Cost Analysis The Price of Precision in High Voltage DC Supplies
There is a significant price disparity between 'hobbyist' high voltage modules and industrial programmable rack-mount systems. This section breaks down the engineering costs associated with 600V+ equipment.
There is a significant price disparity between "hobbyist" high voltage modules and industrial programmable rack-mount systems. This section breaks down the engineering costs associated with 600V+ equipment to justify the investment required for industrial reliability.
The "Insulation Premium"
As voltage increases, the cost of manufacturing does not scale linearly; it scales exponentially.
PCB Layout
High voltage requires wide creepage and clearance distances on the circuit board, increasing board size.
Components
1200V SiC (Silicon Carbide) MOSFETs cost significantly more than standard 60V silicon FETs.
Potting
To prevent arcing at high altitudes or humidity, critical high-voltage sections must be potted (encapsulated) in epoxy resin, a process that adds labor and material costs.
Analog vs. Digital Control Costs
Lower cost. Uses a potentiometer to set a reference voltage. Prone to drift. No data logging.
Higher cost. Requires a DSP, ADCs (Analog-to-Digital Converters) with high bit resolution (16-bit or higher), and isolated communication interfaces.
Value Proposition
For automated lines, the cost of a digital unit is offset by the elimination of manual logging and calibration downtime.
Total Cost of Ownership (TCO)
Purchase price is only one factor.
Failure Rates
A cheap HV supply without proper arc protection will fail when a DUT shorts. Replacing a power supply stops the production line.
Safety Liability
Equipment lacking active discharge circuits poses a safety risk to operators.
Conclusion
In high voltage engineering, safety and stability drive the cost. The premium paid for a digital, isolated system is an insurance policy against equipment damage and operator injury.