Power Module : <span style='color:red'>Working Principle</span>, Structural Features, and Process
Trade news

Power Module : Working Principle, Structural Features, and Process

　　A power module is an electronic device used to convert one form of electrical energy into another for supply to specific electronic systems or devices. It typically comprises an input terminal for receiving the raw power source (such as AC or DC) and one or more output terminals for providing converted and regulated electrical energy. This article summarizes the working principle, structural features, process flow, selection parameters, and design considerations of power modules.　　Working Principle of Power ModuleThe working principle of a power module is based on power electronics technology and control circuitry. Its core consists of switching power devices and control circuits. The following are detailed operational steps of power module operation:　　1. Input Voltage Conversion　　The power module first receives input voltage from the power line, typically AC.　　Next, through rectification circuitry using diodes or bridge rectifiers, AC is converted into pulsating DC.　　Subsequently, filtering circuits utilize capacitors to remove the pulsation, resulting in stable DC.　　2. Output Voltage Regulation　　The converted DC enters a voltage regulation circuit for voltage regulation.　　The voltage regulation circuit operates using feedback control. Specifically, it compares the difference between the output voltage and a reference voltage and controls the regulator’s operation based on this difference.　　Through this regulation, the output voltage is maintained at the set stable value.　　3. Role of Switching Power Devices　　During the power conversion process of the power module, switching power devices (such as MOSFETs, BJTs, IGBTs, etc.) play a crucial role.　　When the switching device is conducting, the power module can convert input energy into output energy. The primary function of the switching device is to achieve intermittent energy conversion to provide the required stable voltage or current.　　When the switching device receives an input or control signal, it generates corresponding switch signals to control its state.　　4. Role of Control Circuits　　Control circuits are another important component of the power module responsible for precise regulation and stabilization.　　Feedback circuits monitor changes in output voltage or current and send feedback signals to comparators. This allows the power module to adjust output energy promptly based on the feedback signal to meet various circuit requirements.　　5. Protection Mechanisms　　Power modules typically feature various protection mechanisms such as overload protection, overvoltage protection, and short circuit protection.　　Overload protection monitors the output current and limits or cuts off the output when the current exceeds a set value.　　Overvoltage protection monitors the output voltage and automatically cuts off the output power when the voltage exceeds a set value.　　Short circuit protection similarly operates by monitoring the output current. When a short circuit is detected, it promptly cuts off the power to prevent damage.　　Structural Features of Power ModuleThe structural features of power modules are summarized as follows:　　1. Modular Design　　Power modules typically employ modular design, making the entire power system more compact and efficient. Each module has independent functionality, allowing for flexible combinations and extensions based on actual needs. This facilitates users in customizing power solutions according to specific application scenarios.　　2. High Integration　　Power modules integrate numerous electronic components and circuits internally, such as transformers, rectifiers, and filters. The optimized design of these components and circuits endows the power module with high efficiency and stability.　　3. High Reliability　　Power modules undergo rigorous production processes and quality control, resulting in high reliability. Additionally, internal redundancy design and protection circuits effectively prevent damage to the system due to abnormal conditions such as power fluctuations, overcurrent, and overvoltage.　　4. Ease of Maintenance　　Due to the modular design of power modules, when a fault occurs, users can conveniently replace the faulty module, thereby reducing maintenance costs and time. Furthermore, the modular structure facilitates upgrades and modifications to the power system.　　Process Flow of Power ModuleThe production process of power modules involves multiple steps, from material preparation to final testing and quality inspection, with each step being crucial. Below is a simplified description of the operation process of power module production:　　1. Material Preparation and Bill of Materials (BOM) Verification　　Based on the design drawings of the power module and the BOM (Bill of Materials) list, prepare the required components, PCB boards, connecting wires, insulation materials, etc.　　Check the quantity, model, and specifications of the materials to ensure accuracy.　　2. PCB Board Processing and Component Soldering　　Clean and dry the PCB board to remove surface stains and moisture.　　According to the design drawings, solder the components onto the PCB board. Pay attention to soldering temperature and time control to avoid solder joints or poor soldering.　　3. Power Circuit Connection and Insulation Processing　　Based on the circuit diagram of the power module, connect the power input and output lines.　　Insulate exposed wires and connection points to ensure safety.　　4. Functional Testing and Performance Debugging　　Conduct functional testing on the power module to check if input and output voltage and current are normal.　　Based on the test results, perform performance debugging to optimize the efficiency of the power module.　　5. Overall Assembly and Enclosure Installation　　Assemble the soldered PCB board, connecting wires, and other components into a complete power module.　　Install the enclosure of the power module to ensure reliable fastening.　　6. Final Testing and Quality Inspection　　Conduct final testing on the assembled power module, including voltage stability, ripple coefficient, load capacity, and other indicators.　　According to quality inspection standards, screen and classify the power modules to ensure product quality.　　