Modular power supplies: Flexibility and scalability for diverse applications

DC power supplies offer a wide range of industry-specific solutions.

They provide essential voltage sources for various applications, including consumer electronics, industrial automation systems, and precision medical instruments. This article will explore the different types of modular power supplies and their uses. Modular power supply units transform power management in electronic systems with their flexibility and scalability. These advanced units include detachable cables and configurable power modules, allowing users to customise their power solutions. They improve system performance and adaptability by enabling adjustable voltage and current outputs, optimising thermal management, and supporting high-power components. Modular power supplies are preferred over discrete solutions due to their superior scalability, efficiency, and simplified design. Modular designs help reduce internal clutter, improve airflow, and facilitate easy expansion and reconfiguration, making them suitable for various applications in electronics and computing.

Table 1: Overview of various DC Power Supply types and their applications

Flexibility: The cornerstone of modular design

A modular and configurable power supply offers exceptional versatility and flexibility for development. It enables a broad range of current and voltage (I-V) characteristics by adjusting or rearranging components on the same platform, eliminating the need for major system redesigns. For example, a 750W modular platform can deliver outputs ranging from 12VDC at 62.5A to 48VDC at 15.6A or any configuration in between, with each output independently regulated to ensure stable performance without interference. Unlike traditional fixed units, modular systems feature interchangeable modules that can be combined to match specific power requirements precisely. This design is especially beneficial in research and development environments where adaptability is crucial. The key benefits of modular power supplies include:

• Customisation and cable management: Users can customise their setup with detachable cables of various lengths, colours, and types, leading to more efficient cable management and improved aesthetics. This flexibility allows adjustable power output to meet changing demands without replacing the entire unit, resulting in cleaner builds and enhanced system efficiency. By reducing cable clutter, modular power supplies enhance airflow and cooling, which helps maintain lower temperatures and prolong component life. This design also supports better overclocking and the addition of extra cooling fans. Modular units often include integral fans that simplify cooling further.
• Adaptable design and multi-purpose functionality: Modular power supplies offer exceptional versatility with customisable output configurations. They support a wide range of voltage and current outputs and have multiple channels to power various devices at once. These power supplies can be easily expanded by adding or removing modules to meet changing power demands without needing a complete redesign. Their broad output range makes them suitable for various applications, from low-power electronics to high-power industrial systems. For example, TDK-Lambda’s new MU4 series provides seamless voltage options from 3.3V to 104V through its configurator.

Table 2: Wide-range of output adjustments (MU4 output voltage ranges) (Source)

Modular power supplies with multiple isolated outputs provide unparalleled flexibility in voltage and current configurations, which is essential for diverse applications needing both positive and negative polarities. Using fractional turn transformer (FTT) technology, such as in XP's RCL175, these systems deliver a wide range of outputs (typically 3.3V to 60VDC) efficiently without compromising performance or adding complexity.

Figure 1: Fractional turn transformer configuration (Source)

FTT technology enhances multiple output supplies by allowing efficient integer turns on the main transformer and using a separate transformer for fractional turns. This results in better regulation, reduced size, and improved efficiency. It simplifies the design process, eliminates the need for post-regulation, and optimises voltage sensing and control. This is particularly beneficial for common voltage combinations like 3.3V and 5V.

As a result, modular power supplies with FTT technology offer a compact, cost-effective, and highly efficient solution for complex power requirements in technical applications.

Figure 2: Modular power supply with a diversified portfolio (Source)

• optimised heat dissipation: Modular power supplies optimise heat waste and extend their lifespan to adapt to different cooling needs. High power density and effective convection cooling reduce the need for forced cooling, making integration easier.

  While products requiring 20 CFM (cubic feet per minute) pose challenges as systems get smaller and noise becomes an issue, 10-12 CFM is more manageable and cost-effective. By combining convection cooling with higher power force-cooled ratings, these power supplies use variable-speed fans that only activate under high temperatures or loads. This enhances reliability and reduces noise.

• Better Space Management and Streamlined Product Lifecycle: Modular power supplies enhance power system design by saving PCB space and simplifying thermal management. Their compact form and high-power density accelerate design iterations and maintenance. In contrast, discrete solutions require extensive expertise, time, and effort for procurement, validation, and integration. This complicates minor design changes and adds inflexibility due to increased space and weight.

  When choosing between power modules and discrete designs, consider the entire product lifecycle. Discrete designs burden your in-house team with design, testing, and certification, risking significant delays. Scaling often requires complete redesigns, extending development timelines. Power modules, on the other hand, streamline logistics and reduce organisational stress. Prequalified modules, like those from Vicor, ensure reliability and compliance, allowing for seamless scalability without extensive redesigns.

• Streamlined installation and enhanced reliability: Modular power supplies optimise efficiency, reduce size and waste heat, and extend their lifespan to adapt to different cooling needs. High power density and effective convection cooling reduce the need for forced cooling, making integration easier. While products requiring 20 CFM (cubic feet per minute) pose challenges as systems get smaller and noise becomes an issue, 10-12 CFM is more manageable and cost-effective. By combining convection cooling with higher power force-cooled ratings, these power supplies use variable-speed fans that only activate under high temperatures or loads. This enhances reliability and reduces noise.

• Simplified compliance: Power converters act as safety barriers between high-voltage mains and SELV electronic networks, undergoing rigorous scrutiny. Simplified compliance in power conversion design is crucial for regulatory approval. Switch-mode power converters for AC/DC and DC/DC applications can generate significant electromagnetic interference (EMI).

