Next generation military vehicles will be providing unprecedented levels of export power and standardization. Analysis has shown that conventional design techniques will come up short in terms of power density, reliability and cost for these applications.

TDI has developed alternative equipment design and construction techniques for highly reliable power conversion that will provide these applications new levels of standardization and performance.

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Highly Accelerated Stress Screening, or HASS, has been established as a best practice for assuring fielded electronic product reliability. HASS is especially productive in power conversion equipment, where component stress levels are typically more aggressive than found in other products. TDI has been instrumental in establishing HASS as a viable, high value-add production process.

This White Paper is the first in a series of documents outlining this process. Background information is provided regarding electronic equipment failure mechanisms and the predictive models that can be used to describe them.

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The paper provides information on the characteristics of batteries, particularly Valve Regulated Lead Acid, environmental aspects and practical system configurations available for system architects designed to provide recharge control in battery backed DC power solutions.

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Uninterruptible Power Solutions are often solved at the facility level with unnecessarily large, inefficient, expensive and complex AC UPS systems. While this provides an easy demarcation line between the facility and end equipment, with each focusing on a different part of the problem, it also results in overall operating efficiency and total cost of ownership being difficult to ascertain and optimize. Initial and operating costs can generally be reduced and system reliability increased by incorporating a relatively simple DCUPS as an integral part of the data processing or communication equipment.

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Improved components, technology and packaging / cooling concepts have reduced the size (watts / cubic-inch), weight (watts / pound) and initial cost (dollars / watt) of power conversion products. When implemented properly, these support new system goals of smaller, lighter and cheaper, along with improved reliability and reduced maintenance (i.e., lower operating costs)

TDI has taken these factors into account to set inviolable guidelines of best practice to assure optimal design in the tradeoff between smaller/lighter/cheaper and the essential goals of maximum reliability and minimum cost of ownership.

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Tin/Lead - "solder" - has served as the primary bonding and conducting agent for electrical interconnection of wires and components in electronic and electrical equipment for decades. However, lead has been determined to be a hazardous substance and the use of tin/lead solders are being restricted by government laws and regulations such as the European Union's RoHS Directive (Restriction of Hazardous Substances).

Accordingly, the RoHS Directive provides some exemptions to permit Tin/Lead in solder joints where reliability and long life are of critical importance (i.e telecommunications infrastructure, servers, security and data storage). Products, which utilize these exemptions are referred to as RoHS 5 compliant, whereas Lead- Free solder assemblies are referred to as RoHS 6 compliant. As new Lead-Free solders and processes are implemented, due caution should be taken to assure that the process and procedures are meticulously correct.

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Modern Electronic Systems are increasingly being applied in outdoor, nonsheltered or semi-sheltered environments. Special measures must be taken in the design and construction of electronic assemblies in these environments to assure optimal reliability. Power conversion equipment presents unique challenges with this regard due to high electrical, thermal and vibration stresses, and the large, irregular shaped components unique to their design.

TDI has developed several alternative equipment design and construction techniques for highly reliable power conversion, compatible with increasing environmental stress levels. The availability of this type of equipment opens up new alternatives for system cost and reliability optimization.

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Modern Electronic Systems are quite often powered from a three-phase power source. While utilizing power modules that operate directly from three-phase power might seem to provide optimal simplicity and flexibility, the added complexity required to realize three-phase power factor corrected circuitry usually negates any potential savings. This paper compares single-phase and three-phase circuits from the component count, stress level and complexity standpoints. It demonstrates that when these items are taken into account, quite often the best choice is a combination of single-phase modules, configured to balance individual power line phases.

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Powering the Information age….. TDI – Modular power Systems is a “Tour De Force” in the design of DC In-bay Power Filters. With the Internet expanding at the rate of 100% every six months, powerful network equipment is finding its way into the domain of the Plain Old Telecom System (POTS) Central Office. TDI is powering this revolution and providing innovative solutions to new problems.

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