7. Packaging and Warehouse Entry　　Package the qualified power modules, indicating model, specifications, quantity, etc.　　Store the packaged power modules in the warehouse, awaiting shipment or subsequent use.　　Selection Parameters of Power ModuleDuring the process of selecting power modules, it is essential to consider a series of key parameters to ensure that the chosen power module can meet specific application requirements. Below is a detailed consideration of these parameters:　　1. Input Voltage Range　　Firstly, it is necessary to determine the input voltage range of the power module, i.e., the range within which it can operate normally. This depends on the power supply situation in the application, such as battery-powered or AC grid-powered. Ensure that the selected module can adapt to the existing input voltage and maintain stability during voltage fluctuations.　　2. Output Voltage and Current　　The output voltage and current of the power module are critical parameters to meet load requirements. Depending on the power consumption and characteristics of the load, choose appropriate output voltage and current levels. Also, consider whether the current output capacity of the power module is sufficient to handle the startup impact of the load and the current requirements during normal operation.　　3. Efficiency and Power Consumption　　Efficiency is the ability of the power module to convert electrical energy, i.e., the ratio of output power to input power. High efficiency means less energy loss and lower heat generation. Additionally, pay attention to the module’s power consumption, especially during standby or light load, to optimize energy use.　　4. Ripple and Noise　　Ripple refers to the AC component in the output voltage, while noise is the interference signal generated by the power module. These parameters are crucial for sensitive applications such as signal processing or measurement equipment. Therefore, when selecting, ensure that the ripple and noise levels of the selected module are below the system’s acceptable threshold.　　5. Temperature Range　　The operating temperature range of the power module is also a factor to consider. In extreme temperature environments, the performance and reliability of the module may be affected. Therefore, choose a module that can operate stably within the temperature range of the application.　　6. Reliability and Lifespan　　The reliability and expected lifespan of the power module are important indicators for assessing its long-term performance. When choosing, consider the module’s MTBF (Mean Time Between Failures) and the manufacturer’s provided warranty period.　　7. Size and Packaging　　The size and packaging of the power module are also factors to consider during the selection process. Ensure that the selected module can fit within the space constraints of the application and is easy to integrate into existing systems.　　8. Certification and Compliance　　The selected power module should comply with relevant safety standards and regulatory requirements, such as UL, CE, etc. This helps ensure the safety and compliance of the power module.　　9. Cost　　Last but equally important is cost consideration. While meeting all performance requirements, strive to choose a cost-effective power module to optimize the overall cost-effectiveness of the system.　　During the design and use of power modules, the following operational issues should be noted:I. Design Phase Considerations1. Clarify Requirements and Specifications　　Before designing the power module, clarify the system’s requirements for power, including voltage, current, power, efficiency, and other specifications.　　Fully consider the working environment of the module, such as temperature, humidity, vibration, and other factors that may affect the performance of the power supply.　　2. Select Appropriate Topology　　Choose the appropriate power supply topology according to the requirements, such as linear power supply, switching power supply, etc., to achieve high efficiency, stability, and reliability.　　3. Optimize Circuit Layout and Wiring　　Reasonably layout circuit components to reduce interference and losses.　　Adopt the principle of wide and short wiring to reduce resistance and inductance, thereby improving power supply efficiency.　　4. Redundancy and Protection Design　　Consider redundancy design for the power module to improve system reliability and stability.　　Design overvoltage, overcurrent, overheating, and other protection measures to prevent module damage or safety accidents.　　5. Electromagnetic Compatibility (EMC) Design　　Consider the electromagnetic compatibility of the power module and use filtering, shielding, and other technologies to reduce interference with other devices.　　II. Considerations During Use1. Proper Installation and Connection　　Follow the manufacturer’s installation guide to ensure the power module is installed correctly and securely fixed.　　Carefully inspect the connections of input and output terminals to ensure good contact, no looseness, or short circuits.　　2. Adjust Parameters Reasonably　　According to actual needs, set the voltage, current, and other parameters of the power module reasonably to avoid overloading or underloading.　　Regularly check parameter settings to ensure consistency with actual requirements.　　3. Monitoring and Maintenance　　Regularly conduct status checks on the power module, including monitoring parameters such as voltage, current, and temperature.　　If any abnormal conditions are detected, take timely measures to address them, such as cleaning dust or replacing damaged components.　　4. Heat Dissipation and Working Environment　　Pay attention to the impact of electromagnetic interference and mechanical vibration in the working environment on the power module and take corresponding measures for protection.　　5. Training and Operational Standards　　Provide training for personnel using the power module to ensure they understand the working principle, operation methods, and safety precautions of the module.　　Establish operational standards to ensure that personnel operate in accordance with the standards, avoiding problems caused by improper operation.
Key word：
Release time：2024-08-22 13:33 reading：510 Continue reading>>
Temperature Sensor : Types, Applications, <span style='color:red'>Working Principle</span> and Much More
Trade news

