How Should The Power Adapter Be Designed To Improve Product Quality?

If you want to ensure the quality and life of the power adapter, you must think about it before designing, so as to avoid the adapter from failing quickly. This is a comprehensive issue of system design and consideration. The performance that affects the life of the adapter includes environmental characteristics, components and power requirements, which are combined in the following aspects.
1. The impact of the actual application environment: high humidity environment, high temperature environment, dusty environment, strong magnetic environment, vibration environment.
2. The influence of the power supply grid: The voltage input of the unstable grid will have an impact on the components of the adapter, thereby affecting the service life of the LED driver.
3. Influence of insulation and installation: Correct installation and good insulation of the product will enhance the application force of the adapter.
4. The influence of electrolytic capacitors: the sealing part of electrolytic capacitors will leak gasified electrolyte, and this phenomenon will accelerate with the increase of temperature. It is generally believed that the leakage rate will increase to 2 times when the temperature rises by 10 °C. Therefore, it can be said that the electrolytic capacitor determines the life of the adapter device. If you choose a high-temperature electrolytic capacitor with a life span of 10,000 hours at 105 degrees, and according to the current estimation of the life of an electrolytic capacitor, the company "every 10 degrees lower, the life will double", then it has a working life of 20,000 hours in an environment of 95 degrees. The working life under the environment is 40,000 hours.
5. Influence of switching times: Most adapters are equipped with capacitor input rectification circuits. When the adapter is connected, a surge current will be generated, which will cause fatigue of the switch contacts and cause problems such as increased contact resistance and adsorption. It is theoretically believed that during the expected life of the adapter, the number of on and off switches is about 10,000 times.
6. Influence of inrush current protection resistors and thermal power resistors: In order to resist the inrush current generated when the adapter is connected, the adapter is usually designed to use resistors in parallel with SCR and other components. When the adapter is turned on, the power peak is as high as tens to hundreds of times of the rated value, resulting in thermal fatigue of the resistor and causing an open circuit. Thermistor power resistors under the same conditions will also experience thermal fatigue.
In general, if you want to design a power adapter with reliable quality, safety and longevity, it is not enough to rely on theoretical knowledge. It also needs a lot of experiments to verify, constantly to find problems, and then solve them.