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Total Power Solutions ®
®
Total Power Solutions ®
®
TECTROL CAPABILITIESTHE DESIGN & MANUFACTURE OF POWER SUPPLIES
® Registered trade-mark of Tectrol Inc.
Flexible and ReliablePower Solutions
Established in 1968, Tectrol has designed and manufactured standard and custom designed power solutions for more than 40 years and remains financially strong as a technology leader in the industry.
While our competitors are becoming more restrictive we remain the most flexible provider of power products with the flexibility to accommodate design challenges and even medium to high run applications. Our leadership, experience and flexibility make us your ideal power supply manufacturer.
We have field proven more than 1,500 designs and are dedicated to the continued research and development of new power technologies to remain effective in the delivery of power supplies offering highest power densities and efficiencies with reduced development times and manufacturing costs.
Our designs range from 30 watt switchers for point-of-sale devices through high-density front ends for datacom applications up to 30 kilowatts. Our ideal customer appreciates a supplier that can partner with your people and deliver
a product that offers high performance at a competitive price and rapid time to market
VALUE PROPOSITIONWHAT SEPARATES US FROM OUR COMPETITORS
* 4 x 11 x 1.6” Package* 12V @ 100 Amps Output * Universal Input (90-264VAC)
Global Resources: Tectrol maintains sales and support staff in key regions with international manufacturing resources of 290,000 sq. feet and >1000 employees.
Service: Dedicated service teams to manage all aspects of service, engineering and manufacturing requests for fast and accurate response to customer requests.
Technology Platforms: Our Research & Development Teams develop our library of power technologies to maintain our technology leadership position. We are approaching power densities in excess of 30W/in3
and operational efficiencies up to 96%.
Time-to-Market: Reducing development time requires a multi-tiered approach to design:
* Continuous R & D of next generation technologies / topologies. * Project management tools to manage responsibilities and milestones of each project * Build prototypes and beta units in house * Common transfer process among manufacturing facilities for ensured quality * Performing engineering, manufacturing and safety qualifications in-house
Quality & Reliability: We strive for 100% quality and reliability with ISO 9001:2008 qualified processes for highest possible consistency ensuring functionality, manufacturability, and compliance to international standards.
Flexibility: We strive to be the most flexilble power source in the industry with an ability to manage design changes, schedule adjustments and inventory management programs for best-in-class cost and capacity management services.
DESIGN & QUALIFICATIONFAST TIME TO MARKET OF HIGH QUALITY POWER SUPPLIES
Product Development - 8 Gate ProcessThe procedure to pass each of the 8 design process gates is comprehensive, focused, and stringent. Engineering, manufacturing and quality assurance collectively establish that design will ensure reliable production, high yield, high quality, consistency, and cost effectiveness before proceeding to the next phase.
1) Commercial Kickoff
• Customer specification accepted • Business case agreed • Cost targets set
2) Engineering Kickoff
• Engineering specification accepted • Design approach & test strategies • NPI Schedule defined • Risk assessment / mitigation
3) Schematic Design Review
• Flotherm / electrical simulation • Production test strategy defined
4) PCB Design Review
5) Prototype Design Review
• Review DVT & HALT • System Test Results • Proceed to first revision A
6) Pilot / Design Review
• SR closure • Qualification testing & reports • EMI Reports (Unit & System) • Agency Approvals • DFM Audit • Cpk Analysis
7) Pre-Production Review
8) Production Release
Any fault identified at any level that either does not meet specifications or the design standards set for the product
results in a “Service Report”. Products may not proceed until all SR’s are resolved to the satisfaction of the fault
initiator and the customer. All SR’s are provided to the project engineer and the customer.
Commercial Engineering Schematic PCB Design Prototype Pilot Pre-Production Kick-Off Kick-Off Review Review Review Design Review Review
PRODUCTIONRELEASE
Design Engineering Workstations Product Qualification & Testing
8 Major Qualification Steps:8 Major Qualification Steps (for new platforms) must occur within the 8 gate development process. The reports
generated for the following steps are delivered to the customer. TECTROL engineering verifies design results through
extensive testing and shared with all teams and the customer. The 8 major steps include:
DVT – engineering prototype phase A computerized testing of the products entire set of operating parameters
is done by the product engineer.
