800 V / 400 A Pulsed Constant-Current PSU Design (Team)

Project Title

800 V / 400 A Pulsed Constant-Current Power Supply – Design Team

Project Overview

We are seeking an experienced power electronics team to design an 800 V / 400 A pulsed constant-current PSU, including full system architecture, simulation, schematic design, PCB layout, and EMI/EMC compliance.

This is a high-power HV pulsed system requiring proven expertise in SMPS design, SiC/IGBT power stages, magnetics, high-current PCB/busbar engineering, and EMI/EMC mitigation. A multi-disciplinary team is strongly preferred.

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System Requirements

- Input: 3-phase, 380 VAC, 50 Hz
- Output: Pulsed constant current
- Max voltage: 800 V
- Max current: 400 A
- Load: 2 Ω
- Current accuracy: ±1%
- MCU-based pulse control
- Controlled rise/fall times
- Isolation and full protection (OV/OC/SC/OT)
- Pre-charge and controlled shutdown
- EMI/EMC compliance required
- Thermal management and safety compliance

Pulse timing parameters will be defined in a later phase.

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Required Expertise

1. System Architect

- Full system architecture ownership
- Definition of topology and system interfaces
- Review and approval of all calculations, schematics, PCB, and simulations
- EMI, thermal, and risk assessment oversight at each stage
- Final design authority and sign-off

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2. Power Electronics / Magnetics Engineer

- Converter topology and power stage design
- SiC MOSFET / IGBT selection and gate driver design
- Transformer and inductor design
- Loss, efficiency, and thermal modeling
- Protection, DC link, and snubber design
- High-current output path and busbar design

Deliverables: detailed calculations, BOM, thermal analysis, and magnetics report.

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3. OrCAD PSpice Simulation Engineer

- Full system simulation of 800 V / 400 A pulsed operation
- Switching, transient, and fault condition analysis
- Device-level and magnetics modeling
- Overshoot, ringing, and stress evaluation

Deliverables: simulation project files, waveforms, and analysis report.

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4. Schematic Engineer (Altium/OrCAD)

- Complete schematic design (power, control, protection)
- Sensing, isolation, and MCU interface circuits
- BOM generation and library management
- Design rule compliance and documentation

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5. High-Power PCB Designer

- High-voltage and high-current PCB layout
- Minimization of switching loop inductance
- Creepage, clearance, and isolation compliance
- Thermal-aware and EMI-conscious routing
- DFM/DRC compliance and manufacturability

Deliverables: Gerber files, stack-up definition, 3D model, and manufacturing package.

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6. EMI/EMC Specialist

- EMI filter design and grounding strategy
- Common-mode and differential-mode noise analysis
- Shielding and pre-compliance planning
- PCB-level EMI review and optimization

Deliverables: EMI/EMC report and filter design recommendations.

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Project Stages

1. System architecture definition
2. Power stage design
3. PSpice simulation and validation
4. Schematic development
5. PCB design and layout
6. EMI/EMC review and optimization
7. Final design approval

Each stage requires formal System Architect approval before proceeding.

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Final Deliverables

- Complete system architecture and design calculations
- Full schematic and PCB design files
- PSpice simulation package with results
- Magnetics, thermal, and loss analysis reports
- EMI/EMC design and mitigation documentation
- BOM and manufacturing files
- Test and validation plan
- Complete engineering documentation package

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Required Experience

- High-power SMPS design (100 kW+)
- 800 V+ power systems
- 400 A+ current handling design
- SiC MOSFET / IGBT-based converters
- Magnetics design expertise
- OrCAD, Altium, and PSpice proficiency
- High-current PCB and busbar design
- Proven EMI/EMC mitigation experience

Please provide real project references including voltage, current, power level, topology, and switching frequency.

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Proposal Requirements

Include:

- Your specific role and expertise
- Relevant high-power project experience
- Maximum voltage/current previously handled
- Recommended topology for this system
- Simulation and PCB design experience
- EMI/EMC experience and approach
- Team structure and responsibilities
- Estimated timeline and cost
- Tools and software used
- Key technical risks and mitigation strategy

Generic proposals will not be considered.

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Important Note

This is a high-voltage, high-current pulsed power system requiring simulation-driven engineering, strict safety margins, and formal stage-gated design reviews. The System Architect will have final authority over all major design decisions.