Industrial & Medical Technology

Emerson R48-3200e Power Rectifier Teardown

17 January 2012
The following is an overview of a teardown analysis conducted by IHS Benchmarking.

Overview / Main Features

The Emerson R48-3200e is a power rectifier of Emerson's eSure line of rectifiers. The eSure rectifiers are a sub-product of Emerson's NetSure line of DC power cabinetized solutions. The R48-3200e rectifier converts standard AC supply voltages into stable nominal -48V DC. The R48-3200e rectifier is used as a single rectifier in an array within the NetSure DC power cabinetized solution. It is hot swappable and offers plug-and-play features that allow for installation without system interruption. It offers DSP control, a wide range of input-voltage and operating temperature.

During the teardown, it was observed that the DSP used in this particular sample is a 32-bit 100Mhz DSP made by Texas Instruments. This DSP is the heart of the system, controlling the SMPS circuitry and handling system integration.

Target Market


Pricing and Availability

Pricing for the R48-3200e is not readily available.

The R48-3200e is available for purchase through Emerson and authorized distributors.

Emerson R48-3200e Power Rectifier - Main PCB TopEmerson R48-3200e Power Rectifier - Main PCB Top

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.

Emerson R48-3200e Power Rectifier Cost AnalysisEmerson R48-3200e Power Rectifier Cost Analysis

Cost Notes

Main Cost Drivers Representing ~50% of total materials cost

Infineon - IPP075N15N3 G - MOSFET - N-Channel, 150V, 100A (Qty:8)
Transformer - Wound, Triple EE Cores, Vertical, w/ Plastic Base
Shenzhen BoMinXing Electronic - 6-Layer, FR4
Inductor - Common Mode Choke, Wound, Toroid, Powdered Iron Core, Vertical, w/ Plastic Base (Qty:2)
Cree - CSD08060A - Schottky Rectifier - Silicon Carbide, 600V, 8A, w/ Ferrite Core (Qty:4)
Chemi-Con - EKMR451VSN271MP50S - Electrolytic - 450V, 270uF, 105C (Qty:4)
Infineon - SPW47N60C3 - MOSFET - N-Channel, 650V, 47A (Qty:4)
Infineon - SPW47N60CFD - MOSFET - N-Channel, 600V, 46A (Qty:4)
Inductor - Wound, EE Core, Vertical, Plastic Bobbin, w/ Plastic Base
AVC - DASA0832B2M-001 - Fan - 12VDC, 0.7A, w/ Integral 3-Wire Harness, Ball Bearing, 1 3-Position Pin Socket Connector & Heat Shrink

Total BOM & Manufacturing Costs (Direct Materials + Conversion Costs) $148.90

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.

Emerson R48-3200e Power Rectifier - Main PCB BottomEmerson R48-3200e Power Rectifier - Main PCB Bottom

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