HALT – The operational limits of the product are determined through accelerated aging. Stresses are created
through rapid temperature changes of up to 60’c/minute, heat exhaustion to 1,000 linear-feet-per-minute and
tri-axial vibration. Stressed to the limit and well beyond specifications, this activity exposes potential latent
failures for design improvements. After correction, testing continues until further failures are experienced.
Qualification/Validation - An independent engineering group audits the product for compliance with
customer specification and TECTROL’s design integrity. It includes computerized testing of the products
entire set of operating parameters. The formal report, typically 100+ pages, is provided to the project engineer
and the customer.
Stress Analysis- Exposes defects undetected by visual inspection or electrical tests to identify potential
contributors to early field failures. Stress levels are defined by NAVMAT P4855-1A.
MTBF Calculation – Determines predicted Mean Time between Failures (MTBF), usually calculated in
accordance with Telecordia / Bellcore reliability specifications
Cpk Analysis – A capability index reveals how well a design tolerance compares with the normal process
variation. Cpk is the actual capability index of a process, which accounts for any difference between the
design target and the actual process mean.
Manufacturability - Proto, Beta & Pre-production processes continually improved for best quality and
consistency of product manufacture.
Agency Approvals - As required by the customer for compliance within their markets.
HALT Chamber EMC Surge / Test High Power Test Loads
ICT (In Circuit Test)
MANUFACTURING & QUALITYAUDITED PROCESS CONTROL & MONITORING
Toronto:ISO 9001 Registered80,000 sq. ft.
• Continuous flow, and flexible low to medium volume assembly lines• SMT / Through hole placement capability - integrated SMT and thru-hole mix - top side, bottom side, and fine pitch.• Dual-wave flow solder machine: - ultrasonic spray flux - convection preheat - nitrogen inerted• High mix, flexible Final Integration & Test (FIT) cells• In-circuit & ATE functional testing• 100% Burn-In (Power-Cycling / Full Load)• HiPot & Ground continuity safety test
Asia:ISO 9002 Registered210,000 sq. ft.
• Full process compatibility with Toronto• Continuous flow assembly lines • Fully integrated assembly lines with : - ICT & ATE Test stations - final inspection station - final packaging station• SMT capability• Automated assembly processes: - SMT chip shooter lines - automated thru-hole insertion• Wave flow soldering• In-Circuit testing (ICT)• Automated Functional Test (ATE )• 100% Burn-In (Power-Cycling / Full Load)• HiPot & Ground continuity safety test
Manufacturing:TECTROL’s manufacturing capabilities range from low to high volume production with varying levels of sophistication utilizing the highest level of manufacturing equipment and process as follows:
• Automated Component Placement (SMT & Through-Hole) – combining SMT and thru-hole insertion in multi-layer boards enables design maximization of circuit density, reliability and cost effectiveness.
• Stringent Process Controls - in-circuit testing, Automated/integrated functional testing, 100% input power cycled burn-in, ongoing reliability testing (ORT) and demonstrated life testing programs.
• MRP & Supplier Collaboration - creates a proactive supply chain for quick response to customer needs.• Cpk Indices - measured processes and testing ensure products function within specifications.
Surface Mount Lines
Manufacturing EngineeringOur manufacturing engineers develop and monitor production processes for consistent manufacturability of our products to the clearly defined design documents. Our processes ensure highest quality standards are maintained within an economical network. The group’s influence is most apparent in our New Product Introduction Process concurrent with the prototype, pilot, and pre-production phases.
At New Product Introduction, the manufacturing engineering teams launch the NPI with all departments for inter-departmental visibility; assigns design, purchasing and manufacturing resources; and establishes the development schedules with key milestones and dates. Once a product has been released, we further our quality efforts with Continuous Process Improvement in all areas of manufacturing resulting in smoother workflows in cleaner environments with effective processes that embrace a PULL production system; Customer focused factory concept; Statistical Process Control (SPC); Sound material handling and ESD prevention practices; visual factory concepts and ongoing problem solving; and point of use stock management.
