How to Choose the Right DC-DC Converter for Your Applications

A DC-DC converter is an electronic circuit that converts a direct current (DC) source into a new DC power form. These electric power converters can be designed in a variety of ways and serve numerous applications, often making it difficult for engineers to decide which ones serve their needs best. Further, new, more advanced converters have entered the market, making it even more of a task to settle on the option that will provide your design with adequate power.

Below, we review some uses for DC-DC converters and how to specify one for your project.

DC-DC Converter Applications

While power electronic converters need to meet various requirements specific to different applications, engineers can expect to use DC-DC converters for specific equipment. When devices require more than one power source and proper energy regulation to operate correctly, DC-DC converters are the go-to choice. The key features of DC-DC converters are their ability to increase or decrease and stabilize the voltage.

A few common DC-DC converter applications include:

• Vehicle Automation Systems
• Vehicle On Board Power
• Mobile Field Operations
• Surveillance Systems
• Radar Systems
• Unmanned Aircraft Systems (UAS)
• Weapon Systems
• Embedded Computing Systems
• Consumer Electronics (like smartphones, video game consoles, televisions, and battery chargers)
• Medical equipment

How to Choose a DC-DC Converter

The goal when considering DC-DC converters for your applications is to ensure they will meet your power density and performance requirements, while minimizing costs. As you research DC-DC converters and whether they fit your needs, you will need to be ready to specify the following information:

1. Input voltage: Input voltage is the source to the power supply. DC-DC converters can run off a range of input voltages or a fixed voltage. Typical fixed input voltages are 28VDC, 12 VDC, and 5 VDC. You’ll need this information when developing power supply specifications.
2. Output voltage: Output voltage from the power supply is the input voltage to your application. You’ll need to know what the input voltage requirements for your application are so you can specify the output voltage needed from the power supply. Power supplies don’t create energy, only convert it from one source to another and clean up the source power to drive your application. Generally, the output voltage is dependent on the input voltage and other conditions. Common output voltages are 28VDC and 12VDC. When running processers, 5 and 3.3 VDC are generally used. Be sure to think about whether you need regulated or unregulated output voltage—most DC-DC converters feature regulated output voltage. Note that isolated or non-isolated converters can be developed with numerous output voltages, which could be helpful. Further, some additional features can allow engineers to adjust the output voltage or turn it on or off.
3. Load current: You will need to know you project’s load current needs in order specify how much output current is required for the intended application. Most of the time, this is stated in output power. Please note that a DC-DC converter operating at full load is more efficient, which can lead to improved thermal management for your application.
4. Operating temperature: The operating temperature is what your DC-DC converter can run at under load. This aspect is critical to consider in line with your application, as a converter running beyond that temperature range can pose a high safety risk.
5. Interfacing: Input and output connectors need to be considered. You can have D-connectors, circular connectors, pins, etc. D38999 is a common military grade connector that is used for robust, rugged environments. Pin and socket size need to be capable of carrying the amount of current. For example, you don’t want 20A of current going through a 15A rated max pin or socket.
6. Mounting and Cooling: Understanding how the power supply will be mounted can help determine if cooling will be needed. Sometimes you will need to cool the power supply by having it mounted on a cooling plate or having fans move air over it.
7. Environmental Factors: When looking for a power supply, it’s good to understand the environment it’s going to be used in. Will it need to survive 100% condensing humidity? Does it need to be moisture proof? Will there be blowing dust or sand? Looking for a power supply with an IP rating might be in order. IP67 is a good rating often seen for a power supply to survive moisture and dust.
8. EMI and EMC requirements: If your product must meet electromagnetic interference (EMI) and electromagnetic compatibility (EMC), ensure the DC-DC converter you select aligns with your goals. A DC-DC converter that is tested for EMI/EMC compliance is a good option in most cases.

These variables all play a role in determining whether you choose one type of DC-DC converter over another. Because many advanced converters now exist, engineers may find it appropriate to speak with a quality converter supplier in the first stages of their product design to make greater sense of the situation.

Find the Right DC-DC Converter for Your Application at ACT

Since 1981, Advanced Conversion Technology (ACT) has provided the United States military branches with various power solutions. At ACT, we design and manufacture AC-DC and DC-DC power supplies to support military applications throughout a range of environments and platforms—all in one facility, located here in the United States. No matter what your power conversion requirements are, we have the expertise and skillset to provide you with quality solutions that will last.

If you are searching for a DC-DC converter for your next project, you can browse our wide selection to find one that meets your needs. Beyond our online inventory, we can modify or customize a solution that will meet the requirements of your specific application. Contact us to find the best power supply solution for your needs.