Up to 106 W/in3: The new AEPS-GROUP DC/DC module series in Brick standard cases


AEPS-GROUP is a full-range designer and manufacturer of planar power modules for extreme applications. The article discusses the results of development and mass production of a new series of DC/DC converters that allows to replace similar products of world famous manufacturers Vicor, VPT, TDK-Lambda, SynQor, Recom and others.

The development of the JETDiR series for 5-700 W power began in 2019 not without the influence of the famous innovative giant in the field of power supply – VICOR.

The experts at AEPS-GROUP (Alexander Electric Power Supplies Group) at the time had proven designs based on the use of cast aluminum enclosures for our classic, 20 year old popular MDM, MR, TESD, TESND series. These designs feature heavy-duty mounting flanges for mounting the modules on the heatsink, resulting in excellent mechanical shock and vibration resistance. However, it is out of the size of the flanges did not allow to achieve design specific capacities of more than 60-80 W / inch3 when assembling a group of modules on a single radiator.

As a result the range of commercially available AEPS-GROUP DC/DC power supply modules includes a new series of seven modules: JETDiR20, JETDiR30, JETDiR40, JETDiR100, JETDiR150, JETDiR300 and JETDiR700, characteristics of which are presented in the table below. A characteristic feature of the design of these modules is a flange-less design – mounting holes are made in the body outline. Figures 1-7 show the devices of this series.

ac dc low profile power supply converter

Fig. 1 – JETDiR20-R1


ac dc low profile power supply converter

Fig. 2 – JETDiR30-R2


ac dc low profile power supply converter

Fig. 3 – JETDiR40-R2B


ac dc low profile power supply converter

Fig. 4 – JETDiR100-R3


ac dc low profile power supply converter

Fig. 5 – JETDiR150-R4


ac dc low profile power supply converter

Fig. 6 – JETDiR300-R5


ac dc low profile power supply converter

Fig. 7 – JETDiR700-R6


The smallest JETDiR20 has the densest layout of electronic components, and the largest and most powerful is the flagship of the whole line – JETDiR700. All seven modules of the JETDiR series have dimensions close to the Brisk form factor, from 31x21x10 mm to 117x61x13 mm. AEPS-GROUP JETDiR series modules in reinforced metal form factor housings are designed for DC electrical networks, typical for distributed power systems using battery support: 12 (10.2-15), 12 (10.2-30), 24 (20-30), 24 (20-60), 27 (20-40), 27 (15-50) and 48 (36-75) V. The entire series has maximum wattage figures of 20, 30, 40, 100, 150, 300, and 700 watts in the designations. To ensure long-term reliability, the load factor of these modules should be chosen from 0.7-0.8. This means that the modules in this series are optimized for an average power of 15, 25, 30, 70, 110, 200 and 600 W, respectively.

The electrical advantages of the JETDiR series modules are that they contain synchronous rectifiers up to an output voltage of 27V, which greatly increases their efficiency. JETDiR contain the necessary functionality of service functions, up to the parallel operation in models with high power.

Design advantages: The JETDiR series modules are very small in size which, combined with high efficiency, gives an excellent structural power density of 49-106 W/in3. The modules are constructed in reinforced aluminum housings with mounting holes that allow the screw heads to be recessed into the housing. The module enclosure has stiffening ribs and also serves as a conductive heat sink. Given that all components are structurally connected to the housing and encapsulated in a rigid thermally conductive compound, the resistance and robustness to mechanical stress is good.

Versions (LP) with a 10-20% reduced profile are available. Such a planar design improves the compatibility of modules in hardware.

Due to the use of aluminum housings JETDiR series modules can operate in some cases without additional heat sink due to the high efficiency, allow the maximum operating temperature at the housing -60 … +130 °C.

JETDiRs are optimal for various applications – flying objects up to 15 km altitude in unsealed and unprotected compartments: airplanes, drones, rockets, helicopters, flying balloons and gliders, meteosondes. In ground transport – in railroads, cars, tracked mobile vehicles. JETDiRs are suitable for telecommunication facilities, mining, supercomputers, radars in outdoor environments, and are used in wide temperature ranges, including in the Arctic and Antarctica, at all altitudes in the mountains, and in deserts.