Quality Assurance:Tectrol utilizes processes qualified to ISO 9001 and Statistical Process Control (SPC) monitors quality at key points within our manufacturing processes to identify and resolve potential issues before they show up on our customer’s dock. Key points measured include:
• Purchase lot (incoming materials) • Pre-test inspection • Auto-insertion (SMT) • WIP inspections • Magnetics production • Burn-in with data logging • Assembly • Final ATE test • Wave/flow solder • Final inspection • PC board testing • Repair service turnaround • Hi-Pot testing (safety)
TECTROL maintains a comprehensive field failure and analysis data to identify failure modes and incidents. Corrective action is taken when any trend is exhibited. Pareto analysis is utilized to resolve identified failure rate items on an ongoing basis in the goal of Continuous Process Improvement.
Wave Solder ICT (In Circuit Test) ATE (Automated Functional Test)
Burn In Chamber, 100% of product, 50˚C, Full Load, Power Cycled
RECENT PRODUCTSDESIGNED & MANUFACTURED BY TECTROL
12V Standard Product PlatformsDescription POWER SIZE OUTPUT PHOTO
TSL200-12-IC-45 (1545)SERVER APPLICATIONS
AC/DC200W
1.54”2.00”8.25”
12.2V @ 16.4A12VSB @ 0.5A
TIP400-12-XX-38Y (1538)INDUSTRRIAL / TEST & MEASUREMENT APPLICATIONS
AC/DC400W
1.50”3.3”5.00”
12V @ 33A5VSB@1A
TFE850-12-P-IC-40 (1540)SERVER / STORAGE / NETWORK APPLICATIONS
AC/DC850W
1.60”3.30”11.00”
12V @ 71A3.3VSB @ 1A
TFE1200-12-P-BM-29 (1529)SERVER / STORAGE / NETWORK APPLICATIONS
AC/DC1200W
1.60”4.00:
10.00”
12V @ 100A5 or 12 vsb @ 0.5A
48V Standard Product PlatformsDescription POWER SIZE OUTPUT PHOTO
TIP400-48-XX-48Y (1548)INDUSTRRIAL / TEST & MEASUREMENT APPLICATIONS
AC/DC400W
1.50”3.3”5.00”
48V @ 8.3A5VSB @ 1A
TFE600-48-P-BM-32 (1532)TELECOM APPLICATIONS
AC/DC600W
1.60”3.30”10.00”
48V @ 12.5A 3.3VSB @ 0.5A
TFE800-48-P-BM-23 (1523)TELECOM APPLICATIONS
AC/DC800W
1.60”3.30”10.00”
48V @ 16.7A3.3VSB @ 0.5A
TFE1800-48-P-BM-37 (1537)POE / TELECOM APPLICATIONS
AC/DC1800W
1.60”4.00”11.00”
48V @ 37.5A3.3VSB @ 0.5A
54V Standard Product PlatformsDescription POWER SIZE OUTPUT PHOTO
TFE100-57-P-BM-31 (1531)TELECOM, HIGH END COMPUTING, POEOUTPUT ADJUSTABLE 50V TO 57V APPLICATIONS
AC/DC1000W
1.60”3.30”10.00”
54V @ 18.5A3.3BSV @ 1A
TFE1400-1254-IC-27A (1527)POWER OVER ETHERNET APPLICATIONS
AC/DC1400W
1.65”4.00” 11.50”
54V @ 14.8A12V @ 50A
TRF2250-54-N-BM-42 (1542) TELECOM RECTIFIERCLIMATE SAVERS GOLD EFFICIENCYCONTROLLER AND SHELF AVAILABLE
