Our Engineering Services Manager, Steve Dodson, examines how a customized standard power solution combines the reliability of an established design with the adaptability needed for a unique, mission-critical application.
Overview
- Customized standard power solutions blend reliability with the flexibility needed by many design engineers.
- Performance, compliance, and application-specific needs drive optimal power supply customization for industries like healthcare.
- XP Power’s customizable, programmable power solutions provide advanced monitoring and real-time adaptability, reducing time-to-market and development costs.
Why select a customized standard power solution?
A fully custom design might offer you precise control, but you’ll likely find it time-consuming and costly. Off-the-shelf standard products are readily available but could well lack the flexibility you need to meet complex application needs.
A customized standard power solution bridges the gap, adapting existing designs with proven reliability and tailoring them to fit unique requirements. This approach is particularly advantageous in industries like healthcare, where mission-critical equipment demands both reliability and specific, adjustable configurations.
Healthcare power supply needs
In healthcare, devices like imaging systems and life support equipment depend on specific power requirements with precise voltage and current control. Many of these systems are also battery-powered, which calls for intelligent monitoring and control capabilities.
As mentioned above engineers have three possible approaches to solving their power problem:
1. Full custom design: Maximum flexibility and precise tailoring to specific requirements, albeit with high costs and long development times.
2. Off-the-shelf standard solutions: Faster, cost effective, and readily available, but often limited in terms of configuration and adaptability.
3. Customized standard power solutions: Combines the reliability of existing designs with tailored features. This option offers a versatile, time-efficient balance, addressing specific needs without the overhead of a full custom solution.
If you’re a healthcare engineer who needs specific power combinations, battery monitoring, and control features to fit within stringent operational and regulatory standards then a custom standard solution could be for you.
Key considerations when developing a customized standard power solution
When developing a customized standard power solution, you should be sure to evaluate the following performance and compliance factors:
Performance parameters
Input and output voltage ranges, current ratings, efficiency, size, and weight are all critical. The optimal configuration should maximize efficiency while minimizing the footprint, especially for compact medical devices.
Safety and compliance standards
Adherence to industry standards like EN62368-1 for ITE equipment and EN60601-1 for medical devices is essential, particularly for products requiring specific Type B/BF/CF classifications, low leakage current, and distinct protection levels (Class I vs. Class II). Compliance with EN55032 standards for electromagnetic compatibility (EMC) mitigates electromagnetic interference, addressing Class A and Class B requirements as needed.
Application-specific customization needs
Factors such as expected device lifespan, cooling requirements, and high quality components impact the reliability of a power supply. Other unique design needs may include low noise fans, digital control interfaces, and sophisticated monitoring for battery health, all of which can influence power supply design.
Real-time control and monitoring in XP Power’s solutions
XP Power's advanced AC-DC power supplies, such as the 1.5kW HPA and 3kW HPF series from the HP range, provide programmable digital control, enabling precise monitoring, diagnostics, and customization. Equipped with standard interfaces like PMBus, CANopen, and RS485, these units can be customized with alternatives like RS232 or UART for increased adaptability. These standard features ease the design process for customized standard power solutions.
The HP range of products utilizes a user-friendly graphical interface which allows real-time monitoring and control of input and output parameters. This offers many benefits such as early detection of voltage or power fluctuations often found in applications with renewable energy sources. For devices requiring multiple non-standard voltages, XP Power supply configurable power supplies that can be further adapted, ensuring all technical and regulatory criteria are met for specialized applications.
Case study: customized power for surgeon carts
The increasing burden of chronic diseases worldwide is raising the need for surgeries which in turn is fueling the demand for surgical carts. These are portable, battery-powered systems equipped with technology to streamline clinical workflows in hospitals.Such devices require a reliable, uninterrupted power supply (UPS) to maintain continuous operation during critical procedures like biopsies, tumor resections, and catheter placements.
XP Power has developed a customized standard power solution UPS with up to 1kW of output power across multiple output options, battery charging capability, and Ethernet-based monitoring. This UPS included firmware features to monitor battery voltage, current, temperature, with real-time status, enabling proactive maintenance and preventing unexpected downtime.
We have also designed a lower power solution with five outputs and Ethernet monitoring, while maintaining the essential monitoring and reliability features. Both designs optimize power efficiency, durability, and lightweight builds to meet operational demands in medical settings. They also offered the customer significant benefits in terms of time to market, development costs and approval charges, over a full custom design.
Summary
As discussed, customized standard power supplies offer design engineers a strategic balance between full custom and off-the-shelf solutions. XP Power’s programmable AC-DC supplies, with digital controls and flexible interfaces, illustrate the versatility of this approach and enable you to meet the exact demands of your application.
Discover how our custom power supplies simplify complex integrations, delivering tailored, efficient and reliable solutions for your unique needs.
Steve Dodson
Steve has been with XP Power for over 20 years and is currently our Engineering Services Manager responsible for the European custom power division. This role demands a hands-on approach to problem solving and project management. Steve leads a team of talented engineers, covering a range of tasks from specification writing, through concept design, initial prototyping, test, and compliance testing.
