How the intelligent GENESYS+™ design reduces lead-times

Posted by Dulcie on April 20, 2018

The GENESYS+™ series is TDK-Lambda’s latest portfolio of 5kW 1U high programmable power supplies. Initially launched with ten output voltage and current base models from 0 – 10V, 0 – 500A to 0 – 600V, 0 – 8.5A, the design, development and manufacturing team had a mandate to maintain very short leadtimes.

The GENESYS+™ 1U high 5kW programmable power supply

If a product target leadtime is not defined at the initial concept stage, the onus will fall upon the amount of inventory carried by manufacturing, which ties up cash and increases the potential for scrap. TDK-Lambda’s EMEA factories, however, have extensive experience in providing short delivery times with assembling modular AC-DC power supplies like the QM series, while keeping minimal amounts of finished product in stock.

To handle the large number of potential configurations, a platform design approach was adopted, featuring a high degree of commonality across the entire product line. This included a common 1U high chassis enclosure, a common display module, one communication interface board, common power processing sub-assemblies and a standard cable harness to cover all the models. This simplifies inventory control and assembly techniques.

To further reduce the number of configurations, some of the most commonly requested communication interfaces are now offered as standard, situated on one board assembly for cost effectivity. These include built in USB, LAN, RS-232 / RS-485 and isolated analogue programming, monitoring and control interfaces.

For higher power systems requiring 10kW, 15kW and 20kW outputs, the concept of ‘Scalable Power Systems’ was introduced. Here, multiple standard 5kW 1U high units are combined, with just one display module being used. The GENESYS+™ advanced parallel function is employed to equally share the load and still provide outstanding transient load performance.

3U high 15kW Scalable Power System

Leveraging the modular approach allows for an efficient supply chain and logistics model. High volume parts can be assembled in low cost facilities, backed up with small production runs locally to handle peaks in demand. Currently there are two TDK-Lambda GENESYS+™ final assembly and test locations, one in EMEA and one in the USA.