Initial Situation
A certain company from the renewable energy and medical technology sector approached TPS Elektronik with the urgent need to modernize its aging power and battery systems. The company required a custom power supply design that could support both industrial production facilities and medical-grade equipment.
In their industrial division, the client needed a custom industrial power supply design capable of handling high-voltage loads and continuous operation in harsh environments. In parallel, their healthcare division demanded a custom medical power supply design that would comply with international safety standards and support the development of critical devices through medical device software development and software development for medical devices.
At the same time, the client was developing an e-mobility product line that required innovative on board charger design and validation against an on board charger reference design. Additionally, the company lacked a reliable partner for a full range of battery test systems—including battery test system, battery testing system, battery management system testing, battery and charging system tester, and battery pack test system—all critical for verifying performance and ensuring compliance with safety regulations.
To further complicate matters, the company was planning a large-scale battery energy storage system design project. This required expertise in the design of battery energy storage system and scalable energy storage system design to support renewable integration into the grid. The challenge extended beyond hardware: they needed support in communication protocol design and even the design and analysis of security protocol for communication to ensure safe and reliable operation.
The previous supplier was unable to deliver this complex mix of power electronics, software integration, and high-voltage testing. Therefore, the customer turned to TPS Elektronik, well known for high power solutions electronic city and long-term collaboration in demanding projects.
The TPS Solution
TPS Elektronik provided a holistic solution by combining engineering expertise with flexible custom power supply design services:
Redesign of Power Supply Systems
- Implemented custom industrial power supply design for the customer’s factory applications, focusing on reliability under continuous high-load conditions.
- Delivered a fully compliant custom medical power supply design, developed in parallel with medical device software development and software development for medical devices, ensuring the strictest safety and quality standards.
E-Mobility Charging Systems
Developed an optimized on board charger design aligned with a proven on board charger reference design, ensuring compatibility, efficiency, and simplified certification.
Comprehensive Battery Testing Solutions
- Designed and deployed multiple battery test systems, including battery testing system, battery management system testing, battery and charging system tester, and battery pack test system.
- Established an automated testing platform that covered the full product lifecycle from prototype validation to long-term durability studies.
Energy Storage Innovations
- Designed a modular battery energy storage system design architecture tailored for renewable integration.
- Supported the design of battery energy storage system with scalability for future expansion.
- Delivered a flexible energy storage system design that ensures high availability and grid compliance.
Advanced Communication & Security
- Integrated robust communication protocol design into both the power supply and energy storage solutions.
- Conducted the design and analysis of security protocol for communication, ensuring data integrity and system resilience against cyber threats.
Results
The project delivered significant improvements across multiple areas:
- Full compliance: All power supplies met CE and medical regulatory requirements.
- Improved efficiency: Industrial power supply redesign improved reliability and reduced downtime by 25%.
- Healthcare innovation: The new custom medical power supply design enabled the successful launch of two new medical devices.
- Battery safety & performance: The integrated battery test systems allowed comprehensive validation, reducing testing time by 35%.
- Future-proof energy storage: The scalable battery energy storage system design provided a flexible platform for grid integration and renewable energy projects.
- Security assurance: The implemented security protocol for communication passed external audits, ensuring reliable long-term operation.
Conclusion
This customer case demonstrates how TPS Elektronik combines expertise in custom power supply design, on board charger design, battery test systems, and energy storage system design to deliver end-to-end solutions. By integrating communication protocol design and robust software development for medical devices, TPS Elektronik ensures not only technical excellence but also regulatory compliance and long-term reliability.
Through this partnership, the customer gained a modernized, scalable, and secure system architecture—proving TPS Elektronik’s role as a trusted partner for high power solutions electronic city and beyond.
