Modular Compatible Design of Electron Beam High-Voltage Power Supply

The high-voltage power supply requirements of electron beam equipment (e.g., electron beam welding, electron beam sterilization) vary significantly: the output voltage ranges from 10kV to 100kV, and the output power covers 5kW to 50kW. The traditional integrated power supply has problems such as high customization cost (single design cycle exceeding 3 months), difficult maintenance (overall replacement required after failure, shutdown exceeding 48 hours), and poor expansion (unable to increase power on demand), which restrict the versatility and upgradeability of the equipment.
The modular compatible design needs to follow three principles: "function division, unified interface, and electromagnetic compatibility": at the function division level, the power supply is divided into three core modules - high-voltage generation module (responsible for AC-DC rectification and DC-DC boosting, divided into three power levels of 5kW/10kW/20kW, which can be paralleled for expansion), control module (realizing voltage and current regulation and protection logic, compatible with RS485/CAN/EtherCAT communication protocols), and detection module (monitoring insulation resistance, module temperature, and output ripple, with standardized data interface); at the unified interface level, the electrical interface uses standard connectors (rated current 50A, withstand voltage 1000V), the communication interface supports Profinet industrial Ethernet, and the mechanical interface adopts unified guide rail installation (width 35mm) to ensure plug-and-play of different modules; at the electromagnetic compatibility level, each module has a built-in EMI filter (suppressing high-frequency interference), and shielded partitions (shielding effectiveness >40dB) are used between modules to avoid electromagnetic radiation from high-voltage modules to control modules (tests show that the interference voltage between modules is <50mV, far lower than the industry standard of 100mV).
The application value of this design is significant: first, shortening the customization cycle. An electron beam welding equipment manufacturer shortened the customization cycle from 3 months to 15 days by combining a 5kW high-voltage module and a standard control module; second, reducing maintenance costs. Only the corresponding unit needs to be replaced when a module fails, reducing the shutdown time from 48 hours to 4 hours and the maintenance cost by 60%; third, flexible expansion. An electron beam sterilization equipment needs to increase the power from 10kW to 20kW, which only requires adding a 10kW high-voltage module without replacing the whole machine, saving 75% of the upgrade cost.