Industrial power supply distribution and security

The power grid system is a vast network that consists of three major sections. The first one is the generation system where energy is created—typically by electromechanical or thermoelectric conversion. The most common generation sources are oil, natural gas, nuclear, hydroelectric, solar, wind, biomass, and geothermal.

The second section is the transmission system over which power is transferred from a generation point to a distribution point. The most common methods are via AC and DC cables, flexible AC transmission systems (FACTS), and pipelines.

Finally, the third section is referred to as the distribution system where power is converted to a usable level and delivered for residential, commercial, and industrial use. It usually consists of multiple voltage levels to accommodate varying user requirements.

All of these systems are equally important; however, the distribution system ensures that the grid system meets the energy requirements of its users. Accordingly, understanding industrial power distribution needs and environmental hazards can help you define PCB layout guidelines for power supply applications to meet these requirements.

Industrial Power Supply Distribution

Industrial facilities use large amounts of energy at various voltage levels. This necessitates that most factories have an internal power system consisting of an external generation, extensive transmission, or wiring network in addition to an industrial power supply main distribution center. The latter supplies power to all electrical and electronic systems within the facility through industrial boards that regulate power distribution.

Example of an industrial power distribution system.

Industrial power distribution system

As shown above, industrial power distribution systems typically supply multiple types of electrical systems. These include:

Factory Power Supply Applications

  • Lighting
  • Computing and peripherals
  • Production equipment
  • HVAC systems
  • Safety

These applications usually require power at various voltage levels. Industrial power system PCBAs are primary elements that enable this diverse distribution. And they may be subject to various high voltage and environmental hazards.

HV and Environmental Hazards for Industrial PCBAs

Building industrial boards that simultaneously meet energy demands and mitigate hazards requires specific PCBA layout guidelines for power supply applications to be instituted into your design. 

PCBA Manufacturing for Extreme Environments - Part 1

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Industrial Power PCBA Layout Guidelines

There are several types of linear and switch-mode power supply boards that are used for industrial applications, including the following:

Power Supplies Used in Industrial Applications (Max Voltage)

  • Full Bridge (5000V)
  • Boost (5000V)
  • Half Bridge (2000V)
  • Buck (1000V)
  • Push-Pull (1000V)

The list above is not exhaustive and only lists HV power supplies that operate at voltages ≥ 1000V. When designing boards for industrial production facility usage, it is necessary to follow a particular set of guidelines, such as those listed below.

Optimal PCBA Layout Guidelines for Industrial Environments

Tempo's Custom PCB Manufacturing Service
  • ISO-9001, IPC-600, and IPC-610 commitment to quality certifications.
  • Execute your full development cycle from proto to validation, NPI, and low volume production.
  • Accurate quote in less than a day.
  • Performs entire turnkey process in as fast as 4 days.
  • DFX support, including DFM, DFA, and DFT from Day 1 of design.
  • Sources components from the most reputable suppliers in the industry. to reduce procurement time.
  • Software-driven smart factory with monitoring and control throughout the manufacturing process.
  • Performs multiple automated inspections during PCB assembly to ensure PCB quality for prototyping.
  • Smooth transition from prototyping to production.

To optimize the effectiveness of instituting the layout guidelines above, work closely with your contact manufacturer (CM) to ensure that your design leverages DFM PCB tolerances for the most efficient and cost-effective development process. Tempo Automation not only leads the industry in fast, high-quality board building, but is also dedicated to ensuring that you have the best user experience.

Tempo employs a white-box turnkey PCBA manufacturing process that promotes collaboration and transparency between engineers and CMs. This allows us to quickly deliver high-quality boards for both standard and non-standard designs that meet energy industry criteria for prototyping and on-demand production. We also provide downloadable DRC files in Altium Designer, Cadence Allegro, Mentor Pads, other CAD formats, and Excel.

If you are ready to have your design manufactured, try our quote tool to upload your CAD and BOM files. If you want more information on CAD files or how to incorporate your design into a CAD format, contact us.


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