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DC-DC Converters, Chargers & Equalizers
Discover our range of DC-DC converters, chargers and equalizers. High-efficient conversions with robust and reliable performance for industrial applications.
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DC-DC Converters
Why Voltage Conversion Matters
DC-DC converters are utilized to transform a DC power source from one voltage level to another (or multiple voltage levels). For instance, the battery in a machine or vehicle might operate at 24V, whereas the system within that machine requires 12V. In such cases, a direct voltage conversion from 24V to 12V is necessary. This is the fundamental purpose of DC-DC converters - to provide the required voltage level.
DC-DC Equalizers
Why Battery Balancing Matters
Industrial vehicles and mobile machines often operate with both 24V and 12V electrical loads powered by the same battery system. When 12V equipment such as control units, sensors, lighting, safety systems, and communication devices draws power from only one battery in a 24V battery bank, battery imbalance can occur over time.
A DC-DC equalizer continuously balances voltage and charge levels between two series-connected 12V batteries in a 24V system. This helps protect battery health, maintain available capacity, and ensure reliable operation of critical 12V loads.
DC-DC equalizers are widely used in material handling equipment, construction, agriculture, forestry, and other industrial OEM applications with mixed-voltage architectures. By maintaining battery balance, they help extend battery life, improve uptime, and reduce total cost of ownership.Why Battery Balancing Matters
DC-DC Converter with IP67
Does your application require robustness?
DC-DC converters with an IP67 rating should be chosen when machines or vehicles operate in extreme environments or under harsh conditions. In most cases, however, DC-DC converters with an IP21 rating are adequate and more cost-effective. We recommend consulting with a DC-DC converter expert to select the most optimal solution for your specific needs.
As an example, Micropower has supplied DC-DC converters with an IP67 rating to customers in various industrial sectors. These vehicles and machines operate in challenging environments, necessitating converters that are waterproof and capable of withstanding harsh conditions, including exposure to water and heavy vibrations. In such scenarios, a DC-DC converter with an IP67 rating is the ideal choice.
DC-DC Converters Efficiency Rate
Why efficiency matters
A DC-DC converter significantly influences the overall efficiency of a system. A highly efficient converter facilitates system cost savings, which should be factored into the total cost estimation. For example, a 5% improvement in efficiency for a 500W converter can result in overall system savings of 20-25% of the DC-DC converter’s cost.
Other critical considerations include the impact of temperature on component longevity. For every 10°C increase in temperature, the lifespan of the converter decreases by 50%. Additionally, a 4% efficiency gap can lead to a twofold increase in temperature rise.
FAQ
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What is a DC-DC converter and why is it used in industrial vehicles?
A DC-DC converter transforms one DC voltage level into another, allowing multiple electrical systems to operate from a single battery source. In industrial vehicles and mobile machinery, DC-DC converters are commonly used to supply 12V, 24V, or 48V equipment while maintaining stable and efficient power distribution throughout the vehicle. -
When should I use a DC-DC converter instead of a battery equalizer?
A DC-DC converter should be used when voltage conversion is required, such as powering 12V loads from a 24V battery system. A battery equalizer is used to maintain charge balance between two series-connected batteries in a 24V system. While both technologies support mixed-voltage electrical architectures, they solve different power management challenges. -
What is a DC-DC equalizer and how does it work?
A DC-DC equalizer continuously balances voltage and charge levels between two 12V batteries connected in series within a 24V battery system. By preventing uneven discharge caused by asymmetric 12V loads, it helps maximize battery capacity, extend battery service life, and maintain reliable vehicle operation. -
What are the benefits of using a DC-DC charger in OEM applications?
A DC-DC charger enables controlled battery charging from an alternative DC power source, such as an alternator, traction battery, auxiliary battery, or onboard electrical system. DC-DC chargers help optimize charging performance, protect batteries from improper charging conditions, and support reliable operation in demanding OEM applications. -
Why is efficiency important when selecting a DC-DC converter?
Efficiency directly affects energy consumption, thermal performance, and system reliability. High-efficiency DC-DC converters reduce power losses, generate less heat, and help extend component lifetime. For OEMs, improved efficiency can contribute to lower operating costs and a reduced total cost of ownership (TCO). -
When is an IP67-rated DC-DC converter required?
IP67-rated DC-DC converters are recommended for construction equipment, forestry machinery, agricultural vehicles, material handling equipment, and other applications operating in harsh environments. Their sealed design provides protection against water ingress, dust, vibration, and shock, ensuring reliable performance under demanding operating conditions. -
How can DC-DC power solutions improve battery lifetime?
Proper DC-DC power management helps reduce battery stress by maintaining stable voltage levels, balancing batteries, and delivering controlled charging. This minimizes uneven battery wear, improves charge acceptance, and helps maximize battery service life in industrial and mobile equipment. -
What types of machines and vehicles use DC-DC converters, chargers, and equalizers?
DC-DC power solutions are widely used in forklifts, warehouse trucks, AGVs, AMRs, construction equipment, agricultural machinery, forestry vehicles, airport ground support equipment, utility vehicles, mining equipment, and other industrial OEM platforms where multiple voltage levels must operate within the same electrical architecture.
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