TDK Lambda Magazine | May 2021

MAGAZINE

MAY 2021

THE SECRETS Behind TDK-Lambda’s Quality Philosophy

TDK-Lambda’s centers worldwide, including the Karmiel manufacturing facility, implement a strict Japanese code to ensure the quality of its power supplies. Among the methods: assessing the durability of each component in a product even if it is made of hundreds of parts; creating intentional bugs in order to challenge the power supply and test its durability; and operating the product non-stop for several months in a locked laboratory cabinet at extreme conditions

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HIGHER THAN EVER

It is no coincidence that Japanese electronics are considered to be among the highest quality products in the world, including the power supplies made by TDK-Lambda. As a company that is part of the Japanese TDK corporation, at TDK-Lambda we have learned and implemented strict procedures aimed at maximizing product quality. As a basis of TDK-Lambda’s openness policy, we share with our customers the main quality practices implemented in the company’s development and production centers around the world, including the factory in Karmiel. These procedures allow us to launch products with maximal longevity. Testing the Testers Startingfromtheproductdesignstage, theTDK-Lambdastaff implementsacomprehensive process that includes the selection and testing of each and every component that the project engineers are interested in. This process is handled by a special team in the company: The Component Engineering Group. The process of selecting and testing the components is especially critical, as it depends on the performance, quality, reliability and, of course, the safety of the product. That is why we have developed a procedure based on the concept that we must rely only on ourselves - and perform supplementary tests in addition to the ones run by component manufacturers. This is how TDK-Lambda Maximizes the Reliability of its Power Supplies

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Initially, only components by trusted vendors will be selected from the company’s databases. The process involves R&D teams from TDK-Lambda’s R&D centers around the world - and QA experts at the Corporation’s headquarters in Japan. A component manufacturer will be awarded the title of “Approved Supplier” if the company has positive experience with its products, and if it does not put at risk the TDK-Lambda supply chain. In other words: the component supplier must be able to supply continuous quantities of reliable components for years. The databases are frequently updated according to tests and investigations: a component with corrosion, or that fails a thermal shock test, for example, will be removed from the database. A supplier with delayed shipments will be downgraded. 1,000 Test Pages Once the most appropriate and high-quality components have been selected - from the most trusted suppliers - our Component Engineering Group operates a validation procedure for each and every component. Although suppliers usually attach a file to each component with the results of their tests, we verify each piece of data - based on our own tests - and even add a series of additional tests: electrical tests, stress tests such as TST (thermal shock test) and more. The parameter that reflects the component’s lifespan - MTBF (Mean Time Between Failures) - is also required for TDK-Lambda’s internal validation. The MTBF is determined following a variety of tests, and will usually be more conservative than what is stated by the supplier. The MTBF of all components will determine the lifespan of the product as a whole.

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This detailed and precise process of Product Evaluation ends with hundreds of test pages per product - and even more. For example, the GENESYS+ 5kW reliability file has about 1,000 test pages. Extreme Scenarios Another procedure, called Component Derating, involves testing that helps us define the terms of use of each component. For each type of electronic component (such as MOSFET, Diode Resistor) the derating is determined with its main parameters: working voltage, working current, internal temperature and more. Through this procedure, a series of extreme scenarios are tested, in order to investigate the product’s functionality beyond its natural conditions. The thermal testing procedure is particularly critical - and also quite long, because it tests the durability of each component under any condition. One of the methods that are applied is to attach thermocouples to the power components. The process begins with testing common circuits for all models in the series, and continues with testing the unique circuits for each model. All tests are performed under extreme conditions: maximal external temperature, maximal power and minimal input voltage - in order to simulate the most difficult working conditions. The Weak Spot The E. CAP LIFE procedure addresses one of the most common problems in Electronics. Even if a product is still working, the electrolytic capacitors inside it age - and tend to show a decrease in performance. In this procedure we monitor each and every capacitor in the product - based on thermal measurements and Ripple calculations. Each of the capacitors is exposed to high temperatures in order to predict its lifespan. The smaller the diameter of the capacitor, the shorter its life. Therefore, in this procedure we place emphasis on testing the small and sensitive capacitors. According to the company’s standards, we must ensure - after measurements in extreme conditions - the maximal lifespan that characterizes our products. Initiated Bugs In the next stages, the components and the entire product undergo additional testing. In a series of tests called AB NORMAL we create a series of initiated faults. For example, power circuits will be disconnected and will undergo short - intentionally. The goal: to identify the components that were damaged in the crash, and to make sure that a rare

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TDK-Lambda’s Testing Procedures - Examples:

PROCEDURE: Component Derating PURPOSE: To define the real operational terms of each component WHAT WE DO: Verifying data provided by component suppliers + conducting a series of additional tests

PROCEDURE: Ab Normal PURPOSE: To make sure that a rare fall, if occurs, will have a minor impact on the application WHAT WE DO: Initiated faults - for example, power circuits are disconnected and undergo short

