Overview
An isolated high-voltage step-down power supply providing a compact, efficient 24 V or 48 V output from 200–800 V DC unregulated bus rails.
- LLC resonant half-bridge topology with secondary-side synchronous rectification.
- Custom transformer design with creepage/clearance meeting IEC 62368 standards.
- Low-EMI soft-switching architecture maintaining high efficiency across load ranges.
- Adaptive dead-time control and output voltage regulation firmware.
- Robust safety protections including hiccup-mode short circuit and overvoltage protection.
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Challenge
Designing a step-down converter from a 400 V DC input rail to 24 V with over 95% efficiency and a 4 kV isolation rating.
Solution
Implemented an LLC resonant half-bridge topology with GaN power switches and planar magnetics.
Outcome
Successfully reduced module size by 50% compared to legacy silicon-based designs while staying within thermal limits.