Projects/Energy & Networking/Mini DC UPS
Case Study

Mini DC UPS

Uninterrupted DC power for network equipment.

A compact DC UPS with an 82 Wh Li-ion battery and four outputs that keeps modems, routers and IP cameras running through power cuts.

Industry
Energy & Power Electronics; Networking & Telecom
Status
In development — schematic and PCB design stage
Timeline
1405 (SH)
Partners
Client: FanapTech — supplies the battery, BMS, adapter, components and enclosure
Mini DC UPS
ALWAYS
ONLINE
01 / The Problem

Every power cut takes the network down.

Modems, routers and IP cameras restart on every short outage, and AC UPS units are bulky and waste energy converting power for devices that run on DC. Each device also needs its own voltage and connector.

Network devices reboot on every momentary outage
Several voltages needed at once, from 5 V to 48 V
PoE devices take power and data over one cable
Energy lost in repeated AC conversions
Outage = Downtime Many voltages, one source
Outage = Downtime
Many voltages, one source
02 / Our Solution

One smart DC source for every device.

Adapter power goes straight to the equipment while the internal battery charges. If mains fails, a hardware power-path stage, independent of software, switches to the battery with no shutdown.

Technical details
Seamless transfer
Seamless transfer
Hardware power path targeting 0 ms transfer time.
82 Wh storage
82 Wh storage
4S2P pack of eight 18650 Li-ion cells with CC-CV charging.
Four outputs
Four outputs
Passive PoE, DC jack (5/9/12 V), USB-A and USB-C PD up to 30 W.
03 / System Architecture

Hardware power, smart control.

Power continuity is handled entirely in hardware; a digital control unit handles monitoring, output control and the interface.

Input & charging
(20 V / 135 W adapter, CC-CV charger)
Power path
(Seamless switching)
Conversion & outputs
(Per-output control)
Control & interface
(MCU, TFT display, RGB LED)
04 / Technical Details

Technical details.

Battery
  • Eight INR18650-29HE cells, 4S2P
  • 14.4 V nominal, 5,700 mAh, 82 Wh
  • CC-CV charging with temperature monitoring
Input & power path
  • 20 V / 135 W adapter, Slim Tip connector
  • Load-priority power path, charging while powering
  • Target transfer time: 0 ms
Outputs
  • Passive PoE: 24 or 48 V, 18 W
  • DC jack: 5, 9 or 12 V, 18 W
  • USB-A: up to 24 W
  • USB-C: PD 3.0 / QC, up to 30 W
Control
  • MCU with per-output power sensing and on/off
  • 1.69″ color TFT, RGB LED, 4-key keypad
05 / Results

Key specifications.

Design targets, to be finalized after prototype testing.

0 ms
Power transfer time (target)
82 Wh
Li-ion battery pack energy
4
Outputs
30 W
USB-C PD 3.0 (target)
Behshad Norouzi

When the mains power drops, it takes over without the slightest pause and keeps the modem, camera or POS terminal running.

Behshad Norouzi
Embedded & Hardware Engineer, ZLab
PEOPLE
TECHNOLOGY
COLLABORATION
REAL IMPACT
06 / The Team

The people behind it.

A multidisciplinary team of engineers, researchers and domain experts.

Mohammadmahdi Nikkhah
Mohammadmahdi Nikkhah
Embedded Systems Engineer
Mohammadhossein Boroumandia
Mohammadhossein Boroumandia
Embedded Software & DevOps Engineer
Mehran Ahmadi
Mehran Ahmadi
Embedded Systems Engineer
Masoud Jalali
Masoud Jalali
Hardware Team Lead
Hasan Mahdavi
Hasan Mahdavi
Embedded Hardware Engineer
Behshad Norouzi Azad
Behshad Norouzi Azad
Embedded, Hardware & Robotics Engineer
07 / Gallery

More from this project.

Visuals of the system and its components.

System block diagram
R&D test boards
Charger and power management test board
Output converter and MCU test board
08 / What's Next

Need a custom power solution for your product?

From specification to schematic, PCB, firmware and prototype testing, the ZLab team is with you all the way.

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