PROCEDURE: E. CAP LIFE PURPOSE: To monitor each and every capacitor in the product WHAT WE DO: Thermal tests; Ripple calculations; exposing capacitors to extreme temperatures in order to predict durability

PROCEDURE: Thermal Shock Test (TST) PURPOSE: To verify functional reliability under severe temperature conditions WHAT WE DO: Exposing each component to cycles of extreme temperatures, either high or low

PROCEDURE: LIFE TEST PURPOSE: The final test that a product undergoes WHAT WE DO: Running the device non-stop for 8 months in a laboratory cabinet under harsh conditions - and taking periodic samples

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fall, if occurs, will have as minor an impact as possible on the application that the product serves - for example a factory production system. The test consists of two main parts: practical tests of power components and theoretical tests for failure scenarios in the smaller components. The Time Tunnel As part of a series of tests for thermal stress sensitivity (TST tests), we expose each component to cycles of extreme temperatures, either high or low. After testing the components, we also expose the entire power supply, as a whole, to these extreme conditions. Suppliers are electrically inspected - before and after exposure to thermal stress, in order to verify their functional integrity. In addition, mechanical tests are performed in order to verify the reliability of the components, the markings found on them and more. The most effective method for assessing the durability of a product over the years, under serious conditions, is to virtually simulate an acceleration in the life of the product. TDK Lambda engineers compute several activity cycles that the product must undergo during the testing (under severe temperature conditions) in order to verify its reliability over the years. Such a technique usually involves hundreds of consecutive activity cycles, equivalent to years of activity in the field. 8 Hot Months The final and decisive test that a product undergoes is its continuous operation for 8 months in a laboratory cabinet in which harsh environmental conditions of 50 degrees. During the running period in extreme conditions - and with maximum outlet power - periodic samples are taken and tested for the product. Among the parameters examined: the voltage, the current, and also its communication capabilities. At the end of the period, the supplier undergoes an even more comprehensive inspection - when it is already out of the cabinet - from the quality of its performance to its internal components condition.

The article is based on a webinar delivered by Karmi Simionovich, the R&D Manager of TDK-Lambda’s Power+Solutions Department. To watch the Webinar click the video in the next page

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Design For High Reliability Webinar By Karmi Simionovich

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Rugged Power Systems for Extreme Environment

When using fan cooled power supplies in extreme outdoor applications, or dusty manufacturing environments, there is a high risk of failures due to dirt and other contaminants entering the products. TDK-Lambda’s CPFE series features baseplate cooling, and therefore can operate in harsh environments where no fan cooling is permitted. These 1000W AC-DC power supplies are available with a special coating that protects against the ingress of dust, moisture and other contaminants - making the product ideal for harsh, dusty applications.

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CUS600M

Compact 3x5 Inch Footprint AC-DC Power Supply

The compact CUS600M is packaged in the industry standard 3x5” footprint and can deliver 600W with forced air or 400W with a 600W peak power with convection cooling. With Medical & ITE certifications, the unit can used in both Class I & Class II (no ground wire) applications, and meets Class B Conducted and Radiated EMI. A 5V 2A standby voltage, remote on/off, remote sense and a Power Good signal is standard on the CUS600M. Other options include an internal fan, single input fuse and output adjustment

Features & Benefits

12, 19, 24, 28, 32, 36 and 48V output voltages

Low off-load power consumption < 0.5W when output is inhibited

400W (600W peak) convection cooled, 600W with fan

Low leakage current - typically <200µA at 265VAC 60Hz

Medical and ITE certifications, Class I and Class II

Class I or Class II (no earth) installation

Quiet Operation

Class B radiated and conducted EMI

IEC/ES 60601-1 3rd edition; IEC/EN/UL/CSA 60950-1 Up to 96% efficient

Operation up to 70oC ambient

Easy To Cool In End System

Medical

Industrial

Testing

LED

COMM

Broadcast

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20 Times Faster than the Standard Version of GENESYS+ TM G+/Fast offers increased dynamics – up to 20 times faster than the standard GENESYS+™ version. The fast-speed model is especially designed for automotive test simulation and automatic test equipment (ATE) applications where faster output dynamics is required. Main features:

• Available for output power of 1,700W, 3,400W and 5,000W, and output voltage of 20V-40V (ideal for car battery simulation) • Up-and-down programming time of less than 2 milliseconds • Lower output capacitance

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The Quietest Modular Power Supply for Medical Devices

Developers of medical devices always look for quiet power supplies in order to improve the experience of both the user and the patient. The noise level of TDK-Lambda’s QM series (and specifically the QM7 unit) was compared with competitors’ units of similar power levels that were available on the market. The sound measurement has been taken at a 1-meter radius from the power unit under test. The results where crystal clear: TDK-Lambda’s QM7 was the quietest. TDK-Lambda’s QM series of modular power supply addresses a wide range of medical applications, including MRI systems, medical aesthetics devices, automated medication dispensers, dental equipment, X-ray machines and more. The QM series is certified to the newest medical and safety standards, and is covered by a 7-year warranty – the longest in the industry for a modular product.