Temperature Sensor : Types, Applications, Working Principle and Much More

　　A temperature sensor is a vital component in many systems where monitoring or controlling of temperature is required.　　It allows one to measure the temperature of an object or environment and provide thermal data which is further used by various devices and applications.　　Temperature sensors play an important role across many industries from automotive and medical to consumer appliances.　　What is a temperature sensor?A temperature sensor is a device that helps in measuring the temperature of its environment, object or substance and converts the measurement into an electronic signal.　　This electronic signal is further processed by auxiliary instrumentation such as temperature indicators, temperature controllers and temperature recorders to display or use the temperature data.　　There are various types of temperature sensors available based on different sensing technologies like thermistor, thermocouple, Resistance Temperature Detector (RTD) etc.　　What are different types of temperature sensors?Some of the common types of temperature sensors are:　　Thermocouple　　A thermocouple is a temperature sensor made by joining two different conductors at their ends to form a thermocouple junction. The voltage produced is dependent on the temperature difference between the thermocouple junction and a reference junction. Thermocouples are inexpensive, rugged and can measure a wide range of temperatures.　　Resistance Temperature Detector (RTD)　　An RTD is made up of a pure metal like platinum, copper or nickel which exhibits change in electrical resistance when exposed to change in temperature. The resistance increases linearly as temperature rises which makes it easy to convert to temperature using a simple formula. RTDs provide good accuracy over a wide temperature range.　　Thermistor　　A thermistor is a type of resistor whose resistance varies significantly with temperature changes. It exhibits a non-linear but known resistance-to-temperature relationship. Negative temperature coefficient (NTC) thermistors decrease in resistance with rising temperature while positive temperature coefficient (PTC) thermistors increase in resistance. They provide high accuracy and fast response time.　　Integrated Circuit Sensor　　An integrated circuit temperature sensor consists of a temperature sensitive circuit integrated onto a silicon chip that outputs voltage proportional to sensed temperature. They are small in size, inexpensive and mass producible. But accuracy is less as compared to other sensor types.　　Infrared Sensor　　Infrared sensors detect infrared energy radiated from an object or surface and produce an electronic signal proportional to the temperature. They are contactless and suitable to measure temperature without disturbing the environment but have less accuracy.　　What are the advantages and disadvantages of temperature sensors?Advantages　　• Provide accurate and repeatable temperature measurements.　　• Respond quickly to temperature variations.　　• Can measure a wide range of temperatures from below zero to thousands of degrees Celsius depending on type.　　• Rugged, withstand vibrations and withstand hostile environmental conditions like humidity and pressure.　　• Low cost options available for general purpose temperature measurements.　　• Integrated circuit temperature sensors are small, mass producible and inexpensive.　　Disadvantages　　• Contact sensors disturb the medium whose temperature is being measured.　　• Thermocouples produce small voltage signals requiring amplification.　　• Response time of temperature sensors depends on thermal mass and insulation which limits fast temperature tracking.　　• Temperature sensors have limited lifespan and require calibration over time.　　• Special sensors are needed for measuring ultra-low or ultra-high temperatures.　　How important is a temperature sensor?　　A temperature sensor plays a vital role in maintaining quality and safety standards across many industries.　　Some key applications where temperature sensors are mission critical include:　　• Medical equipment and patient monitoring – Ensures safe temperatures for drug infusion, surgical/therapy devices, incubators etc.　　• Automotive – Monitors engine temperature, fuel systems, brake fluid, transmission oil, exhaust gas recirculation.　　• Industrial manufacturing – Controls processes in plastics molding, food processing, chemical reactions requiring specific temperatures.　　• HVAC equipment – Essential component in thermostats, air conditioners, refrigerators to regulate temperatures.　　• Fire/overheat detection – Prevents accidents by triggering alarms when abnormal high temperatures detected.　　• Consumer appliances – Maintains safe cooking temperatures in ovens/stoves, cool temperatures in refrigerators.　　Where are temperature sensors used?Industrial applications　　Oil and gas plants to monitor pipeline temperatures, boiler temperatures.　　Pulp and paper industry for dryer skin temperatures, consistency measurements.　　Power plants to monitor transformer temperatures, boiler steam temperatures.　　