electronics #ActionPower

Case Study: Solving the "Singing" 48V Power Module in a Server Rack 🎵➡️🔇 A client's new high-density server power module was failing final QA. The issue? An audible, high-frequency "singing" noise under specific loads—a classic yet elusive problem. The Challenge: 🔸 Audible noise from the main power inductor, unacceptable for datacenter environments. 🔸 Efficiency dip of ~3% at mid-load, creating a thermal hotspot. 🔸 Project timeline at risk due to unpredictable debugging. Root Cause Analysis: Our team diagnosed it as combined magnetostriction (from the core material) and winding vibration (from the AC current). The standard ferrite core and bobbin winding structure acted like a tiny, unwanted speaker. Our Engineered Solution: We didn't just swap a part. We redesigned the magnetic solution: Core Material: Switched to a specialized low-magnetostriction ferrite blend. Winding Tech: Implemented pressure-wound, flat wire construction to minimize air gaps and dampen vibration. Process: Used vacuum impregnation with a high-thermal-conductivity epoxy to lock the windings and improve heat dissipation. The Results: ✅ Audible noise eliminated. (Passed acoustic QA) ✅ Mid-load efficiency improved by 2.5%. ✅ Peak temperature reduced by 15°C. ✅ Client secured a major order, and the design is now in mass production. The lesson? Not all inductors are created equal. A component engineered for the application's specific stresses is often the key to reliability. Struggling with noise, thermals, or efficiency in your #UPS, #ServerPower, or #IndustrialDesign? 👉 Let's diagnose it. DM me "Noise" for a copy of the full technical case study. #PowerElectronics #CaseStudy #EMC #HardwareDesign #ThermalManagement #Engineering #Magnetics #Innovation #[IKP ELEC]

Ever wondered how a Battery Management System (BMS) accurately measures current? There are two primary methods employed: shunt-based sensing and Hall effect sensing. Shunt-based sensing utilizes a small resistor to measure voltage drop, which is then used to calculate current. Alternatively, Hall effect sensing detects the magnetic field generated by the current flow, converting it into an electrical signal. Both methods offer unique advantages in monitoring and managing battery performance. Understanding these techniques provides valuable insight into the inner workings of modern battery systems. Watch full video here: https://lnkd.in/deS5tGxY #BatteryManagementSystem #electronics #engineering #HallEffect #ShuntSensing

🔍 Beyond the Datasheet: 5 Hidden Factors in Inductor Selection for High-Reliability Systems 🔍 Selecting a power inductor isn't just about inductance (L) and saturation current (Isat). In mission-critical applications like #UPS, #EnergyStorage, and #IndustrialPower, the devil is in the details. Oversight can lead to field failures, audible noise, and thermal shutdowns. After supporting 1000+ designs, we've compiled the top 5 often-overlooked factors: 1️⃣ Core Loss vs. Copper Loss Dominance: Are your losses coming from the core (AC) or the windings (DC)? At high frequencies, core loss can dominate and cause unexpected efficiency drop and heating. The choice between ferrite and powder cores is critical here. 2️⃣ The DC Bias Curse: That 100µH inductor isn't 100µH at full load. The real inductance under DC bias is what matters. Always analyze the normalized inductance vs. DC bias curve, not just the headline spec. 3️⃣ Thermal Derating is Non-Negotiable: A 40°C ambient is not a 25°C lab bench. Core materials age faster, and winding resistance increases with temperature. Always model performance at your system's worst-case operating temperature. 4️⃣ Acoustic Noise (The "Singing" Inductor): Magnetostriction can turn your inductor into a tiny speaker. If your application demands silence (e.g., medical, audio), you need a core material and potting process designed to minimize piezoelectric effects. 5️⃣ The Mechanical Factor: Vibration & Shock: Board flex or constant vibration can cause micro fractures in the core or windings, leading to intermittent failures. For automotive (IATF16949) or aerospace, mechanical robustness is as important as electrical performance. Your inductor is the heart of your power system. Its reliability determines yours. We've created a detailed Technical Guide that dives deep into each of these factors with simulation data, test results, and selection methodologies. 👉 Want a copy? Comment "Guide" below, and I'll send you the PDF directly via DM. #PowerElectronics #Magnetics #HardwareDesign #Reliability #Engineering #Electronics #PSD #ThermalManagement #IATF16949 #[IKP]

⚡Why does a diode allow current in one direction but block it in the other? The answer lies in its I-V characteristics! 📉⚡ 🔁 Understanding the Current-Voltage (I-V) curve of a diode is crucial for designing rectifiers, regulators, and switching circuits. Let’s break it down! 📌 Key Regions of the I-V Curve ✅ Forward Bias Region (+V, +I) ⤷ Small current flows until threshold voltage (Vₜ) is reached ⤷ Silicon diode: ~0.7V | Germanium diode: ~0.3V | LEDs: ~1.8V - 3.5V ⤷ After Vₜ, current rises exponentially ✅ Reverse Bias Region (-V, ~0I) ⤷ Minimal leakage current flows (almost no conduction) ⤷ Acts as an open circuit ✅ Breakdown Region (-V, High -I) ⤷ If reverse voltage exceeds limit, breakdown occurs ⤷ Zener diodes are designed to operate in this region for voltage regulation 📊 Where Are These Curves Used? ⤷ Rectifier Circuits → Convert AC to DC ⤷ Voltage Regulators → Maintain steady voltage (Zener diodes) ⤷ LED Circuits → Light emission for indicators & displays ⤷ High-Speed Switching → Schottky diodes for fast response 💡 Choosing the right diode requires understanding its I-V curve! Engineers use this data to optimize circuit performance and efficiency. ➡ What’s your go-to diode for circuit design? Let’s discuss in the comments! 💬 ♻️ Repost to share with your network if you find this helpful. 🔗 Follow Ashish Shorma Dipta for posts like this. #ElectricalEngineering #Diodes #PowerElectronics #Semiconductors #CircuitDesign