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Looking for Modular Power Supplies? This is how TDK-Lambda can quickly answer all your needs!

As the original inventor of modular AC-DC power supplies in 1979, TDK-Lambda continues to serve the industry with its advanced QM series. The QM series addresses a wide range of applications, including medical equipment, industrial (robotics / automation), test and measurement, laboratory / life sciences, communication & broadcast and renewable energy. Here are our answers to the customers’ most urgent needs, especially during these challenging times: Looking for short lead-time to answer your urgent delivery needs? During the COVID-19 crisis and due to the high demands from different industries, our UK factory uses its experience and its robust logistic method to answer customers' needs in a very short lead-time. For us, this is also a life-saving matter. Since the COVID-19 outbreak, our deliveries to healthcare customers have increased dramatically. That includes the QM5modular power supply for X-ray equipment, and the Vega modular power supply for COVID-19 testing. Need to comply with the latest safety certifications and standards? The QM series is certified to the newest standards:

• Medical IEC/ES 60601-1 3rd edition • IEC 60601-1 4th edition EMC compliant • ITE (Information Technology Equipment) • IEC/EN/UL/CSA 60950-1 • IEC/EN/UL/CSA 62368-1 • CE Mark for LVD, EMC and RoHS

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Your users ask for a QUIET device? The QM series features a very low audible noise - for an enhanced patient/user experience. With efficiencies of up to 91%, less internal heat is produced, allowing for the use of low-speed cooling fan. Reliability is even improved as lower speed airflow reduces dirt and contaminants. Trying to maximize your flexibility? The five models in the series (QM4, QM5, QM5H, QM7 and QM8) cover the 550W-2,000W range. QM offers up to 18 outputs, and a wide selection of modules to perfectly match your requirement. Input voltage range is 90-264VAC; and output voltage range is 2.8-105V. Output current is up to 110A. Thinking for the long term? The QM series is covered by a 7-year warranty – the longest in the industry for a modular product. This means lower cost of ownership for customers. TDK-Lambda’s 40-year legacy in the modular field continues with non-stop developments and improvements. Need our professional advice? Let’s talk about your project! TDK-Lambda supports clients in Israel with a local commercial and engineering staff. You can also select a product using our simple online configurator that enables an optimized module selection with a choice of signals, leakage current and even standby voltages: https://config.emea.tdk-lambda.com/nv/?ccode=il

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Z+

NEW ! USER MANUAL FOR Z+

Compact Programmable DC Power Supplies

Suitable for bench or 2U rack mounting, the Z+ is a very compact programmable power supply offering power levels from 200 to 800W, voltages of up to 650V and currents of up to 72A. Multiple remote programming methods are available including built-in USB, RS232 & RS485 and optional LAN, GPIB & isolated analogue interfaces. The units can operate in either constant current or constant voltage mode and accepts a wide 85-265Vac input. The product is backed with a five year warranty

Features & Benefits

2U high – Minimises system rack height

Built-in USB, RS232 & RS485 – Highly flexibile system integration

Optional LAN, GPIB & Isolated analog programming interfaces – Choice of additional communications

Outputs up to 650Vdc – Wide application coverage

Arbitrary function generation – Convenient for repeated test processes 5 year warranty – High reliability

Industrial

Testing

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SUCCESS STORIES

GENESYS+™ GSP 15kW in 3 Units

GENESYS+ TM was Chosen by a Developer of Agricultural Drones

The agriculture drones market is expected to grow from $1.2 billion in 2020 to $5.7 billion by 2025. Key factors driving the growth of this market include pressure on global food supply due to growing world population; and increase in venture funding for the development of agriculture drones*. A new TDK-Lambda customer, that develops advanced drones for agricultural applications, was looking for programmable power supply for its testing lab. Our GENESYS+ was chosen to serve the unique needs of the customer. The programming features of Gen+ answer the client’s requirements for maximal precision, computer remote control and performance re programming. The programmable power supply has 19” Rack Mount capability for ATE and OEM application, and is equipped with built-in USB, RS-232/RS-485 interface. Programming is enabled via LabVIEW™ and IVI Drivers. GENESYS+ is manufactured in TDK-Lambda’s facility in Karmiel, Israel. Its users enjoy local technical support - and a 5-year warranty.

*https://www.marketsandmarkets.com/Market-Reports/agriculture-drones-market-23709764.html?gclid=CjwKCAjwg4 EBhBwEiwAzYAlsmvrhhLus74zbYL5f_SC8Ix7U8fVoXWzFQU2K9H0-Zmyo4Y28pDdIBoCGzoQAvD_BwE

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TDK-Lambda’s family of programmable power supplies sets new standards in flexibility, reliability and innovation

R&D, Manufacturing and Headquarters: 56 Ha’haroshet st. Karmiel Industrial Zone Marketing & Sales: 1 Alexander Yanai, Segula Industrial Zone,

Petach Tiqva 03-9024333

info@tdk-lambda.co.il www.tdk-lambda.co.il

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