Iron and steel industry for molten metal temperatures, annealing furnace controls.　　Automotive　　Engine coolant temperature sensor in radiator.　　Intake air temperature sensor.　　Exhaust gas temperature sensor before catalytic converter.　　Transmission fluid temperature sensor.　　Rear differential and transfer case temperature sensors.　　Medical　　Patient thermoregulation- temperature probes in incubators, warming blankets.　　Medical sterilizers- monitors autoclave temperatures.　　Hyperthermia therapy- controls localized temperature increases.　　HVAC　　Thermostat temperature sensor　　Duct-mounted temperature sensors　　Outdoor temperature sensors　　Household appliances　　Refrigerator/freezer temperature sensors　　Oven temperature sensors　　Water heater thermostats　　What is the difference between thermal sensor and temperature sensor?The main difference between a thermal sensor and a temperature sensor are:　　Thermal sensors detect heat without direct contact while temperature sensors measure temperature through properties like resistance that change with temperature.　　Thermal sensors provide relative heat indication without units while temperature sensors provide measured temperature output in units like Celsius or Fahrenheit.　　How do temperature sensors work?Temperature sensors function based on different working principles depending on the sensing technology used:　　Thermistors　　Thermistors are made from semiconductor materials that change resistance predictably with temperature changes. As temperature rises, the mobility of charge carriers in the semiconductor increases resulting in lower electrical resistance that can be measured.　　Thermocouples　　When two different conductors are joined together, a voltage is produced dependent on their Seebeck coefficient and the temperature difference between the junction and reference junction. The output voltage is linearly proportional to temperature and is measured.　　RTDs　　Resistance Temperature Detectors use metals like platinum that change resistance reliably with temperature. Resistance increases linearly as temperature rises following PRT (Platinum Resistance Thermometers) or ITS-90 standard curves.　　Integrated circuits　　Complementary metal–oxide–semiconductors (CMOS) and bipolar transistors on an IC change current or voltage levels proportionally to temperature which is output analog or digital signals.　　Infrared sensors　　Infrared sensors contain a detector which absorbs infrared radiation from the target. The absorbed IR energy causes the detector temperature to rise above ambient. This temperature change alters the electrical properties to provide an output signal related to target temperature.　　How to design a temperature sensor?　　The steps involved in designing a temperature sensor are:　　1. Select sensing element material based on required temperature range, accuracy, response time etc. like RTD, thermistor etc.　　2. Design sensor probe matching application requirements like immersion, surface, air temperature sensing.　　3. Choose appropriate housing material that withstands application environment. Consider thermal insulation, heat transfer etc.　　4. Design signal conditioning circuitry to convert sensor output to standardized signals compatible with instruments like amplifiers, filters, transmitters etc.　　5. Develop calibration curves and apply compensation algorithms in microcontroller if required for high accuracy.　　6. Implement temperature scaling and linearization if needed in firmware or hardware.　　7. Add optional features like remote sensor with transmission line, displays, alarms, microprocessor integration.　　8. Test prototype under standard reference temperatures for calibration, accuracy, repeatability.　　9. Enhance product through validation testing under field conditions, certifications.　　10. Prepare design documentation for manufacturing.　　What is the range of a temperature sensor?Temperature sensors can measure a wide range of temperatures based on the sensing technology and construction. Some common measurement ranges are:　　• Thermocouples: -250°C to 1350°C　　• RTDs: -200°C to 650°C　　• Thermistors: -55°C to 150°C　　• Integrated circuits: -55°C to 150°C　　• Infrared sensors: -50°C to 500°C　　Special types of sensors further extend the limits to measure very low cryogenic temperatures below -200°C for applications like liquified natural gas plants, high energy physics labs.　　Similarly, special metallurgical thermocouples and optical pyrometer sensors go up to 3000°C for processes like steel making, glass welding.　　ConclusionAn accurate and reliable temperature sensor is fundamental for process and quality control across major industries due to its role in monitoring, regulating and safety applications.　　Understanding sensor types, principles, design and selection based on application demands is key.　　Advancing technologies are continuously improving sensing capabilities to wider ranges, higher precisions and intelligent outputs.　　As temperature measurement takes a more vital role, evolution of sensors will keep pace with the emerging trends.
Key word：
Release time：2024-07-10 13:19 reading：645 Continue reading>>

