Hochleistungs-SMPS-Designs

Hochleistungs-SMPS-Designs

Switch mode power supplies (SMPS) come in many output power levels, ranging from sub 1W to multiple kilowatts. SMPS designers focusing on high-power applications must choose their topology carefully and pay particular attention to issues such as component choice and cooling system design. Plus, there are ever-increasing energy efficiency standards and an array of applicable regulations to consider.

Overview of high-power markets and applications

High-output power supplies are found in many applications in the medical, industrial, transportation, and automotive segments.

Power supplies designed for medical applications may appear identical to their commercial-grade equivalents, but due to the risk-adverse nature of medical applications, they must be held to very high standards of safety, EMC and reliability. Medical power supplies have been designed to meet and be approved to the medical equipment IEC60601-1 safety standard and IEC60601-1-2 EMC standard, which influences the internal power supply design.


Figure 1: a selection of RECOM’s large portfolio of industrial-grade power supplies. (Source: RECOM)
Medical equipment typically requires longer design cycles than other types of equipment and medical equipment designers often require more design support from the power supply vendor. In addition, medical equipment usually has a greater life expectancy than other equipment. Therefore, power supplies designated as medical-grade generally need to be supported by the power supply vendor for many years.

High-power applications in the medical field include

  • Surgical tables
  • Motorized hospital beds
  • Diagnostic or biological facilities
  • Test or measurement systems
  • Portable hemodialysis machines
  • Respiratory equipment (e.g., ventilators, CPAP machines)
  • MRI, CT, and PET scanners
  • Laser equipment


The industrial environment is a fertile one for high-power applications. Industrial DC/DC and AC/DC power supplies are everywhere in a state-of-the-art automated factory. Some examples include:

  • Industrial automation and control
  • Industrial machines such as lathes
  • Material handling equipment
  • Welders
  • Electric heaters and ovens
  • Industrial robots
  • Test and measurement equipment


Industrial grade power supplies need to offer a reliable and stable performance of a wide range of operating temperature, high humidity and shock/vibration conditions, as well as coping with output short circuits or input voltage surges. Many industrial power supplies include high speed data and control bus interfaces and are integrated into a factory supervisory control and data acquisition (SCADA) network to improve the efficiency, response times and accuracy of industrial operations. The complexity of these systems require isolated DC/DC power supplies to break ground loops, isolate sub-systems to make the overall SCADA fault tolerant and to increase operator safety.

DC/DC and AC/DC power supplies in railway applications must function reliably for many years under extreme conditions such as heat, cold, shock and vibration. The EN50155 standard specifies carefully defined requirements for information systems and electronic components used in railway engineering and rolling stock. EN50155 lays down minimum requirements for the input voltage range, electrical isolation, operating temperature, shock and vibration, humidity, and EMC, as well as equipment reliability and expected useful life. Railway applications include:

  • Railway rolling stock
  • On-board and trackside application
  • High voltage battery-powered applications
  • Distributed power supply architectures


The rapid adoption rate of electric vehicles (EV) is making daily headlines, fueling a boom in the development of power supplies for EV charging infrastructure. Consumers are also demanding larger capacity batteries with faster charging times. This demand is spurring an increase in battery operating voltage from 400V to 800V, increasing the demand for high-power charging solutions.


Figure 2: A typical EV home charging system (Source: RECOM)


High-power EV chargers can take several forms based on the installed location and the end user. Charging powers vary from less than 2 kW in applications such as electric scooters to up to 1 MW for large fleet and utility vehicle charging.

Most EV chargers are unidirectional as the on-board charger (OBC) built into the vehicle is not designed to transfer power bidirectionally, but an EV equipped with a DC charging socket offering direct access to the high voltage battery is potentially capable of acting as an energy storage system (ESS), enabling a variety of vehicle-to-other use cases: vehicle-to-home (V2H) power generation, vehicle-to-grid (V2G) peak shaving opportunities, vehicle-to-vehicle (V2V) charging, or jumpstarting another EV. Eventually, the EV charging ecosystem is expected to transition from a unidirectional to a bidirectional topology, but many regulatory hurdles and technical issues must be surmounted before it is widely adopted.

