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Global Compliance Power Supply Hardware Development for Automotive Manufacturing

n-ix.com

Manufacturing

Automotive

Electronics

Regulatory Compliance and Scalability Challenges

Existing power supply units require urgent redesign to meet new EU electromagnetic emission standards and global efficiency requirements. The client needs to support 5V-54V voltage range across multiple product lines while maintaining strict efficiency parameters and meeting production deadlines.

About the Client

Austrian-based manufacturer of inductive components, transformers, and power supply systems for automotive and industrial applications

Certification and Market Readiness Goals

Develop 5V-54V power supply line with universal 90V-264V input compatibility
Achieve compliance with EU, US, Japanese, and Israeli electromagnetic emission standards
Implement on-site testing infrastructure for radiation, voltage, and efficiency validation
Deliver production-ready designs within 12-month regulatory compliance window

Core System Capabilities

Multi-voltage output configuration (5V-54V DC)
Universal AC input (90V-264V, 47Hz-63Hz)
Integrated EMI/EMC compliance circuitry
Thermal management system for efficiency optimization
Modular transformer construction for easy manufacturing

Engineering Tools and Methodologies

Schematic Design (Pulsonix)

Board Layout (LeCroy Waverunner LT264)

EMI Testing (Rohde&Schwarz ES SCAN Athena)

Precision Measurement (Selective microvoltmeter, Precision power meter)

Testing Infrastructure Requirements

Automated compliance testing framework
Thermal imaging integration for efficiency monitoring
Real-time EMI/EMC measurement systems

Performance and Reliability Standards

90%+ efficiency across full voltage range
Operating temperature tolerance (-40°C to +85°C)
10-year mean time between failures (MTBF)
Radiated emissions <30MHz per CISPR 22 Class B

Business Value Projections

Enables immediate market access across 80+ countries through multi-standard certification, reduces client's R&D costs by 40% through modular design, and establishes foundation for future automotive power supply innovations while ensuring 100% compliance with upcoming EU regulations.