Differences and advantages and disadvantages of DC-DC converter module and discrete design
Almost all electronic products need to be equipped with a power converter solution to convert different voltage inputs and outputs. The new power converter solution has a highly integrated feature that can greatly shorten the design time of the product.
High-efficiency DC-DC converter module makes design more streamlined and lower cost
When you are designing electronic products, you always need to think first. Do you want to design the power converter yourself or buy ready-made modules? For DC-DC converters, it is necessary to select a specific size, power consumption, isolation, safety, EMC and electrical performance, and consider factors such as inventory and timely listing of products. Decisions are often quite difficult. However, with the introduction of many low-cost power modules, this problem is no longer so difficult to decide, because there are already many highly integrated power conversion modules on the market that can provide better power conversion functions and reduce your the cost of.
In high-power applications, for example, if you want to achieve a power of 600W, you usually choose to buy a ready-made power module, because it is impractical to add a large-volume power module on the motherboard. But in low-power applications such as 1W, many places will use simple isolated converters that can power isolated data interfaces, or generate low-power "points" for an analog circuit of an operational amplifier rail (for example, -5 V) Voltage, these converters can be purchased from reputable sources, and use surface mount or through-hole modules, and the price is about $2. However, many users believe that they can design and implement converters with a lower total cost and use basic theory and device application notes.
In fact, it is not just a cost comparison between the purchased module and the BOM of the discrete design, there are many hidden costs that need to be calculated. For example, if we want to use ten discrete components to implement a 1W isolated converter, the direct cost includes the need to place and inspect 10 components, compared with the use of modules, only the cost of one component needs to be processed. On the other hand , Procurement of 10 components may need to go through five manufacturers (including professional magnetic materials), and the use of modules only needs to face one supplier. In addition, 10 components may have 8 different component types, so they also need to be stored, inspected, stocked, and picked. It is relatively simple to use only one module.
On the other hand, there are also some indirect costs that need to be calculated, such as the cost of circuit area. When a discrete design is used, the motherboard is unlikely to be smaller. The use of embedded magnetic surface mount modules can make the volume smaller. The module can have professional power circuit design, and reduce the cost of product certification, and there is no need to carry out the PCB design of the module, which reduces the time invested in engineering and the cost of design support. If certification by a safety regulatory agency is required, there will be continuous certification and inspection costs, and multiple suppliers will be used for supply, and there are also regulatory, quality assurance and control requirements. The use of modules can avoid these troubles.
If transformers and other magnetic components are to be designed and manufactured by themselves, then all the above factors must be considered again, including the preparation of a variety of wire types and gauges, insulation materials, hardware and magnetic cores. For example, if the transformer has more than six windings, the wire diameter is less than 0.07mm and the core diameter is 4mm, special technology and equipment are required. Of course, you can also directly purchase magnetic components yourself, but its price is as expensive as the entire DC-DC module.
All these costs and related indirect costs and time delays can be avoided by only purchasing proven and reliable modules, and you can also save "opportunity costs" so that your company can focus on core business and focus on other things. Valuable places allow products to be marketed faster and sold earlier.
The latest low-cost products have appeared on the market, and they also have significant performance improvements over previous products. For example, the NXE series from Murata has the additional advantages of patent-pending embedded magnetic materials, which can provide better performance and lower cost than typical discrete or competitor components. The NXE series adopts Murata’s proprietary "Detectable Planar Grid Array" (iLGA) package, which is pin-compatible with 1 W industry standard package, so that existing users of DC-DC converter modules can upgrade and realize their Advantage.
In the past, the decision to “manufacture or buy†DC-DC converters often made people hesitant, because there are quite a few factors to consider. Today, the new generation of low-cost modules can already meet more low-power applications. If you are making a choice between "manufacturing or buying" a DC-DC converter, you might as well take a look at Murata's NXE series solutions.
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