アイガ電子工業 Product Lineup

This is a case study on the design and development of a DC power supply unit for FA computers. There was a request to develop a low-cost, high-reliability, and long-life power supply. 1. Selecting components that allow for long life, 2. Reviewing the circuit to reduce ripple current, thereby extending the life of aluminum electrolytic capacitors, 3. Improving the accuracy of overcurrent detection to suppress component heat generation, and other measures were implemented, making long life possible. Additionally, there was a request for high efficiency, achieving 95% efficiency. 【Case Overview】 ■ Input voltage range: AC85V to 127V ■ Output specifications: P5=16A, P12=6A, N12=0.5A, N5=0.5A ■ Number of channels: 4 channels ■ Efficiency: Over 70% *For more details, please refer to the related links or feel free to contact us.

• Power Supplies

This is a case study on the design and development of a DC power supply for large analytical devices. The output voltage is high, ranging from -8kV to +8kV, and there were concerns about fluctuations in the power supply voltage due to environmental factors, including humidity. There was a request to develop a power supply unit that addresses these issues. To prevent the effects of humidity, the circuit board was housed inside a stainless steel enclosure, and the area around the board was potted with insulating material to mitigate concerns about voltage fluctuations. Additionally, this design made it impossible for operators to physically access the circuit board, thereby enhancing safety. 【Case Overview】 ■ Application: Large analytical devices ■ Input Voltage Range: DC24V ±10% ■ Output Specifications: -8kV to +8kV ■ Number of Channels: 1 channel ■ Efficiency: Not specified *For more details, please refer to the related links or feel free to contact us.

• Power Supplies

This is an example of a DC stabilized power supply for elevator monitoring devices and a signal transmission device with communication conversion functions. It is necessary to ensure compatibility between the power supply and the monitoring system. Previously, communication was done using RS422 + PT 5C, but RS485 has been added to enhance compatibility in development. With the addition of RS485, the capacity of the power supply has been increased. Additionally, a nickel-cadmium battery has been incorporated to ensure operation for several hours during power outages as part of emergency measures. 【Case Overview】 ■ Application: Elevator control room ■ Input voltage range: AC 85V to 264V ■ Output specifications: 5V/3A, 24V/1.2A, 48V/0.05A ■ Number of channels: 3 channels ■ Efficiency: 80% *For more details, please refer to the related links or feel free to contact us.