AC/DC auxiliary supplies must also match the EV charger requirements in terms of efficiency and value. Charging wall boxes and charging stations are often installed in overvoltage category three (OVC III) environments with the potential for significant dips, surges, and transients from lightning strikes, which the power supplies must also withstand. Additionally, environmental conditions can be harsh as the chargers are often mounted in damp, dusty or dirty garages, and the AC supply voltage available may be three-phase 480VAC or 277VAC. Auxiliary AC/DC modules must operate reliably in this environment along with switching regulators and DC/DC converters that provide internal voltage conversion and isolation.

Design considerations for high-power applications

Switched-mode power supply (SMPS) topologies are overwhelmingly preferred to linear designs for high power applications due to their higher efficiency and greater power density. There are numerous switching topologies for DC/DC converters, with varying combinations of performance and cost. A low-power application often uses a flyback or forward topology for reasons of simplicity and cost effective, but a high-power application places the emphasis on maximizing efficiency and performance – two metrics that invariably increase both cost and design complexity. RECOM's AC/DC and DC/DC Books of Knowledge provide detailed introductions to the various converter topologies and their applications.

Four topologies are widely used in high-power DC/DC converter designs: the two-transistor push-pull, the two-transistor half-bridge, the full-bridge, and the resonant LLC converter. The first topology mentioned is least used for EV-charging application, so is not covered here, but its principle of operation is discussed in detail in the RECOM DC/DC Book of Knowledge.

Half-bridge and full-bridge converters



Figure 3: The half-bridge and full-bridge topologies (Source: RECOM)


The half-bridge circuit shown in Figure 3 can be scaled up well to higher power levels and is based on the forward converter topology. The transformer only sees half of the input voltage on each switching cycle, so the transformer is larger than with other topologies. It also has the disadvantage that if both switches Q1 and Q2 are on at the same time there will be a high shoot-through current, so there needs to be a dead-time between the on-time cycles of each switch. This limits the duty-cycle to about 45%. However, the half-bridge topology benefits from a low component count which makes it suitable for low-cost 230V AC and PFC applications.

The disadvantages of the half-bridge can be eliminated with the full bridge topology shown on the right in figure 3, which uses four switches which are activated in the sequence Q3 + Q1: ON, Q2 + Q4: OFF and then Q2 + Q4: ON, Q3 + Q1: OFF, so that the transformer primary side always sees the whole input voltage on each switching cycle. A dead-time is still needed to ensure zero-voltage switching (ZVS) for higher efficiency and lower switching losses but it can be much shortened to get almost a 50% duty cycle.

A full bridge topology thus has all the advantages of the half-bridge, but none of its disadvantages. However, the timing circuit is more complex and two isolated high-side drivers are needed rather than one, but the additional component cost is less significant in a high-power application.

Resonant LLC converter



Figure 4: the half-bridge LLC converter (Source: RECOM)


The resonant LLC converter (Figure 4) is a half-bridge topology that uses a resonant technique to reduce the switching losses by using zero voltage switching, even in no-load conditions. This topology scales up well to high power levels and offers conversion efficiencies in the upper 90% range. They are the most popular choice for EV high-speed chargers due to the availability of complex controllers and the need to keep losses to an absolute minimum.

The topology has two resonant frequencies. The first is the series resonance tank formed from CR and LR and the second the parallel resonance tank formed by CR and LM + LR. The advantage of the double resonances is that one or the other takes precedence according to load. So, while a series resonant circuit has a frequency that increases with reduced load and a parallel resonant circuit has a frequency that increases with increasing load, a well-designed series parallel resonant circuit has a stable frequency over the whole load range. The switching frequency and values of LR and CR are chosen so that the transformer primary winding is in continuous resonance and sees an almost perfect sinusoidal waveform.

The resonant LLC has the advantage over both push-pull and half-bridge topologies of being suitable for a wide range of input voltages. The downside to the resonant LLC topology is its increased complexity and cost.

Bi-directional EV charging requires a different approach. A unidirectional OBC is typically an LLC resonant converter but this is a unidirectional topology. A bi-directional CLLC resonant converter is therefore preferred for the DC-DC stage, as it combines high efficiency with a wide output voltage range in both charging and discharging modes.

High-power design considerations for AC/DC converters

Low-power designs can make do with a simple diode bridge rectifier, but a higher-power AC/DC designs must use a power factor correction (PFC) input stage to comply with EMC regulations. The PFC can either combined with the DC/DC stage into a single unit or added as a standalone front end in a modular design.