Turn to

/ 1

Popular categories
Semiconductors Circuit Protection Electromechanical Embedded Solutions Connectors, Interconnects Sensors, Transducers Optoelectronics Development Kits Test and Measurement Power Fans, Thermal Management Boxes, Enclosures, Racks Cables, Wires Passive Components Others
  • Week of hot material
  • Material in short supply seckilling
model brand Quote
RB751G-40T2R ROHM Semiconductor
CDZVT2R20B ROHM Semiconductor
TL431ACLPR Texas Instruments
MC33074DR2G onsemi
BD71847AMWV-E2 ROHM Semiconductor
model brand To snap up
BU33JA2MNVX-CTL ROHM Semiconductor
TPS63050YFFR Texas Instruments
BP3621 ROHM Semiconductor
IPZ40N04S5L4R8ATMA1 Infineon Technologies
ESR03EZPJ151 ROHM Semiconductor
STM32F429IGT6 STMicroelectronics
Hot labels
ROHM
IC
Averlogic
Intel
Samsung
IoT
AI
Sensor
Chip
Original authorized brand
More Licensed Brands>>
Information leaderboard
  • Week of ranking
  • Month ranking

About us

Qr code of ameya360 official account

Identify TWO-DIMENSIONAL code, you can pay attention to

AMEYA360 mall (www.ameya360.com) was launched in 2011. Now there are more than 3,500 high-quality suppliers, including 6 million product model data, and more than 1 million component stocks for purchase. Products cover MCU+ memory + power chip +IGBT+MOS tube + op amp + RF Bluetooth + sensor + resistor capacitance inductor + connector and other fields. main business of platform covers spot sales of electronic components, BOM distribution and product supporting materials, providing one-stop purchasing and sales services for our customers.

Please enter the verification code in the image below：

verification code