  Modular power supplies, which are pre-designed and tested for stringent safety and EMC standards, mitigate emissions issues from unpredictable broadband noise. Using multiple off-the-shelf supplies risks cumulative leakage currents and safety violations, as these supplies often lack adequate margins for additional connections.

  Choosing a modular, configurable power supply ensures compliance, reduces testing costs, and speeds up regulatory approvals. Compared to dealing with multiple suppliers, using a single vendor simplifies the resolution of compliance issues.

Scalability: Meeting growing power demands

Modular power supplies offer adaptability and efficiency, allowing gradual expansions or modifications to meet changing demands with minimal downtime. Users can adjust power output as needed by adding or removing self-contained power modules. This scalability is particularly beneficial in industrial sectors and , where variable power requirements and dynamic computational loads demand optimised energy consumption and operational costs. Some of the key benefits include:

• Internal modularity: Internal modularity in power systems allows businesses to start small and expand as needed by adding or removing hot-swappable, user-replaceable power modules, enhancing efficiency and reducing capital expenditure. This flexible approach simplifies capacity upgrades, minimisess downtime during maintenance, and adapts to changing power demands. standardised bricks enable quick Customisation, while easy configuration displays streamline installations. Pre-engineered assets and simple plug-in modules eliminate complex cabling and hazards, ensuring future compatibility and scalability without engineering skills—additional modules self-test and auto-configure, providing disturbance-free connections and load protection. With self-diagnostics, easy-swap spare modules, and an advanced design eliminating fault propagation, these systems ensure no single point of failure and unmatched reliability, boasting 1,000,000 hours MTBF.
• Load management: Modular power supply units (PSUs) efficiently manage increased loads. For example, a UPS with a maximum capacity of 200 kVA can start at 100 kVA and then be scaled up to 200 kVA as needed. A modular PSU can be configured for different power levels between 100 and 200 kVA, with options like 100, 130, 150, 180, and 200 kVA available in each cabinet. Power levels can be increased through field upgrades by a service operator. While other PSUs are standard for power levels below 20 kVA, typically for small computer installations, these modular PSUs use a unique current-sharing technique that allows parallel operation without a static transfer switch. They also include a generator-friendly input filter, making the UPS appear as an inductive load to external generators.

Applications across diverse industries

The flexibility and scalability of modular power supplies make them ideal for a wide range of applications:

• Data centres: Modular power supplies adapt to the dynamic power needs of server racks, easily scaling with the addition of new equipment or increased computing demands.
• Telecommunications: Modular power systems can be reconfigured as network infrastructure evolves, supporting new technologies and increased power requirements.
• Industrial automation: Manufacturing processes with varying power needs benefit from easily adjustable power configurations.
• Medical equipment: Modular power supplies can be tailored to meet the precise power requirements of different medical devices while adhering to strict safety standards.
• Renewable energy systems: These power supplies adapt to fluctuating energy production and storage needs in solar or wind power installations.
• Test and measurement: Laboratories and testing facilities can configure power supplies to meet the diverse needs of different experiments or testing scenarios.

The UPS for : Crucial features for modern needs

power our digital lives. Downtime can disrupt services, cause societal impacts, financial losses, and potential dangers. Modern use dedicated infrastructures like UPS systems to ensure continuous operation and resilience.

Three core pillars define the suitability of modular power supply systems for modern :

1. Operational Resilience and Reliability
2. Lifecycle Cost Optimization
3. Flexible Scalability and Integration

Legrand’s key UPS technologies include modular architecture for easy scaling and maintenance, advanced power electronics for high efficiency, and intelligent control systems for optimised performance. These features make them perfect for .

1) Operational Resilience and Reliability:

• High availability: Achieved through N+1 redundancy.
• Low mean time To repair (MTTR): Ensuring quick fixes when issues arise.
• Hot-swappable components: Allowing maintenance without downtime.

Figure 4: Examples of N+1 redundancy configuration (Source)

2) Lifecycle cost optimization:

• High energy efficiency, especially at partial loads.
• Smart battery management for extended life.
• Reduced maintenance and servicing costs.
• Longer component lifetimes.
• Improved serviceability.

Figure 5: Legrand UPS solutions deliver up to 96.6% efficiency, ideal for energy-saving and cost-effective (Source)

3) Flexible scalability and integration:

• Scalable power capacity ('pay as you grow').
• Compatibility with various electrical infrastructures.
• Compact footprint and flexible installation options.
• Advanced communication and integration capabilities.

Figure 6: Keor MOD: Scale as needed. Add servers to racks and upgrade UPS without infrastructure changes (Source)

Figure 7: High power density and compact footprint (Source)

Figure 8: Full communication ports and interfaces like (USB, dry contacts, RS232, RS485, ModBUS, ethernet, parallel, IN/Out logic signals, etc.) (Source)

These UPS systems are designed to meet the evolving needs of various data center types, from small on-premises facilities to large hyperscale and colocation centers. They focus on providing reliable power protection while optimising energy efficiency, reducing total cost of ownership (TCO), and offering the flexibility to adapt to changing infrastructure requirements.

Conclusion

Modular power supplies represent a significant advancement in power management technology, offering flexibility, scalability, and efficiency across various applications. Their ability to adapt to changing power requirements, improve thermal management, and simplify installation makes them a preferred choice in , Telecommunications, Industrial Automation, Medical Equipment, Renewable Energy Systems, and Test and Measurement Environments.

As global distributors we offer a diverse range of modular power supplies to meet these needs, ensuring reliable performance and compliance with stringent safety standards. As the demand for adaptable and efficient power solutions grows, modular power supplies are set to play a critical role in supporting the next generation of technological advancements.