7 Cost Saving Ideas for CPE Power Supplies

When trying to find the optimum CPE PSU for your project, a number of factors should be considered. When looking at cost, there are a few elements that will affect the overall price of a power supply unit. We are going to examine 7 ways in which you can save costs on your project.

1. Single vs Full Range AC Input

When deploying large volumes of power supply units, single range is the most cost-effective option. An added benefit to this choice is the fact that many regions use single range AC input, e.g. Europe and USA/Canada​. Moreover, full-range inputs need a higher efficiency transformer, larger Bulk cap, and uprated MOSFET​, thus offering fewer opportunities for cost optimization. Full range is, therefore, best suited to applications where multiple geographies need to be supported e.g. with interchangeable AC plugs and multi-voltage countries such as Brazil​.

You can view our article on Full Range vs Single Range AC inputs here.

2. Desktop vs Wall mount Case

The latest PSU technology, using new high-efficiency chipsets and taking advantage of improvements in semi-conductors, enables high power output delivery from wall-mount cases. Wall mount solutions are smaller in form-factor then their desktop equivalents, with less parts (no ac cable), use less packaging, and are more cost-effective.

NetBit wall-mount PSU designs are now available with up to 50W output​ in our standard range and 58W in custom applications.

Download our whitepaper on Desktop vs Wall mount here.

3. Bespoke / Rightsizing Power Output

Legacy platform designs offered limited choices for output power options with larger gaps in the power range. NetBit has now launched a broad selection of next generation PSU

Platform designs with nominal power outputs of 12, 15, 18, 24, 30, 36, 42 and 50W.

Bespoke designs can be customized to specific applications and projects offering customers the flexibility to choose an exact power match between PSU and system whilst providing a cost-effective solution.

You can find our full product roadmap here.

4. Primary Side Regulation (PRS)

 Next generation PWM IC’s are paving the way to offering PSR benefits in mid-power applications, up to 24W​. Previously limited to 12W, PSR enables a more simple, compact design (ideal for custom projects). It also requires fewer parts in the PSU which can reduce PCB footprint and part count​, thus saving on overall cost.

NetBit has used PSR technology for Tier 1 US and EU MSO customers with great success.

5. ​Transient Versus Continuous Power Capability

Higher Transient Power Capability offers a more flexible, profitable and proactive design approach. Nominal power of the PSU is calculated based on both steady-state (continuous) and transient loads​. New CPE features (e.g. Wi Fi 6 and audio enhanced audio capabilities) add fast transients to power loads and lower continuous loads​ increase transient power​. Bespoke PSU design is available to meet the exact steady-state and transient load.

NetBit can fully customize PSUs design to reduce nominal power rating and provide necessary transient headroom without degradation to performance or derating.

6. Hold Up Time 

Legacy / older hold-up requirements come with an additional cost. Some of these designs still require either 20ms @ 240VAC, 50Hz and/or 16.67ms @ 120VAC, 60Hz​. Elongated hold-up time is frequently not as critical as it once was as faster SoCs and memory can now quickly save important data before total power loss​. A large Bulk E-Cap is required to maintain one full cycle, especially at low (100-120VAC) input voltage, which drives unit cost and limits scope for miniaturisation.

7. Inrush Current

The industry standard for Inrush Current is 100A​ and IEC 60065 standard limits for inrush current for a 1.0 – 2.5A output PSU is 100A​. Tightening inrush current reduces PSU efficiency​ by driving the need for an NTC with significant impedance, this in turn can require the need for higher efficiency switching semiconductors to offset this power loss. Such tight requirements can increase the complexity of the design. Limiting inrush current to 30A requires a soft-start PSU design which adds even more cost.

Each of the factors mentioned above plays a role in the PSU design cost and complexity. Having knowledge of these impacts when specifying your PSU can drive significant cost reduction for a given application. If you are working on a project and would like to see how our sales team could assist you on cost-effective PSUs for CPE, contact us via sales@netbit.com.