• Power Supplies

This is a case study of a slot-type power supply unit compatible with AC/DC input for public equipment. With the installation of a no-fuse breaker, there was a challenge in fitting the circuit configuration within the space required by the customer. However, we proposed a change in the shape of the power supply unit, making it possible to fit within the effective space. Additionally, it was designed to allow for the replacement of components with a limited lifespan, such as capacitors. Although the breaker is mounted outside the enclosure, structural measures have been implemented, such as adding a cover, to prevent human error from inadvertently activating the switch. [Case Overview (Excerpt)] ■ Application: Monitoring device ■ Input Voltage Range - AC100/110/115V (AC85V to 127V) - DC100/110/125V (DC80V to 163V) ■ Output Specifications: 5V/15A, 15V/1A, -15V/1A, 24V/3A *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case study of a power supply for overseas communication base stations (module for VME 6U size). For domestic use, we had produced two types of power supplies, but for overseas use, there was a request to produce one type that could be used for two different applications. However, making it a dual-purpose specification required an increase in output by 10%, which raised concerns about cost. Therefore, we removed lower-priority functions and simplified the design to achieve a lower cost. [Case Summary (Excerpt)] - Application: Railway/Communication Base Station - Input Voltage Range: AC100/110V (AC80V to 132V) - Output Specification: 5V/22A - Number of Channels: 1 channel - Efficiency: 65% or more *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case study of a DC/DC converter (module for VME 3U size) that supports ultra-wide input. At the customer's request, they wanted to cover multiple models with DC24V/48V/72V/110V, but due to cost issues and the complexity of purchase management, they consulted about wanting to consolidate into one model. Additionally, for overseas products, it was necessary to switch control circuits for each input voltage range. By innovating the control circuit, we achieved continuous input of DC24V/48V/72V/110V without the need for manual switching of the input power supply voltage. 【Case Overview】 ■ Application: Railway safety equipment ■ Input voltage range: DC24V/48V/72V/110V (DC16.8V to 138V) ■ Output specifications: 3.3V/10A ■ Number of channels: 1 channel ■ Efficiency: 65% or more ■ Size: 40W × 129H × 233D ■ Applicable standards: JIS E 5006, JIS E 4031, IEC62236-3-2, IEC61000-4-2, IEC61000-4-11, JIS C 60068-1, VME compliant, etc. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case study of an AC/DC power supply for sequencers (PLC) applications. We consolidated two models of power supply units manufactured for both domestic and overseas markets into one model and conducted design development. By incorporating input harmonic suppression circuits that are not typically found in general products, we are able to accommodate both domestic and international standards. Aiga Electronic Industries, which operates industrial-custom-power.com, offers proposals for the consolidation of power supply units. Please feel free to consult us. [Case Overview (Excerpt)] ■ Application: PLC ■ Input Voltage Range - AC100/110/115V (AC85V to 127V), AC200/240V (AC170V to 264V) - DC100/110/125V (DC80V to 163V) *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case study of an inverter power supply for driving power protection devices within a railway substation (converting DC input for railway substations to AC). Previously, small inverters were installed one by one for each protection device using a pseudo-sine wave. Through operational adjustments on the system side, it became possible to supply power with a single unit, contributing to overall cost reduction for the system. Additionally, at the customer's request, we provided a sine wave output, enhancing added value. Aiga Electronic Industries, which operates Industrial Custom Power.com, also has a track record in inverter design and development. Please feel free to consult us. 【Case Overview】 ■ Application: For railway power protection devices ■ Input Voltage Range: DC100/110V (DC85V–140V) ■ Output Specifications: AC235V/25.5A ■ Number of Channels: 1 channel ■ Efficiency: Over 70% ■ Size: 40W×129H×233D *For more details, please refer to the related link page or feel free to contact us.

• Inverter

This is a case study of a power supply for overseas monitoring and control (for VME 6U size modules). It incorporates a DC/DC converter specified by the customer. By adding a control circuit, we achieved a simple configuration that reduces costs. Aiga Electronic Industries, which operates Industrial Custom Power Supply.com, procures customer-specified components and provides integrated services for design development, manufacturing, and inspection in-house. Please feel free to consult us. 【Case Overview】 ■ Application: Railway information monitoring and control device ■ Input voltage range: DC24V (DC21.6–30V) ■ Output specifications: 3.3V/3A, 5V/5A ■ Number of channels: 2 channels ■ Efficiency: Over 80% ■ Size: 56W × 262H × 233D ■ Applicable standards: VCCI CLASS A, IEC61000 6-4, IEC61000 6-5, VME compliant, etc. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case of manufacturing a DC stabilized power supply for plant control devices. We received an inquiry about introducing a versatile power supply that can accommodate multiple control devices and support both AC and DC inputs. We developed a power supply that can interchangeably use input and output modules. By avoiding complex control for both input and output, we simplified the circuit and improved reliability. By developing a power supply that combines versatility and high reliability to meet the customer's requirements, we achieved a case where the customer was very satisfied. 【Case Overview (Excerpt)】 ■ Application: Plant control devices ■ Input Voltage Range: AC 85–132V, DC 80–163V ■ Output Specifications: 5V/12V/15V/24V/48V ■ Number of Channels: 1–10 channels ■ Efficiency: 80% *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

