A ruggedized power supply for all occasions
A ruggedized power supply may or may not be a military power supply solution. They are designed to be used in extreme conditions where reliability and performance is essential. This includes resistance to shock and vibration, continuity of input and output sources and extreme temperature operational compatibility. If they are not certified to MIL-STDs their design can yield some benefits in functionality that would otherwise not be allowed on a battlefield ready MIL-STD product.
Technical Features
Over engineering of ruggedized power supplies to gain a MIL-STD product is not always necessary, and a compromise in some areas may yield better solution. For instance, to withstand extreme conditions, circuit boards are usually encased in metal and shielded from electromagnetic influence; if you don’t care about this as you are working in a temperate region with no electromagnetic interference likelihood, a lighter more cost-effective unit may be manufactured.
Due to performance being a key attribute of ruggedized power management systems, gold plating may be used to prevent corrosion in hygrothermal environments and to reduce shorting. A range of input options also provide military power supplies with versatility needed in the field with ruggedized power supplies providing likewise. While these features may be present in some commercial off-the-shelf (COTS) products, military products allow for lead solder to be used which has been replaced by tin alternatives due to it being a hazardous environmental waste. While there are other slight differences like this, COTS will in general share common features to military solutions. Below are some technical features that ruggedized power management systems may have when manufactured with ruggedness in mind:
Military-grade single phase transformers are typically used in airborne applications, tanks and submarines. The highest quality transformers will work under extreme temperatures and shock loading environments. These devices are encapsulated to protect them from vibration, dust, humidity, moisture, biodeterioration, and salt or other corrosives. Reflective coatings on the exterior are used to reflect radiant heat away from the device.
Three-phase transformers are designed to meet the high temperature needs of military electronics and telecommunications. Similar to single-phase transformers, three-phase transformers are encapsulated to protect against extreme conditions. The best three-phase transformers are relatively compact through the use of better materials and technology utilized with a trade-off being cost.
Heavy-duty AC-DC converters are usually military-grade converters and should be able to withstand the highest loads and resist the worst environmental conditions. They should also be able to withstand high-velocity shock scenarios as well as extreme hygrothermal environments. They are typically run off a generator.
DC-AC inverters provide powerful and low maintenance current inversion that may be used in vehicles. DC-AC inverters are designed to be lightweight and endure a variety of environmental challenges. DC-AC inverters are able to convert voltage from base level to another while also ensuring protection from overheating, over-voltage, and short circuiting.
The best DC converters can endure extremely rugged conditions and offer a wide range of adjustable voltage output with low electrical noise. DC-DC converters are often used for drones.
Over-voltage protectors help prevent voltage spikes and anomalies in power supply units or in the devices that rely on these units for power.
Electromagnetic Interference (EMI) filters protect electrical circuits from disturbances that cause degradation of information and data loss.
Military grade ruggedized power management systems include protective cases designed to prevent damage when supplies are reduced.
Hermetic sealing prevents air and gas from interfering with the operation of the ruggedized power supply, reducing the negative impact of outside conditions.
Inductors store energy and maintain a steady voltage despite varying current and typically encapsulated to ensure their ability to function in adverse conditions.
Summary
No matter your usage a ruggedized power supply should meet many challenges without fault. While these devices include MIL-STD certified power supplies, a ruggedized power supply can be adapted more to meet your granular needs.
