Power Electronics
Custom Power Converter Design
At Spark, we specialise in providing bespoke power converter design and consultancy services to meet your specific needs. From DC-DC and AC-DC power supplies to advanced safety-critical systems, our team delivers cutting-edge solutions with voltage ranges from 3V to 15kV and current ratings up to 10kA.
• Plug-Top Adapters: Compact, high-efficiency designs for various applications.
• Battery Charging Solutions: Custom CC/CV charging for Li-Ion, NiMH, and LiPo battery packs.
• Intelligent Sequencing: Software-configurable start-up/shut-down sequencing for optimised operations.
• Advanced Protection Profiles: Power sharing, fault detection, and protection strategies for reliable performance.
• Redundant & Contingency Power: Supply redundancy designs for safety-critical systems.
• UPS & Backup Power Solutions: Uninterruptible power supply systems for enhanced reliability.
We not only design and manufacture power converters but also provide expert consultancy to help you determine the best power supply topology for your unique requirements. With Spark, you can be confident in solutions that are robust, efficient, and precisely tailored to your needs.
Custom Power Electronics Solutions
Engineers at Spark have extensive experience in developing and assembling power electronic systems for use in challenging environments. These include applications in defence, oil and gas downhole drilling, subsea oil and gas production control, aerospace, medical equipment, and a variety of commercial and industrial settings. Solutions are designed to operate reliably across voltage ranges from 3V to 15kV, even in harsh conditions.
Expertise in Semiconductor Technologies
The team has in-depth knowledge of semiconductor device control and packaging, including:
• MOSFET
• IGBT
• SCR/Thyristor
• Silicon Carbide (SiC) MOSFET
• Gallium Nitride (GaN)
Capabilities in Power Electronics
• Solar Array Monitoring and Balancing: Units that manage shade compensation and optimise solar panel performance.
• Solid-State Relays: Customised AC and DC relays, including MOS junction and hybrid MOS/electromechanical contactors.
• Programmable Fuses and Circuit Breakers: Solid-state devices with bespoke I²t curve characteristics.
• Active OR-ing Modules: High-power solutions for power sharing, power sequencing, and efficient fault isolation.
• Thermal Management: Custom heatsinks designed with advanced thermal simulation tools.
This expertise enables the development of solutions that are precise, efficient, and suited to the specific demands of each application. The focus is on addressing operational challenges with reliability and performance in mind.
Custom Magnetics Solutions by Spark
At Spark, we specialise in providing bespoke magnetic component solutions tailored to the unique requirements of your power electronics applications. With expertise in advanced ferrite cores and cutting-edge technologies, we deliver high-performance custom solutions for a variety of industries.
Our Custom Magnetics Capabilities:
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• Ferrite Power Inductors: Assembly of custom ferrite power inductors tailored to your specifications.
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• Ferrite Power Transformers: Customised transformer assembly for fly-back, forward, current sense, and resonant topologies.
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• Integrated Inductor-Transformer Components: Experts in “integrated inductor-transformer” components, commonly used in LLC power supply applications for compact and efficient systems.
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• Planar Transformers: High-performance planar transformers for high-efficiency, high-power-density applications.
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• Custom Core Grinding and Shaping: Precision grinding and shaping of ferrite cores to meet specific performance requirements.
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• Custom Bobbin Prototyping: Utilising the latest 3D printing technologies to produce and prototype custom bobbins for unique applications.
Our team combines technical expertise with state-of-the-art tools to produce magnetic components that are robust, efficient, and optimised for your application’s performance. Whether you require a custom inductor, transformer, or integrated magnetic solution, Spark ensures reliable and innovative results.
