Satisfaction Paths and Technical Practices for Customized Requirements of High-Voltage Power Supplies

With the professional development of fields such as industrial manufacturing, medical equipment, and scientific research experiments, standardized high-voltage power supplies have been difficult to meet the personalized needs of segmented scenarios (such as special voltage and current parameters, extreme environment adaptation, and customized interface protocols). As a core solution to solve this contradiction, customized high-voltage power supplies have their demand satisfaction capability become an important indicator to measure the technical strength of enterprises. From demand analysis to solution implementation, it is necessary to establish a systematic customization process and break through key technical difficulties to achieve accurate matching between customized requirements and product performance.
The analysis of the types and scenarios of customized requirements is the prerequisite for meeting the requirements, and the demand differences in different fields determine the customization direction and technical focus. The customized requirements in the industrial field focus on parameter adaptation and environmental tolerance: for example, industrial coating equipment requires the high-voltage power supply to have an adjustable output voltage of 0-10kV and an output current of 0-500mA, and needs to have dust resistance and temperature resistance (-20℃ to +60℃) characteristics; new energy testing equipment requires the high-voltage power supply to support a wide range of voltage regulation (0-20kV) and a current response speed of <50μs to simulate battery testing needs under different working conditions. The customized requirements in the medical field focus on safety and accuracy: for example, the high-voltage power supply for CT equipment needs to have an output voltage of 30-150kV and a ripple coefficient of <0.05% to ensure imaging clarity; the extracorporeal shock wave lithotripsy equipment requires the high-voltage power supply to have a pulse output mode (pulse width 1-10μs, repetition frequency 1-10Hz) and a leakage current of <100μA to ensure patient safety. The customized requirements in the scientific research field emphasize extreme parameters and flexibility: for example, particle accelerators require high-voltage power supplies with an output voltage of ≥100kV and current stability of <0.01%, and support remote programming control; materials science experiments require high-voltage power supplies to have multi-channel output (4-8 channels), and each channel's voltage can be independently adjusted (0-5kV) to meet the needs of simultaneous testing of multiple samples. In addition, special scenario requirements also include shape customization (such as miniaturization design, volume <500×300×200mm to fit the equipment space), interface customization (such as supporting industrial bus protocols such as RS485, CAN, EtherNet/IP), and protection level customization (such as IP65 protection to adapt to outdoor environments).
The standardization of the customization process is the guarantee for the accurate implementation of requirements, and it is necessary to achieve seamless connection between requirements and solutions through multi-link collaboration. The customization process is usually divided into five stages: in the demand analysis stage, engineers need to communicate in-depth with users, clarify core parameters (voltage, current, power, accuracy), environmental conditions (temperature, humidity, vibration), safety standards (such as IEC 61010, UL 61010), interface protocols and other requirements, form a "Customized Requirement Specification", and confirm with users to avoid demand deviations; in the scheme design stage, based on the requirement specification, conduct circuit design (such as topology selection, component selection), structural design (such as heat dissipation design, insulation design), control scheme design (such as control algorithm selection, software interface design), and use simulation software (such as ANSYS, PSpice) for performance simulation to verify the feasibility of the scheme (such as output accuracy, dynamic response), and form a "Customized Scheme Design Report"; in the prototype verification stage, produce 1-2 prototypes, conduct comprehensive tests (including high-voltage withstand voltage test, output accuracy test, environmental adaptability test), and invite users to conduct on-site trials, optimize the scheme according to test data and user feedback, such as adjusting the heat dissipation structure to reduce temperature rise and optimizing the control algorithm to improve stability; in the mass production stage, formulate production process documents (such as welding process, assembly process, test process) according to the optimized scheme, use automated equipment (such as SMT placement machines, high-voltage test benches) for production, and each product needs to undergo more than 10 factory tests to ensure performance consistency; in the after-sales debugging stage, send engineers to the user's site for equipment installation and debugging, provide operation training, and establish a long-term technical support mechanism (such as 7×24-hour technical hotline, regular maintenance return visits) to solve problems during use.
