High-precision testing plays an irreplaceable role in fields such as electronic component research and development, industrial control, new energy equipment detection, and aerospace product verification. Its core demand is to acquire precise, steady and dependable test data, which imposes extremely rigorous demands on the performance of all supporting equipment in the test system. As a critical power conversion component in high-precision testing systems, the DC-DC converter undertakes the task of transforming the input DC voltage into a steady, low-interference DC voltage that satisfies the power requirements of precision test apparatuses, sensors, and signal processing units. The precision, ripple, interference and steadiness of its output directly decide the validity and exactness of test outcomes. Consequently, choosing an appropriate DC-DC converter is pivotal to guaranteeing the quality of high-precision testing. This paper will examine the key factors and practical guidelines for choosing DC-DC converters in high-precision testing scenarios, offering targeted references for test engineers and related professionals.
First and foremost, output precision and voltage regulation capability are the key indicators for choosing DC-DC converters in high-precision testing. Unlike ordinary industrial or communication scenarios, high-precision test apparatuses (such as precision oscilloscopes, signal analyzers, and high-precision sensors) have extremely high demands for power supply steadiness, and even minimal voltage fluctuations may result in significant discrepancies in test data. The output precision of a DC-DC converter refers to the divergence between the actual output voltage and the rated output voltage, typically expressed as a percentage.When you need to test something carefully you should pick converters that can give you a very accurate output, like ±0.5% or better. If you are working with something that needs to be extremely precise like testing parts for semiconductors you should use converters that can do better like ±0.1% or higher.
The converters ability to control the voltage is also very important. This includes two things: line regulation and load regulation. Line regulation is, about how the converter can keep the output voltage steady when the input voltage is changing. Load regulation, by contrast, indicates how stable the output remains when the load current changes. To prevent output voltage deviations triggered by shifts in input power or test load—and thereby ensure consistent test conditions—both of these indicators must be restricted to within 0.1%.
Secondly, low output ripple and noise are indispensable requirements for DC-DC converters in high-precision testing. Ripple and noise are inherent voltage fluctuations in the output of DC-DC converters, which will interfere with the signal acquisition and processing of precision test equipment, leading to distorted test signals and reduced data accuracy. High-precision testing systems, especially those involving weak signal testing, have extremely strict restrictions on ripple and noise. To achieve low ripple and noise, it is recommended to select converters with advanced circuit design (such as synchronous rectification technology) and built-in high-performance filtering modules.
Thirdly,dynamic response speed is an important factor that cannot be overlooked in high-precision testing scenarios featuring variable loads. Many high-precision testing processes involve instantaneous changes in test load—for instance, dynamic performance testing of new energy vehicle power components and transient response testing of power management chips. Too slow a dynamic response speed of the DC-DC converter will result in obvious overshoot or undershoot of the output voltage during load variations. It will then fail to deliver a stable power supply to the test equipment promptly, thereby impairing the accuracy of transient test data. Recommended are DC-DC converters with a transient response time of less than 2ms. Such converters can swiftly adjust the output voltage when the load changes, thus ensuring that the output stays stable within the permissible range. Additionally, the load capacity of the converter should have a certain margin. Generally speaking, the rated output current of the converter ought to be 1.2 to 1.5 times the maximum current demanded by the test load. This not only prevents the converter from being damaged by overload but also guarantees stable output under extreme load conditions.
Furthermore, stability and reliability serve as the fundamental guarantees for long-term high-precision testing. Long-time continuous operation is often required in high-precision testing. Should the DC-DC converter fail, it will not only interrupt the test process but also potentially cause damage to costly precision test equipment. As a result, the converter must possess excellent long-term stability. During prolonged operation, the output voltage drift should be confined to a narrow range. In terms of reliability, priority should be accorded to converters equipped with comprehensive protection functions. These functions are like a safety net for the converter. They have things like over-voltage protection, over-current protection, short-circuit protection and over-temperature protection. This means the converter is protected from getting damaged when something goes wrong like when the input voltage's not right or there is a short circuit or it gets too hot.
The mean time between failures of the converter is also very important to know. It is like a report card for the converter. A higher mean time, between failures means the converter will work well for a time. This means it is more reliable. This can reduce the frequency of maintenance and replacement, thus ensuring the continuity of test work. Moreover, the converter must comply with relevant international and national safety as well as EMC standards—UL60950-1 and EN55022 Class B, to name a few—to avoid electromagnetic interference with test equipment.
Other factors, including size, heat dissipation performance, and cost, also need to be taken into comprehensive consideration based on the actual testing scenario. For laboratory-based high-precision testing, the installation space is relatively ample. More focus can therefore be placed on performance indicators like accuracy and low noise. For portable high-precision testing equipment—on-site calibration instruments, for example—miniaturized and integrated DC-DC converters should be chosen. This is to meet the lightweight and compact design requirements of the test system. Closely linked to the converter’s stability is its heat dissipation performance. Excessive temperature rise will not only diminish the conversion efficiency of the converter but also have an impact on its output accuracy and service life. You should really consider using converters that can get rid of heat well.This means looking at things like heat sinks and quiet fans that are built in.These things help the converter work smoothly even when it is really hot.When you think about how much things cost do not go for the most expensive option,you should pick a converter that does what you need it to do and is priced fairly.The converter you choose should be good enough for the test you are doing.Converters that are good enough, for your test should be what you are looking for.
In conclusion, selecting a DC-DC converter for high-precision testing requires focusing on core performance indicators such as output accuracy, ripple and noise, dynamic response speed, and comprehensively considering stability, reliability, size, heat dissipation and cost according to the actual test scenario. Only by selecting a converter that fully matches the needs of the high-precision testing system can we provide a stable, pure and reliable power supply guarantee for the test equipment, ensure the accuracy and validity of test data, and promote the smooth development of research and development, production and detection work in related fields.
We at IDEALPLUSING not only provide products, but also strive to provide customers with suitable power supply solutions and quotations.
Our core competitiveness lies in carefully selecting a variety of power supply options to help customers evaluate and choose the most suitable power supply solution.
We can offer AC DC power supply, DC AC inverter, AC AC power source(single phase or 3 phases),AC DC Ground Power Unit...
Share our interesting knowledge and stories on social media