Fig. 5: Three-phase Vienna Rectifier topology PFC (source: RECOM)


For higher power AC/DC converters, a three-phase PFC topology such as the Vienna rectifier (Figure 5) can be used. This is an active three-level topology that reduces high switching voltage stress on the transistors by using a capacitive divider to halve the supply voltage. The input diodes can be either partly or fully replaced with synchronized switching transistors to increase the efficiency further.

RECOM’s AC/DC Book Of Knowledge, mentioned earlier, covers AC/DC converter design in greater detail.

Cooling system design

Another design consideration is the operating temperature of the power supply, whether AC/DC or DC/DC. There is a well-established relationship between operating temperature and reliability for semiconductor components. Higher temperatures equate to higher failure rates, with a statistical halving of the reliability for every 10°C increase in temperature. Managing and dissipating excess heat is thus an important priority for the power supply designer. Even though high-power designs typically boast efficiencies well in excess of 90%, thermal management is still required.

The most common cooling techniques for AC/DC and DC/DC power supplies include conduction, convection, air, and liquid cooling techniques. Each of these cooling techniques can provide a temperature management solution that increases the effectiveness and efficiency of the application.

Conduction cooling is the transfer of heat from a higher-temperature part to a lower-temperature part by direct contact. For example, many DC/DC converters have a flat surface that is designed to mount directly to an external heat sink or cold plate that will conduct the heat away from the power device by direct contact, thereby cooling it.

Convection cooling transfers heat from the power device by the action of the natural air flow (a low-density fluid) surrounding and contacting the device. Many power devices are rated for natural convection cooling so long as the air surrounding the unit remains within a limited temperature range that is cooler than the device.

Fans can also be mounted on the front or rear of either the power supply or the surrounding cabinet to supply forced air cooling. This method allows for greater power density. Many power supplies that require forced air cooling will specify a minimum airflow to achieve rated power.

Liquid cooled power supplies use circulating fluids to cool down the system resulting in higher power capabilities with little noise as there is no cooling fan. The advantage of liquid cooling is that hot spots can be targeted and individually cooled without the need for bulky internal heat sinks.

Silicon carbide: an emerging trend in high-power design

High power designs value high efficiency over component cost or design complexity compared to their low-power counterparts so many innovations appear first in the high-power segment.

For example, a high-power design has traditionally used Si MOSFETS or Si IGBTs for the power switching function, but wide bandgap devices based on silicon carbide (SiC) and gallium nitride (GaN) are beginning to replace silicon devices in this application. SiC is the more mature technology and is being adopted in high-power systems due to its unique combination of critical electric field, electron velocity, high melting point (300°C), and high thermal conductivity. On the transistor level, this leads to a low on-state resistance (R(DS)on) that allows for low switching loss and low conduction losses, making it ideal for high-current applications.

In a DC/DC design, the faster switching speed of the SiC devices leads to greater power density through the use of much smaller magnetics and much greater efficiency due to lower switching losses. The higher operating temperature of SiC also reduces the development time and cost associated with thermal management design.

In an AC/DC design, the use of SiC allows the replacement of the conventional PFC boost topology, with its power-wasting diode bridge, by the more-efficient totem-pole PFC. Eliminating the bridge rectifiers improves PFC efficiency by switching at a higher frequency and reducing the number of semiconductor devices in the conduction path from three to two.

The theoretical advantages of the totem-pole PFC architecture have been recognized for many years, but a high-power implementation was previously impractical as the body diode of the Si MOSFETs limits totem-pole application to discontinuous-mode operation (DCM) and low power levels. In contrast, the SiC MOSFET allows the totem pole PFC to operate in CCM for high efficiency, low EMI, and increased power density.

A SiC MOSFET also has advantages over an IGBT. The IGBT does not contain a body diode so an ultrafast freewheeling diode may be used instead. But the IGBT’s maximum switching frequency is limited to around 20kHz due to high switching and conduction losses. The low maximum switching frequency increases the weight and size of the magnetics and passive components compared to a SiC solution.

RECOM standard high-power product families

RECOM offers many families of high-power standard products that are optimized for the markets discusses earlier.