The breakthrough of customized technical difficulties is the core of ensuring product performance, and targeted solutions need to be adopted for different demand scenarios. The problem of parameter compatibility is a common challenge in customization: when users' requirements involve both high voltage and large current, it is necessary to balance the insulation design and heat dissipation design in the circuit, such as using a multi-layer insulation structure (polytetrafluoroethylene film + epoxy resin) to improve voltage withstand capacity, and at the same time reduce the temperature of power devices (such as controlling the IGBT junction temperature to <120℃) through a combination of heat pipe heat dissipation and fan forced heat dissipation; when the requirement involves a wide range of voltage regulation, it is necessary to adopt a multi-gear topology design (such as a segmented resonant topology) to achieve efficient conversion in different voltage ranges, avoiding a significant drop in efficiency of a single topology under wide-range regulation (such as maintaining efficiency above 85%). The problem of stability assurance needs to be addressed from multiple dimensions: in component selection, high-precision and high-stability components are selected (such as precision resistors with an error of ≤0.1%, high-voltage capacitors with a temperature coefficient of ±5%); in circuit design, a voltage sampling feedback loop (such as using differential sampling to reduce interference) and a current limit protection loop are added; in software algorithms, an adaptive PID control algorithm is used to adjust output parameters in real time to offset the impact of environmental changes (such as temperature drift) on performance. The problem of cost control needs to be solved through optimized design and supply chain management: in the scheme design stage, priority is given to using mature domestic components instead of imported components to reduce procurement costs (such as domestic IGBTs cost 30%-50% lower than imported ones); in the production stage, modular design (such as designing high-voltage modules, control modules, and sampling modules as independent modules) is used to improve the reuse rate of parts and reduce production complexity; in supply chain management, long-term cooperation agreements are signed with core component suppliers to obtain bulk procurement discounts.
The innovation and iteration of customized technology is the key to improving the ability to meet requirements, and it is necessary to keep up with the development trend of industry technology. The application of wide-bandgap semiconductor devices (GaN, SiC) has brought performance breakthroughs to customized high-voltage power supplies: GaN devices have fast switching speed (<10ns) and high temperature resistance (junction temperature ≥150℃), which can realize the miniaturization (volume reduced by 40%-60%) and high efficiency (efficiency increased to more than 95%) of customized power supplies, especially suitable for miniaturized customization needs; SiC devices have high voltage resistance (≥10kV) and low on-resistance, suitable for high-voltage customization scenarios (such as ≥50kV output). The application of digital control technology improves the flexibility of customization: the digital control system based on FPGA and DSP can realize the rapid switching of different output modes (such as continuous output, pulse output) and parameter adjustment (such as voltage stepping, current limiting) through software programming, without modifying the hardware circuit, shortening the customization cycle (such as from 3 months to 1-2 months). The integration of intelligent functions expands the value of customization: integrating state monitoring functions (such as temperature monitoring, voltage and current monitoring, fault diagnosis) into customized power supplies, and realizing remote monitoring and early warning through the industrial Internet platform to help users grasp the equipment operation status in real time; integrating energy recovery functions to recycle excess energy generated during the testing process, reducing energy consumption (such as energy consumption reduced by 15%-20%) to meet users' energy-saving needs.
In conclusion, meeting the customized requirements of high-voltage power supplies is a systematic project of "demand analysis - scheme design - prototype verification - mass production - after-sales support", which needs to be realized through standardized processes, breakthroughs in technical difficulties, and innovation and iteration of technology. Enterprises need to establish a professional customized R&D team and accumulate rich industry application experience to quickly respond to the personalized needs of different fields; users need to clearly sort out their own needs and maintain close communication with enterprises to ensure that customized products accurately match the application scenarios. In the future, with the continuous advancement of technology, customized high-voltage power supplies will develop in the direction of higher precision, higher efficiency, and more intelligence, providing more powerful technical support for the professional development of various industries.