AC/DC2250W
2.50”5.20”11.50”
-54V @ 41A 15VSB @ 0.3A-15VSB @ 0.1A
TRF2100-400-P-BM-15 (1515)BROADCASTING APPLICATION
AC/DC2100W
2.50”5.20”11.50”
100-400V @ 5A
Products - Coming Soon!Description POWER SIZE OUTPUT PHOTO
TMP-400-24-XX-66Y (1566)MEDICAL APPLICATIONS
AC/DC400W
1.50”3.30”5.00”
24V @ 16.7A5VSB @ 1A
TCP1200 (1547)INDUSTRRIAL / TEST & MEASUREMENT APPLICATIONS
AC/DC1200W
1.60”5.00”10.50”
7~24V @ 350W5V @ 30A12V @ 12A24V @ 6A
TFE3000-54-P-BM-25 (1525)TELECOM, INDUSTRIAL, BROADCASTING APPLICATIONS
AC/DC3000W
1.60”3.30”15.00”
48V @ 62.5A5VSB @ 1A
TSL1100-12-P-IC-67 (1567) & TSL1100-12-P-TB-68 (1568)SERVER / NETWORKING APPLICATIONS
AC/DC1100W
1.57”2.14”12.65”
12V @ 92A3.3 or 5VSB @ 2A
RECENT PRODUCTSDESIGNED & MANUFACTURED BY TECTROL
Medical DesignsDescription POWER SIZE OUTPUT PHOTO
# 1428DEFIBRILLATOR WITH 4 BAY CHARGER
AC/DC100W
8.75”14.75”3.00”
8-18V @ 6.5A
# 1491ULTRA SOUND IMAGING
AC/DC165W
2.90”5.10”8.10”
3.0V @ 17.8A
# 1326DRUG DISPENSING
AC./DC 286W
6.25”6.00”20.00”
5V @ 10A12v @ 3A24V @ 3A36V @ 3A
# 1367B ULTRA SOUND IMAGING
AC/DC310W
6.60”7.50”14.00”
12 OUTPUTS
# 1429 ULTRA SOUND IMAGING
AC/DC900W
6.50”5.60”18.00”
17 OUTPUTS
Custom DesignsDescription POWER SIZE OUTPUT PHOTO
# 1543HD DIGITAL CAMER SYSTEM
AC/DC305W
(Dual AC Input)
1.60”4.00”12.87”
12V @ 25.4A5V @ 0.75A
# 1570MONILE DATA COMPUTING (VEHICLE)
DC/DC415W
1.50”4.70”9.50”
31V @ 10A5.5V @ 10A5.5V @ 3A24V @ 1A
# 1535 / 1536NETWORKING APPLICATION
AC/DC1200W
1.60”4.00”16.00”
12V @ 100A
# 1509 / 1509AAM/FM TRANSMITTER
AC/DC2000W
2.50”5.20”11.75”
15-53V @ 6.26A
# 1515 / 1515HAM/FM TRANSMITTER
AC/DC2000W
2.50”5.20”11.75”
100-400V @ 5A 100-320v @ 6.26A
Modified Standard DesignsDescription POWER SIZE OUTPUT PHOTO
# 1558AUDIO / VIDEO CONTROLLER
AC/DC374W
1.40”3.30”12.30”
12V @ 28A-7.5V @ 5A
# 1560BROADCASTING
AC/DC400W
1.60”3.10”12.75”
12V @ 28A-7.5V @ 5A
# 1556CELLULAR REPEATER
AC/DC900W
1.60”3.30”10.00”
54.4V @ 16.5A
# 1527ASWITCHER / ROUTER
AC/DC1400W
1.70”4.00”10.00”
12V @ 50A54V @ 13A
# 1569INIFINIIBAND ETHERNET
AC/DC1800W
1.60”5.00”11.42”
48V @ 37.5A12V @ 0.4A
Tectrol Headquarters39 Kodiak CrescentToronto, Ontario, CanadaM3J 3E5
Tel: + 1 (416) 630-8108Fax: + 1 (416) 638-0553
Eastern United States [email protected] [email protected]
Western United States Canada, Asia & Latin [email protected] [email protected]
Central/Southeast United States [email protected]
www. t e c t r o l . c om
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