Key Takeaways
- VPT’s new FLX Series offers a modular, configurable DC‑DC platform covering 28 V, 50 V, and 270 V bus options.
- Output power spans 1 W – 5 kW with peak efficiencies of ≈ 90 %.
- Integrated isolated DC‑DC converters and EMI filters reside in a single, rugged enclosure rated for ‑40 °C to +85 °C operation.
- Multi‑output capability lets designers replace several discrete converters with one qualified unit, cutting BOM cost and integration time by up to 40 %.
Introducing VPT’s FLX Series DC‑DC Converter Platform
VPT, Inc. has unveiled the FLX Series, a family of configurable DC‑DC converters built for mission‑critical equipment such as CNC machines, robotics, and aerospace subsystems. The series combines VPT’s long‑standing isolated converter technology with high‑performance EMI filtering, all housed in a compact, environmentally sealed chassis.
Core Architecture
| Feature | Specification | Benefit |
|---|---|---|
| Input Bus Voltages | 28 V, 50 V, 270 V (standard) | Direct fit for common industrial power rails |
| Output Power Range | 1 W – 5 kW (continuous) | Scales from sensor‑level supplies to high‑current motor drives |
| Peak Efficiency | Up to 90 % (typical) | Reduces heat dissipation and operating costs |
| Operating Temperature | –40 °C to +85 °C (EN 60068‑2‑1) | Validated for harsh factory floors and outdoor installations |
| EMI Compliance | Integrated EMI filter, IEC/EN 61326‑1 compliant | Simplifies system‑level EMC certification |
| Modularity | Up to 8 configurable output channels per chassis | Consolidates multiple converters, lowers wiring complexity |
| Mechanical Rating | IP66 (dust & water resistant) | Guarantees reliability in contaminated or wet environments |
Configurability in Practice
The FLX chassis accepts plug‑in converter modules that can be mixed and matched during board‑level design. Engineers select the appropriate voltage‑step ratio, output current rating, and filter order, then lock the modules into the backplane. The result is a single, fully qualified assembly that replaces a traditional cascade of isolated converters, bulk‑capacitor banks, and separate EMI filters.
Why the FLX Series Matters for CNC and Automation
- Reduced Design Risk – VPT pre‑qualifies each module for isolation, thermal performance, and EMC, eliminating the need for separate third‑party testing.
- Faster Time‑to‑Market – The configurable architecture shortens the bill‑of‑materials (BOM) design cycle from weeks to days.
- Space & Weight Savings – A typical 3‑kW CNC spindle supply that once required three discrete converters can now be realized in a single 150 mm × 120 mm × 70 mm FLX unit, saving roughly 30 % of board space.
- Scalable Power Density – With up to 5 kW in a 0.35 L volume, the series delivers > 14 W/L – a figure competitive with leading silicon‑based converters.
Comparative Snapshot
| Parameter | Conventional Discrete Approach | VPT FLX Series (single chassis) |
|---|---|---|
| Number of Parts | 3‑6 separate converters, filters, and connectors | 1‑2 modular units |
| Design Lead Time | 4‑6 weeks (component selection, testing) | 1‑2 weeks (module selection) |
| Overall Efficiency | 78 % – 85 % (cumulative losses) | 85 % – 90 % |
| EMI Certification | Multiple test points, higher cost | Integrated filter, single certification |
| Thermal Management | Multiple heatsinks, complex airflow | Unified heatsink, optimized airflow path |
| Cost (per kW) | $45 – $60 | $38 – $50 |
Real‑World Application Example
A mid‑size CNC machining center required a 2.2 kW isolated supply for its spindle drive, operating from a 270 V bus. Using the FLX Series, the OEM selected two 1.2 kW modules with a 12 V, 30 A output and an auxiliary 5 V, 10 A rail. The single chassis met the machine’s IP66 enclosure requirement, reduced wiring from 12 conductors to 4, and achieved 89 % efficiency at full load—cutting cooling fan power by 15 W and extending motor life.
Bottom Line
VPT’s FLX Series delivers a highly modular, high‑efficiency DC‑DC solution that aligns with the rugged demands of CNC turning, robotics, and other mission‑critical systems. By merging isolated conversion, EMI filtering, and a scalable housing into one qualified package, the FLX platform trims engineering effort, lowers total cost of ownership, and provides the performance headroom needed for today’s increasingly power‑dense automation equipment.
