800 V / 400 A Pulsed Constant-Current PSU Design (Team)

About the project

Project Title 800 V / 400 A Pulsed Constant-Current Power Supply – Design Team Project Overview We are seeking an experienced power electronics team to design an 800 V / 400 A pulsed constant-current PSU, including full system architecture, simulation, schematic design, PCB layout, and EMI/EMC compliance. This is a high-power HV pulsed system requiring proven expertise in SMPS design, SiC/IGBT power stages, magnetics, high-current PCB/busbar engineering, and EMI/EMC mitigation. A multi-disciplinary team is strongly preferred. --- System Requirements - Input: 3-phase, 380 VAC, 50 Hz - Output: Pulsed constant current - Max voltage: 800 V - Max current: 400 A - Load: 2 Ω - Current accuracy: ±1% - MCU-based pulse control - Controlled rise/fall times - Isolation and full protection (OV/OC/SC/OT) - Pre-charge and controlled shutdown - EMI/EMC compliance required - Thermal management and safety compliance Pulse timing parameters will be defined in a later phase. --- Required Expertise 1. System Architect - Full system architecture ownership - Definition of topology and system interfaces - Review and approval of all calculations, schematics, PCB, and simulations - EMI, thermal, and risk assessment oversight at each stage - Final design authority and sign-off --- 2. Power Electronics / Magnetics Engineer - Converter topology and power stage design - SiC MOSFET / IGBT selection and gate driver design - Transformer and inductor design - Loss, efficiency, and thermal modeling - Protection, DC link, and snubber design - High-current output path and busbar design Deliverables: detailed calculations, BOM, thermal analysis, and magnetics report. --- 3. OrCAD PSpice Simulation Engineer - Full system simulation of 800 V / 400 A pulsed operation - Switching, transient, and fault condition analysis - Device-level and magnetics modeling - Overshoot, ringing, and stress evaluation Deliverables: simulation project files, waveforms, and analysis report. --- 4. Schematic Engineer (Altium/OrCAD) - Complete schematic design (power, control, protection) - Sensing, isolation, and MCU interface circuits - BOM generation and library management - Design rule compliance and documentation --- 5. High-Power PCB Designer - High-voltage and high-current PCB layout - Minimization of switching loop inductance - Creepage, clearance, and isolation compliance - Thermal-aware and EMI-conscious routing - DFM/DRC compliance and manufacturability Deliverables: Gerber files, stack-up definition, 3D model, and manufacturing package. --- 6. EMI/EMC Specialist - EMI filter design and grounding strategy - Common-mode and differential-mode noise analysis - Shielding and pre-compliance planning - PCB-level EMI review and optimization Deliverables: EMI/EMC report and filter design recommendations. --- Project Stages 1. System architecture definition 2. Power stage design 3. PSpice simulation and validation 4. Schematic development 5. PCB design and layout 6. EMI/EMC review and optimization 7. Final design approval Each stage requires formal System Architect approval before proceeding. --- Final Deliverables - Complete system architecture and design calculations - Full schematic and PCB design files - PSpice simulation package with results - Magnetics, thermal, and loss analysis reports - EMI/EMC design and mitigation documentation - BOM and manufacturing files - Test and validation plan - Complete engineering documentation package --- Required Experience - High-power SMPS design (100 kW+) - 800 V+ power systems - 400 A+ current handling design - SiC MOSFET / IGBT-based converters - Magnetics design expertise - OrCAD, Altium, and PSpice proficiency - High-current PCB and busbar design - Proven EMI/EMC mitigation experience Please provide real project references including voltage, current, power level, topology, and switching frequency. --- Proposal Requirements Include: - Your specific role and expertise - Relevant high-power project experience - Maximum voltage/current previously handled - Recommended topology for this system - Simulation and PCB design experience - EMI/EMC experience and approach - Team structure and responsibilities - Estimated timeline and cost - Tools and software used - Key technical risks and mitigation strategy Generic proposals will not be considered. --- Important Note This is a high-voltage, high-current pulsed power system requiring simulation-driven engineering, strict safety margins, and formal stage-gated design reviews. The System Architect will have final authority over all major design decisions.

Skills required