For medical applications, RECOM’s modular REM and RACM series converters offer complete, compliant solutions that reduce design time, simplify end-user certification and provide faster time to market. These medical grade DC/DC converters and AC/DC power supply series feature reinforced isolation with two means of patient protection (2 x MOPP), low leakage (BF and CF ratings) and > 8mm creepage and clearance distances. Reinforced isolation provides an additional level of safety beyond the standard functional isolation to comply with the medical safety standard ES/IEC/EN 60601-1 3rd Ed.

For industrial power supplies, RECOM offers the most comprehensive industrial portfolio available, with over 25,000 standard products. RECOM industrial-grade power supplies are cost-effective, safety-approved, and EMC-certified power supplies in many form factors with power levels up to 10kW and isolation from 1kVDC up to 5kVAC.

For railway use, RECOM and its subsidiary Power Control Systems (PCS) offers three-phase AC input battery chargers with active power factor correction, complying with railway standards, available with ratings at 3.2kW (RMOC3200 series) and 5kW (RMOC5000 series) which can be cascaded up to 20kW. The RMOC3200 series also operates with DC inputs up to 800V. Outputs from both series are available suitable for 24Vnom up to 110Vnom (and all in between 36/48/72/96). RECOM also offers DC/DC and DC/AC railway power supplies for both on-board and trackside applications.

For EV charging, RECOM offers a wide range of isolated DC/DC converters suitable for powering the high-side gate drivers as well as OVCIII-rated auxiliary power AC/DC converters. PCS offers full-custom solutions that include battery chargers, balancers and conditioners for mobile and stationary applications. The inputs can be single- or three-phase, and the outputs can be customer-specified to 20kW or more. Bidirectional designs are available for energy recovery applications. All products provide full protection, monitoring, and control through intelligent interfaces.

RECOM custom high-power design capabilities

PCS specializes in customized solutions and has an ideal solution for any application requiring high-power plug & play units. Whether the input is high voltage DC from a fuel-cell or single/three phase AC, RECOM Power Solutions ensure high power density and excellent efficiency.

RECOM supplies solutions for industry, automation, medical engineering, and transportation for stationary or mobile installation depending on application. These solutions ensure top functionality, reliability, and extremely long life with active PFCs on AC lines or overvoltage-protected DC inputs on DC lines as well as the latest switching topologies and concepts with digital control. Platform designs make excellent price/specification ratios possible as well as lower time-to-market with modified standard solutions.

Consult this page to see high-power designs that have been developed as platform solutions. RECOM can quickly modify these solutions to satisfy unique customer needs in a quick and cost-effective manner. Platform features include:

  • DC output: 12, 24, 36 , 48, 110, 500 VDC or other voltages on request
  • Excellent efficiency and compact design
  • Cascadable power and n+1 redundancy
  • Standard, modified standard and full custom design solutions
  • Digital interfaces for control and monitoring (e.g., PM-Bus)


PCS also offers modular high-power PFC stages with ratings up to 4kW. These PFC front ends can achieve power factors of more than 0.95 with typical efficiency of 92%.

Why choose RECOM for a high-power application

RECOM offers an extensive range of high-power supplies that satisfy AC/DC, DC/DC, and DC/AC requirements. The table below summarizes our standard and customized high-power product capabilities.

Attributes High Power solutions for DC or AC line
AC/DC or DC/DC Available Features / Options:
Power (W) up to 50000W Modules, cascadable up to 20000W
Isolation Isolated or non isolated
Nr. of Outputs Single or multible outputs
Vin (V) 20 - 264 1AC
200 - 600 3AC
200 - 2500VDC
Vout (V) low voltage or >1kV
Isolation (kV) up to 6kV
Connection Screw Terminals, Cage Clamps
others on request
Mechanical style Open frame
Chassis mounting, enclosed
19"-Rack style
Certifications CE, EN 55024, EN 55032, EN 62368, UL 60950-1, EN 50155
MIN Operating Temp (°C) -40.0 / -50.0
MAX Operating Temp (°C) 70.0 / 85.0
Protections OCP, OTP, OVP, SCP
Trim Pin Output Voltage Adjustment ADJUSTABLE
Interfaces I²C, Ethernet, CAN, ….?
Directives REACH, RoHS 2+ (10/10), WEEE
Warranty 3 Years
Regulation Regulated

For more information on high-power designs, browse our large selection of standard products that cover a large number of market segments and applications. Or download one of our technical resources: whitepapers, reference designs, application notes, reports, or selection of applicable safety standards.

If you’re considering a custom project design, to find out how we can help.