Bulk Power Supply Design

About the project

Hello, I am looking for an experienced power electronics engineer or engineering company to design and develop a high-reliability industrial AC-DC power supply for continuous 24/7 operation. **Application:** High-Precision Industrial Testing and Power Distribution Systems. The project requires a complete custom design or an adaptation of an existing platform (ODM), with full engineering IP transfer. Upon project completion, I require ownership of all design files and documentation necessary for manufacturing, maintenance, and future modifications. ## Project Requirements ### 1. Overview We require a high-reliability, industrial-grade power supply for continuous 24/7 operation. The power supply will be used in **High-Precision Industrial Testing and Power Distribution Systems**, where reliability, stability, and long service life are critical. The design must be suitable for long-term industrial use and utilize high-quality components from reputable manufacturers. ### 2. Technical Specifications #### BOM Quality Requirements * All critical semiconductors (MOSFETs/IGBTs) must be from Tier-1 manufacturers such as Infineon, STMicroelectronics, or Wolfspeed. * Electrolytic capacitors must be industrial-grade with a minimum 5,000-hour life rating from manufacturers such as Rubycon or Nippon Chemi-Con. * All components should be sourced from reputable manufacturers with long-term availability. ### 3. AC Input Requirements * Input Type: Three-phase AC * Voltage Range: 187–230 VAC (200V-class industrial grid) * Frequency: 47–63 Hz * Power Factor: ≥ 0.9 ### 4. DC Output Requirements * Adjustable Output Voltage: 36–44 VDC * Adjustable Output Current: 0–120 A * Continuous Output Power: 4.3 kW @ 36 V * Peak Output Power: 5.3 kW @ 44 V * Ripple & Noise: ≤1% of output voltage (maximum 400 mVp-p) ### 5. Protection Features The design must include: * Over Voltage Protection (OVP) * Over Current Protection (OCP) * Short Circuit Protection (SCP) * Over Temperature Protection (OTP) * Input Under Voltage Protection (UVP) * Input Over Voltage Protection * Inrush Current Limiting * Output Fuse **Target efficiency:** 85–90% ### 6. Mechanical & Environmental Requirements * Maximum Dimensions: 280 × 120 × 240 mm * Industrial chassis-mount enclosure * Forced-air cooling using temperature-controlled fans * No power derating up to +40°C ambient * Target MTBF: ≥100,000 hours ### 7. Required Engineering Deliverables (Full IP Transfer) Upon completion, the following must be provided: 1. **Schematics** * PDF * Original source files (Altium, Protel, or OrCAD) 2. **PCB Design** * Gerber files * PCB source/layout files 3. **Firmware** * Complete commented source code * Programming instructions 4. **Bill of Materials** * Complete BOM with original manufacturer part numbers 5. **Mechanical Design** * STEP or IGES 3D CAD files 6. **Documentation** * Calibration procedures * Test procedures * Compliance test reports (if applicable) ## Please let me know: * Do you have experience designing industrial AC-DC power supplies in the 4–5 kW range? * Have you previously designed power supplies for industrial testing, power distribution, or other mission-critical applications? * Can you provide a complete custom design with full IP ownership transfer? * What topology would you recommend for this application? * What is your estimated development timeline? * What is your estimated engineering cost? * Can you share examples of similar projects you have completed (subject to confidentiality)? I look forward to your response. Thank you.

Skills required