This is a case of a DC stabilized power supply for a plant control room. It is a multi-channel power supply device with a specification of 7 channels. Each output is designed for high current, and each output voltage is modularized, allowing for unit-level replacement. Due to the nature of the power supply device, safety must be thoroughly considered. In addition to electrical and control specifications, the design has been enhanced mechanically to ensure that operators cannot easily access it. [Case Overview (Excerpt)] ■ Application: Plant Control Room ■ Input Voltage Range: AC 170–220V Three-phase ■ Output Specifications: 5V/100A, -3V/300A, -1.8V/300A, -5.2V/90A, -2V/150A, 5V/240A, 12V/20A ■ Number of Channels: 7 channels ■ Efficiency: 82% *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request to fit a power supply with an output of 24V 10A and an input of AC 100-200V wide range, including peripheral circuits such as output signal control, into a size of 60×250×150. Typically, in natural air cooling, the power supply is calculated at 8.5cc per watt, and if a standard circuit design is used, it will not fit within the requested size. Therefore, our company has achieved high efficiency by adopting a synchronous rectification circuit at the output to enhance the conversion efficiency of the switching regulator, fitting it into the size of 60×250×150. [Challenges] ■ Power supply with output of 24V 10A and input of AC 100-200V wide range - We want to fit it into a size of 60×250×150, including peripheral circuits such as output signal control. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The customer had designed and manufactured a power supply of 24V 3.5A with an input of AC/DC 100V at a width of 50mm. Due to the specifications of the equipment, it was necessary to change the width to 27mm, but there were concerns about heat dissipation performance, and they consulted us. By innovating the shape of the heat sink and considering the opening position of the cover, we were able to improve the heat dissipation efficiency even at 27mm and ensure the performance of the power supply. Additionally, by achieving this without adding a cooling fan, we were able to miniaturize the power supply. [Challenges] ■ Designed and manufactured a power supply of 24V 3.5A with an input of AC/DC 100V at a width of 50mm ■ It was necessary to change the width to 27mm due to equipment specifications ■ There were concerns about heat dissipation performance *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

A malfunction occurred in the power supply unit, and since it is from an overseas manufacturer, we were unable to conduct a failure investigation, so we received a request from your company. As it was an old device, there were no drawings available, so we conducted an on-site investigation of the device to identify the cause of the failure and the faulty components. After identifying the faulty components, we addressed the issue by replacing the relevant parts. [Challenges] ■ Malfunction occurred in the power supply unit ■ Overseas manufacturer, unable to conduct failure investigation ■ No drawings available due to it being an old device *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The customer in this case was using a DC power supply for industrial equipment from another company, but it had many issues and was discontinued. After conducting a failure analysis, we found that the problems were not due to individual components, but rather inherent design flaws, such as poor noise immunity. In response, we proposed a circuit design and implementation that is resistant to noise. Before our design was implemented, the customer experienced frequent troubles, but after using the power supply designed by us, they have been operating without any issues. [Challenges] ■ Used a DC power supply for industrial equipment from another company ■ Had many issues and was discontinued *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request from a customer to manufacture two models of custom power supplies, with the desire to keep development costs as low as possible. The two models of custom power supplies had similar specifications. Therefore, we shared the printed circuit board patterns. By designing it in advance to accommodate only component swaps, we were able to reduce the board development costs. [Challenges] ■ We want to manufacture two models of custom power supplies. ■ We want to keep development costs as low as possible. *For more details, please refer to the related link page or feel free to contact us.

• Circuit board design and manufacturing

We received a request from the customer to shorten the development period for the power supply unit. Normally, it takes about 6 months to go from design to manufacturing and evaluation for a 1 to 2-channel power supply unit, but this time they inquired whether it could be done in 3 months. Our company has a system in place to shorten the design lead time by creating a library of design specifications and drawings. In this case, we were able to shorten the design lead time by developing a design with similar specifications, allowing us to complete the development period, including evaluation, in 3 months. [Challenges] ■ We want to shorten the development period for the power supply unit (we would like it to be completed in 3 months) - For a 1 to 2-channel power supply unit Normally: It takes about 6 months from design to manufacturing and evaluation. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request from a customer to develop a power supply with an ultra-wide input voltage range of 12 to 110V. Typically, when the range is wide, it is necessary to separate the power supply by input voltage, such as 12 to 24V or 48 to 72V, or to use a switch to toggle between them. By using a buck-boost switching converter that can automatically switch between boost and buck operations, we can accommodate an ultra-wide input range of DC 24V to 110V. Eliminating the switch allows for stable output and improves reliability. [Challenges] ■ Development of a power supply with an ultra-wide input voltage range of 12 to 110V ■ When the range is wide - It is necessary to separate the power supply by input voltage, such as 12 to 24V or 48 to 72V - Or it is necessary to use a switch to toggle between them *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The customer in this case is aiming to develop a power supply for industrial machinery to be used in extremely cold regions and has requested a design for a power supply that can operate at -30°C. We will change semiconductors such as ICs and capacitors to low-temperature compatible components. When used in extremely cold regions, the key point is whether the device can operate normally within the required temperature range, as the characteristics of electronic components can change with temperature. For example, capacitors can have their capacitance halved at lower temperatures, which may prevent achieving the intended effect, so we designed with consideration for the variation of components due to temperature. [Challenges] ■ Development of a power supply for industrial machinery to be used in extremely cold regions ■ Request to design a power supply that can operate at -30°C *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request to develop a power supply unit that can be used in salt-damaged areas, with a waterproof structure that can also withstand salt damage. The housing used for the power supply unit has been designed with an IP67 equivalent waterproof structure. Additionally, while we previously used aluminum housings, corrosion due to salt damage was occurring, so we developed a stainless steel case. By using a gasket in the gap between the case and the lid, we thoroughly implemented measures against salt damage and prevention. [Challenges] ■ Development of a power supply unit that can be used in salt-damaged areas ■ Request for a waterproof structure that can also withstand salt damage *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

