Bulk Power Supply Design

Hello,

I am looking for an experienced power electronics engineer or engineering company to design and develop a high-reliability industrial AC-DC power supply for continuous 24/7 operation.

**Application:** High-Precision Industrial Testing and Power Distribution Systems.

The project requires a complete custom design or an adaptation of an existing platform (ODM), with full engineering IP transfer. Upon project completion, I require ownership of all design files and documentation necessary for manufacturing, maintenance, and future modifications.

## Project Requirements

### 1. Overview

We require a high-reliability, industrial-grade power supply for continuous 24/7 operation. The power supply will be used in **High-Precision Industrial Testing and Power Distribution Systems**, where reliability, stability, and long service life are critical. The design must be suitable for long-term industrial use and utilize high-quality components from reputable manufacturers.

### 2. Technical Specifications

#### BOM Quality Requirements

* All critical semiconductors (MOSFETs/IGBTs) must be from Tier-1 manufacturers such as Infineon, STMicroelectronics, or Wolfspeed.
* Electrolytic capacitors must be industrial-grade with a minimum 5,000-hour life rating from manufacturers such as Rubycon or Nippon Chemi-Con.
* All components should be sourced from reputable manufacturers with long-term availability.

### 3. AC Input Requirements

* Input Type: Three-phase AC
* Voltage Range: 187–230 VAC (200V-class industrial grid)
* Frequency: 47–63 Hz
* Power Factor: ≥ 0.9

### 4. DC Output Requirements

* Adjustable Output Voltage: 36–44 VDC
* Adjustable Output Current: 0–120 A
* Continuous Output Power: 4.3 kW @ 36 V
* Peak Output Power: 5.3 kW @ 44 V
* Ripple & Noise: ≤1% of output voltage (maximum 400 mVp-p)

### 5. Protection Features

The design must include:

* Over Voltage Protection (OVP)
* Over Current Protection (OCP)
* Short Circuit Protection (SCP)
* Over Temperature Protection (OTP)
* Input Under Voltage Protection (UVP)
* Input Over Voltage Protection
* Inrush Current Limiting
* Output Fuse

**Target efficiency:** 85–90%

### 6. Mechanical & Environmental Requirements

* Maximum Dimensions: 280 × 120 × 240 mm
* Industrial chassis-mount enclosure
* Forced-air cooling using temperature-controlled fans
* No power derating up to +40°C ambient
* Target MTBF: ≥100,000 hours

### 7. Required Engineering Deliverables (Full IP Transfer)

Upon completion, the following must be provided:

1. **Schematics**

* PDF
* Original source files (Altium, Protel, or OrCAD)

2. **PCB Design**

* Gerber files
* PCB source/layout files

3. **Firmware**

* Complete commented source code
* Programming instructions

4. **Bill of Materials**

* Complete BOM with original manufacturer part numbers

5. **Mechanical Design**

* STEP or IGES 3D CAD files

6. **Documentation**

* Calibration procedures
* Test procedures
* Compliance test reports (if applicable)

## Please let me know:

* Do you have experience designing industrial AC-DC power supplies in the 4–5 kW range?
* Have you previously designed power supplies for industrial testing, power distribution, or other mission-critical applications?
* Can you provide a complete custom design with full IP ownership transfer?
* What topology would you recommend for this application?
* What is your estimated development timeline?
* What is your estimated engineering cost?
* Can you share examples of similar projects you have completed (subject to confidentiality)?


I look forward to your response.

Thank you.