Airborne high frequency switching power supply design - Power Circuit - Circuit Diagram

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The airborne high-frequency switching power supply products have been specifically designed for AC 400Hz input, making them ideal for meeting the unique needs of military radar, aerospace, naval, locomotive, and missile-launching applications. In response to user demands, the development of localized on-board high-frequency switching power supplies for electronic weapon systems represents a significant breakthrough, breaking international monopolies and enhancing the mobility of our military equipment while ensuring superior performance.

Two input modes are available on these units: 115V/400Hz IF AC power supply and 28V DC power supply. Each input method has its own strengths and limitations. The 115V/400Hz power supply offers stable voltage fluctuations and higher device tolerance, whereas the 28V DC power supply requires isolation and regulation before being supplied directly to equipment components. The on-board power supply operates in challenging environments, requiring adaptability across a wide temperature range (-40°C to +55°C), as well as resistance to stress, vibration, and humidity. This necessitates a more rigorous design process to ensure reliability. Below, I will primarily discuss the switching power supply developed for the 115V/400Hz intermediate frequency AC input mode, which can adjust its output voltage between 270Vdc and 380Vdc, delivering an output power of no less than 3000W. It is fully equipped to meet military-grade power supply requirements.

System Configuration and Main Circuit Design

Figure 1 illustrates the overall circuit block diagram. The design is divided into two primary sections: the boost power factor correction circuit and the DC/DC conversion circuit. After filtering the 115Vac/400Hz IF AC power supply, the boost power factor correction (PFC) circuit performs power factor correction, boosts the voltage, and stores energy. Subsequently, the DC/DC half-bridge conversion, high-frequency rectification, filtering, and output filtering are executed. A feedback control loop ensures the adjustable output voltage ranges from 270Vdc to 380Vdc.

Overall Circuit Schematic Block Diagram

This system is designed with meticulous attention to detail, ensuring that each component functions seamlessly under extreme conditions. The combination of advanced power management techniques and robust hardware makes this solution indispensable for modern military applications. By addressing critical challenges such as thermal management, electromagnetic compatibility, and durability, we have achieved a product that not only meets but exceeds industry standards. Future enhancements will focus on further miniaturization and efficiency improvements, paving the way for even more sophisticated power solutions.

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