Traditionally, when the manufacturer we had been outsourcing the production of power boards to went out of business, we received a request for board production from them. Until now, we had only outsourced visual inspections, and no electrical operation tests were conducted. Although the request was for board production, we proposed the development and manufacturing of an automatic testing device, as well as conducting electrical operation tests in-house. By providing a comprehensive solution, we were able to reduce the burden on our customers. [Case Overview] ■ Issue: The manufacturer we had been outsourcing to went out of business. ■ Proposal: Development and manufacturing of an automatic testing device, and conducting electrical operation tests in-house. ■ Result: Reduced the burden on customers through a comprehensive solution. *For more details, please refer to the related link page or feel free to contact us.

• Circuit board design and manufacturing

We were using a custom power supply, but we received a request to use general-purpose DC/DC converters and AC/DC switching power supplies to aim for cost reduction and shorter development lead times in the production of power supplies. In this case, by using general-purpose AC/DC power supplies and DC/DC converters, we were able to meet the required specifications. Therefore, we designed a combination of off-the-shelf components to achieve cost optimization. [Challenges] - Aim for cost reduction and shorter development lead times - Production of power supplies using general-purpose DC/DC converters and AC/DC switching power supplies *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The power supply of a special inspection device within the power plant has failed, and since it is a discontinued maintenance item, the manufacturer is unable to respond, leading to a consultation with our company. Upon hearing the situation, it was noted that there were requests not only for the replacement of the power supply unit but also for improvements to the inspection device, and they requested that we handle the replacement of the inspection device. In this case, we addressed not only the power supply unit but also the replacement of the existing inspection device, and we implemented VA/VE proposals to address the issues that had previously occurred. By providing a consistent response from the power supply unit to the testing device, we were able to reduce the burden on the customer, resulting in a highly satisfactory case. [Challenges] ■ The power supply of a special inspection device within the power plant has failed. ■ It is a discontinued maintenance item, and the manufacturer is unable to respond. ■ There are requests for improvements to the inspection device, not just for the replacement of the power supply unit. ■ They would like us to handle the replacement of the inspection device. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The manufacturer of the power supply unit we had been using has discontinued production and it has been discontinued, so we received a request to produce a power supply unit with the same specifications. After confirming the specifications of the power supply unit and equipment through hearings, we manufactured a power supply with the same specs. By replacing components such as electronic parts with our standard products, we shortened the lead time for supplying parts during maintenance. [Challenges] ■ The manufacturer of the power supply unit we had been using has stopped production and it has been discontinued. ■ We would like to have a power supply unit with the same specifications produced. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request to design a commercial power supply used in large PCs to continue outputting for a certain period of time even if the input voltage is interrupted due to power outages or other issues. In response, we have developed a power supply unit with a backup function that incorporates a rechargeable battery, allowing it to output 5V20A for 10 minutes after the input voltage is cut off. 【Case Overview】 ■Challenge - Design a commercial power supply used in large PCs to continue outputting for a certain period of time even if the input voltage is interrupted due to power outages or other issues. ■Solution - Incorporate a rechargeable battery to continue outputting 5V20A for 10 minutes after the input voltage is cut off. - Develop a power supply unit with a backup function. *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

