Custom Solutions
YEG Powerline has 25 years of power supply design and manufacturing expertise. YEG Powerline can provide cost-effective solutions for almost any electrical and mechanical configuration requirement, with output power ranging from a few watts to well over 30kW.
We can design and manufacture power supplies in almost any voltage and current and multiple output combinations with the required control.
The power supply styles can be open frame right through to enclosed product with IP5x or IP6x protection plus additional ruggedisation.
Types of bespoke power supplies we can make for you
• AC-DC power supplies
• Rectifiers and battery chargers
• DC-DC converters
• Bespoke LED drivers
• Sine-wave inverters
• Phase and frequency converters
• DC-input dimmable back-light inverters for LCD displays
• DC-output UPS systems
• Laboratory power supplies
• Complete power systems in 19" and 23" racks.
Our industrial and application experience:
• Access Control
• Broadcast
• Custom 19" & 23” Rack Systems
• EPOS
• Fire Detection
• Industrial
• LED Displays and signage
• Medical
• Professional Audio
• Process Control
• Railway
• Scientific Instruments
• Traffic controls
• Weighing
Our design capability
Our extensive knowledge of power supply product development and manufacturing enables us to be a specialist resource to our customers. The design process can start from very basic information or ideas and from that we can produce your initial product specification and mechanical drawings as part of a detailed proposal.
YEG Powerline will either adapt a specialist standard product or design or build a full custom solution.
Semi custom route
The benefits of customising a standard power supply are shorter development times and minimal safety approval issues. This route is good for prototypes or small to medium volume production. As volumes increase further, the modification can be incorporated at one of our manufacturing partners.
Examples of such semi customisation are:
• Converting open frame to enclosed PSU
• Enclosing a standard PSU, adding Filter switch, etc..
• Ruggedisation
• Adjusting output voltage
• Meeting needs for unusual multiple output voltage combinations
• Modify output loom or change connector
• Converting to DIN rail mounting
• Converting to 19" or 23" Rack mounting
• Paralleling multiple power supplies together
• Fan noise reduction on power supplies
Full custom design
Full custom designs are optimised for the user application, e.g. low electrical noise, unusual load demands or harsh environments and will incorporate only the features required by the customer thus minimising unit cost. Custom power supplies are designed and built with required cabling and mounting points ready for turnkey installation.
Time scales to produce engineering prototypes varies depending on complexity but is typically 8 weeks but this can be less if we are modifying an existing product.
Compliance
Proving compliance to all required standards may involve using external test facilities; however our designs are tested using pertinent in house tests from the following:
• Conducted EMC
• Radiated EMC
• Harmonics
• Mains born high energy transient testing
• Voltage Dip and Surge testing
• Climatic chamber
• High resolution thermal photographic imaging
• ESD up to 15 KV
• Fully automated power supply test equipment
• Transient response and bode plot analysis (optimises power supply response)
• Isolation (including type testing)
• Safety critical magnetic component isolation with-stand.
Safety and EMC standards we work to:
• Rail-specific standards including EN50155, EN50121-3-2, EN 61000, IEC 61373 shock and vibration, and RIA 12, RIA 13 and RIA 20
• UL508, EN60950 and equivalent standards for heavy industry
• DO160 standards for airborne applications
• MIL-STD-461 & MIL-STD-810 standards
• EMI filtering to meet any standard, typically EN55022 Class B
Production facilities
YEG Powerline has volume manufacturing both in the UK and China. All facilities are covered by Quality Control Systems and internationally recognised Safety Approvals Agencies.
UK production facility
The production facility has over 20,000sq ft of production area. The entire design and manufacturing process is controlled by stringent quality procedures in accordance with certification to BSEN ISO9001:2008.
The facility has multiple transformer winding stations, several surface mount and through hole automated assembly lines, hand and assisted manual assembly lines, conveyor driven lead free solder process and inspection lines, multiple pre-testers and bracket lines, 8 dedicated fully-automatic power supply test stations and multiple soak test chambers.
In addition to being a full scale manufacturing plant in its own right the UK site also manufactures volume product during the launch phase of units scheduled for long-term offshore manufacture.
Far East production facility
Our offshore manufacturing facility in China is a huge power supply specialist manufacturing facility with capability to produce around 2 million power supplies per year.
The factory is covered by various international approval standards and works to the most stringent quality control procedures. Through the offshore manufacturing facility, PSU Designs is able to supply high volume product into competitive market places.
Ruggedisation Capabilities
YEG Powerline has experience of many extremely rugged applications, including railways, industrial machinery, cranes, earth moving equipment, power utilities, oil exploration, airborne, military, marine, industrial PC and telecom with some products designed to give up to 30 years service.
YEG Powerline Ruggedisation Capabilities:
• High output voltages - up to 800Vdc
• AC or DC input
• Single or multiple outputs
• Single or dual redundant
• Rugged PC power supplies
• EMI filtering to meet any standard, typically EN55022 Class B
• Alarms and other interface connections
• Ruggedising and/or conformal coating, or full encapsulation
• Rail-specific standards including EN50155, EN50121-3-2, EN 61000, IEC 61373 shock and vibration, and RIA 12, RIA 13 and RIA 20
• UL508, EN60950 and equivalent standards for heavy industry
• DO160 standards for airborne applications
• MIL-STD-461 & MIL-STD-810 standards
• Operating temperature ranges including -55°C to +80°C
• Full electronic protection
• Extended temperature range
• High IP ratings, typically IP54 and above
• Ruggedised for shock and vibration
• Custom enclosures and racking
EMC and Safety Compliance Support
We are available to offer assistance with EMC compliance. We carry a wide range of filter samples and use of our EMC pre-compliance chamber. The chamber can be used for testing emissions, static discharge susceptibility, fast transient susceptibility and measurement of power factor. This valuable resource is made available on a free-of-charge basis to our customers along with full engineering support and up-to-date advice on EMC, safety related issues and legislation.
Please contact us with your requirements or questions by clicking here to go to our secure, on-line enquiry form.