A company operating in the renewable energy sector approached TPS Elektronik<\/a> with a complex engineering task. The customer aimed to modernize a power conversion unit that had originally been developed more than ten years earlier. The existing design showed limitations in efficiency, thermal behavior, and operational stability, particularly when exposed to fluctuating input voltages.<\/p>\n\n\n\n The objective was to develop a buck-boost converter design capable of stable operation during both charging and discharging cycles. The customer requested technical support in buck-boost converter circuit design, including buck-boost converter design calculations and validation of relevant buck-boost converter design equations to improve overall energy conversion performance.<\/p>\n\n\n\n In addition, the legacy system relied on hard-switching power supply concepts, which led to increased thermal stress, switching noise, and reduced component lifetime. Under transient load conditions, the existing power supply on\/off hard switch behavior proved inconsistent and required improvement.<\/p>\n\n\n\n Beyond power conversion, the system also required a reliable circuit protection concept. The customer requested support in circuit breaker design, including a compact miniature circuit breaker design suitable for space-constrained installations. As parts of the system were software-controlled, the scope also included the implementation of a circuit breaker design pattern in microservices to improve fault tolerance in distributed control software.<\/p>\n\n\n\n The project further required the integration of an analog integrated 2-D optical flow sensor to monitor airflow and thermal behavior inside the converter housing during operation.<\/p>\n\n\n\n TPS Elektronik delivered an end-to-end engineering solution covering concept development, simulation, hardware design, and system validation.<\/p>\n\n\n\n The updated system demonstrated measurable improvements compared to the legacy design:<\/p>\n\n\n\n This case study illustrates TPS Elektronik\u2019s engineering expertise in buck-boost converter design and circuit protection concepts for renewable energy applications. By combining hardware development, buck-boost converter design calculations, PCB layout optimization, and software-based protection mechanisms, TPS Elektronik supported the modernization of a complex power conversion system.<\/p>\n\n\n\n The project covered both electrical and software-related aspects, ranging from optimized power supply switching behavior to the application of circuit breaker design patterns in distributed control systems.<\/p>\n\n\n\n With experience in DC-DC buck-boost converter design, circuit protection development, and sensor integration, TPS Elektronik<\/a> supports customers in developing reliable and efficient power electronics solutions tailored to industrial requirements.<\/p>\n\n\nTPS Elektronik Solution<\/h2>\n\n\n\n
Converter Design and Simulation<\/h4>\n\n\n\n
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PCB Design and Integration<\/h4>\n\n\n\n
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Power Supply and Switching Optimization<\/h4>\n\n\n\n
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Circuit Protection Design<\/h4>\n\n\n\n
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Testing and Validation<\/h4>\n\n\n\n
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Results<\/h2>\n\n\n\n
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Conclusion<\/h2>\n\n\n\n