In the power supply device, we received a request to enable ON/OFF control of each output of the power supply in response to external signal commands. By adding a controller circuit, we made it possible to perform output control according to external commands while maintaining the input voltage. In this case, the control is based on external commands, but it is also possible to incorporate a control circuit that sequentially activates outputs without external input. 【Case Overview】 ■ Issue - We want to enable ON/OFF control of each output of the power supply in response to external signal commands. ■ Solution - Added a controller circuit - Performed output control according to external commands while maintaining the input voltage *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request from a customer to develop a power supply unit capable of high current output, such as 200-300A, with multi-channel output. There are concerns about rising maintenance costs and decreased safety due to the inability to manage channels individually if the multi-channel outputs are integrated. We also received a request to address these issues. By creating a separate output unit for each output voltage and combining them, we can accommodate individual management. By individualizing the units, repairs can be done quickly and at low cost, which can also help reduce running costs. [Challenges] ■ Development of a power supply unit capable of high current output, such as 200-300A, with multi-channel output ■ Concerns when integrating multi-channel outputs - Increase in maintenance costs - Decreased safety due to inability to manage individually - Need to replace the entire power supply unit in case of failure *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request for the development of a power supply for an ultrasonic exploration device. Since high-frequency circuits are used in this power supply, it was necessary to design and develop it with high frequency in mind. When using high-frequency circuits, adopting a highly efficient switching power supply can lead to increased noise, which may result in malfunctions. Therefore, we adopted a dropper power supply. While the dropper power supply has lower efficiency compared to switching power supplies, it is low-noise and effective for use with high-frequency circuits. [Challenges] ■ Development of a power supply for an ultrasonic exploration device ■ Design and development must consider high frequency due to the use of high-frequency circuits ■ Adopting a highly efficient switching power supply can lead to increased noise and potential malfunctions *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

We received a request from a customer using a power supply unit manufactured several decades ago, asking for repairs due to a malfunction. Many of the components are discontinued, and the manufacturer has also ceased support, which is why they consulted us. While there was an option to replace it with a new power supply unit, they were planning to replace the entire equipment soon, so we proposed an overhaul that would only involve replacing the electrolytic capacitors and other components with a limited lifespan. [Issues] ■ The power supply unit manufactured several decades ago has malfunctioned and needs repair. ■ Many of the components are discontinued. ■ The manufacturer's support has also ended. *For more details, please refer to the related link page or feel free to contact us.

• Contract manufacturing

In the development project for a power supply device for aircraft, there was a request for miniaturization. While there was a request for natural air cooling, attempting to accommodate this would require more than three times the required volume. By switching from natural air cooling to conductive cooling, miniaturization becomes possible. In this case, we implemented the internal circuit board and mounted components on an insulated heat-dissipating aluminum plate, allowing us to adopt a conductive cooling method. As a result, we achieved the miniaturization of the power supply device based on the specified requirements. [Challenges] ■ Miniaturization of the power supply device for aircraft ■ Attempting to accommodate natural air cooling would require more than three times the required volume *For more details, please refer to the related link page or feel free to contact us.

• Power Supplies

The manufacturer we had commissioned for the production of the power supply board has gone out of business. We received an inquiry asking if we could take on not only the board production but also the electrical operation testing. Although the initial request was for board production, we proposed the development and manufacturing of an automatic testing device, as well as conducting the electrical operation tests in-house. By providing a comprehensive solution, we were able to reduce the burden on the customer. [Case Summary] ■ Issue: Inquiry about whether we could handle not only board production but also electrical operation testing ■ Proposal: Development and manufacturing of an automatic testing device, and conducting electrical operation tests in-house ■ Result: We were able to reduce the customer's burden through a comprehensive solution *For more details, please refer to the related link page or feel free to contact us.

• Circuit board design and manufacturing

Our company handles industrial electronic equipment such as industrial power supplies, control devices, elevators, and electronic components. In particular, we develop a wide range of excellent products from prototypes to finished products (software to hardware), including power supplies, monitors, and control terminal devices. 【Product Line】 ■ Industrial Power Supplies ■ Control Devices ■ Elevators ■ Electronic Components *For more details, please download the PDF or contact us.

• Contract manufacturing