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.