In the PCBA industry, power applications with heat transfer challenges are everywhere—power supplies, motor drives, RF amplifiers, EV systems, and high-power LED lighting, to name a few. When boards handle high currents and voltages, they generate heat that—if unmanaged—can reduce efficiency, shorten component life, or even cause outright failure. That’s why advanced thermal management is essential. At 𝗔𝗻𝗮𝗹𝗼𝗴 𝗧𝗲𝗰𝗵𝗻𝗼𝗹𝗼𝗴𝗶𝗲𝘀, 𝗖𝗼𝗿𝗽. (ATC), we regularly produce assemblies using state-of-the-art, high thermal conductivity substrates and heat-transferring materials. From heavy-copper and metal-core designs to advanced thermal interface solutions, our expertise helps engineers push the limits of power density while keeping reliability high. 𝗗𝗼 𝘆𝗼𝘂 𝗵𝗮𝘃𝗲 𝗽𝗼𝘄𝗲𝗿 𝗮𝗽𝗽𝗹𝗶𝗰𝗮𝘁𝗶𝗼𝗻𝘀 𝘄𝗶𝘁𝗵 𝗵𝗲𝗮𝘁 𝘁𝗿𝗮𝗻𝘀𝗳𝗲𝗿 𝗰𝗵𝗮𝗹𝗹𝗲𝗻𝗴𝗲𝘀? ATC will partner with your design engineers to implement new processes and materials that deliver the reliable, high-performance PCBAs your systems need to stay cool, efficient, and built to last. https://lnkd.in/gFP_dmdp #PCBA #PowerElectronics #ThermalManagement #ElectronicsManufacturing #AnalogTechnologiesCorp

Unexpected Resonances – EMI Filters vs. Converter Control Loops: Sometimes the hardest problems in power electronics aren’t inside the converter itself, but in how it interacts with its environment. A classic example: resonances between EMI filters and converter control loops. The issue: *EMI filters add extra poles and zeros into the system. If the converter’s control loop isn’t designed with this in mind, their interaction can create unexpected resonances. *The result? Oscillations, instability, failed compliance tests, or strange field failures that are hard to reproduce. How to predict and damp: *Model the input impedance of the converter and the output impedance of the EMI filter – instability often arises when the two are comparable. *Use Middlebrook’s criterion as a design guideline. *Add damping networks (RC snubbers, resistive damping in filter capacitors, or active damping). *Validate with frequency response analysis (FRA), not just time-domain testing. Lesson learned: An EMI filter is not just an add-on for compliance – it becomes part of the control system. Treating it as such early in design saves painful debugging later.

EMI filters are not passive “bolt-ons” for compliance, but active participants in the system’s dynamic behavior. Better treat EMI filters as part of the control system early on.

𝐓𝐚𝐜𝐤𝐥𝐢𝐧𝐠 𝐄𝐌𝐈: 𝐨𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧 𝐨𝐟 𝐭𝐡𝐞 𝐜𝐨𝐦𝐦𝐨𝐧-𝐦𝐨𝐝𝐞 𝐜𝐡𝐨𝐤𝐞   In power electronics, not all currents are created equal.   Differential mode (DM) currents are usually the ‘useful’ ones — they flow in opposite directions between conductors and drive the load. Their magnetic fields cancel out, so they typically don’t radiate much.   Common mode (CM) currents, on the other hand, are typically unwanted. They flow in the same direction on multiple lines and return through parasitic paths like ground or chassis. This creates large loop areas that efficiently radiate high-frequency noise.   That’s where the common mode choke comes in: it presents high impedance to CM currents, attenuating noise — while leaving DM signals largely unaffected. This is done by winding coils such that a CM current magnetizes a core where a DM current would not, due to the opposing winding directions.   By selectively blocking only the CM noise component, CM chokes support clean, reliable operation in systems like inverters, motor drives, and DC-DC converters.   #EMI #CommonMode #PowerElectronics #EMC #Magnetics #SignalIntegrity #MagnetecGmbH #ElectricalEngineering

Tips for Designing SEPIC Converters – New Application Note available 💪✨ The SEPIC (Single-Ended-Primary-Inductor-Converter) is a non-isolated switching power supply topology generating an output voltage that can be higher or lower than the input voltage. This is a common requirement in applications like battery-powered devices and chargers, automotive power systems, photovoltaic converters, LED lighting, and power factor correction stages. The new Application Note ANP135 provides details on: 🔹 SEPIC operation in continuous (CCM) and discontinuous conduction mode (DCM), 🔹 design considerations for coupled and uncoupled inductors, 🔹 the ripple current steering technique to reduce EMI noise, 🔹 the impact of leakage inductance on the converter performance, 🔹 SPICE simulations and measurements on a real DC-DC SEPIC converter prototype. 📰 Read our full press release here: https://we-online.link/Yd 📄 Or jump directly to the full Application Note: https://we-online.link/Ye #ApplicationNote #SEPIC #knowledge #support #WürthElektronik #morethanyouexpect