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Eltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier Teardown

05 January 2012
The following is an overview of a teardown analysis conducted by IHS Technology Teardown Services.

Overview / Main Features

The Eltek FlatPak 48/3000 is a power rectifier of Eltek's FlatPack2 line of rectifiers. It converts standard AC voltage into 48V DC. It is used as a single rectifier in an array within any FP2 system solution. It is hot swappable and offers plug-and-play features that allow for installation without system interruption.

During the teardown analysis, it was observed that a 16-bit, 32MHz DSC (digital signal controller) made by Freescale is the heart of this rectifier - controlling the SMPS circuitry and providing handling system integration.

Eltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier Main ImageEltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier Main Image

Target Market

Telecommunication

Pricing and Availability

The FlatPack2 48/3000 is available through Eltek and authorized distributors.

Eltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier - Main PCB Top and BottomEltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier - Main PCB Top and Bottom

Volume Estimations

For the purposes of this teardown analysis, we have assumed a lifetime production volume of 80,000units.

As a reminder, teardown volume production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.

Eltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier Cost AnalysisEltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier Cost Analysis

Cost Notes

Main Cost Drivers Representing ~56% of total materials cost

Infineon - IPW60R045CP - MOSFET - N-Channel, 650V, 60A (Qty:2)
Fairchild Semiconductor - FDL100N50F - MOSFET - N-Channel, 500V, 100A (Qty:2)
International Rectifier - IRFP4568PbF - MOSFET - N-Channel, 150V, 171A (Qty:4)
4-Layer - FR4, Lead-Free
Heatsink - Extruded / Machined Aluminum (Qty:2)
Sunon - PSD1204PQBX-A - Fan - 12VDC, 9.6W, w/ Integral 4-Wire Harness, 1 4-Position Pin Socket Connector
Infineon - IDH12SG60C - Schottky Rectifier - Silicon Carbide, 600V, 12A (Qty:2)
Manufacturing Cost
Transformer - Wound, PQ Core, Horizontal, Plastic Bobbin, w/ Plastic Base, Paper Label & Kapton Tape Insulators
Heatsink - Extruded / Machined Aluminum (Qty:2)

Total BOM & Manufacturing Costs (Direct Materials + Conversion Costs) $126.36

What Is Not Included in our Cost Analysis

The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.

Country of Origin / Volume Assumptions

Based on markings, the unit was assembled in China. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc. were sourced in China)

Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies (such as China), we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.

Remember also that labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.

Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for China.

Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.

Eltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier - Controller PCB A Top and BottomEltek Valere 241119.105 Flatpack2 48/3000 HE G92 Power Rectifier - Controller PCB A Top and Bottom



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