Compact 1000 W DC/DC Power Conversion for Military Drone Jamming Applications

Reference Project – High-Efficiency DC/DC Power Conversion for Compact Drone Jamming Devices

Sector

Military / Defence Electronics

Application

Compact drone jamming device requiring a rugged, high-efficiency DC/DC power conversion stage for reliable operation in demanding field environments.

Background and Requirements

Modern defence electronics require power conversion solutions that combine high output power, compact mechanical dimensions and excellent thermal behaviour. In mobile and mission-critical systems such as drone jamming devices, available installation space is limited, while the power electronics must operate reliably under demanding environmental and thermal conditions.

For this serial production project, a compact DC/DC converter solution was required to support a high-power electronic subsystem with stable and efficient power conversion. The main design objectives included:

1. Compact 1000 W DC/DC power conversion in a space-constrained device
2. High efficiency to minimise losses and reduce thermal stress
3. Excellent thermal performance for passive cooling concepts
4. Galvanic isolation between input and output
5. Rugged design suitable for demanding mobile and defence-related applications
6. Reliable operation in serial production
7. Short-circuit, over-current and over-temperature protection
8. Stable performance under varying load conditions

The solution was developed for serial production, with an estimated annual quantity of approximately 400–500 units.

Technical Solution

To meet the electrical, mechanical and thermal requirements of the application, the CALEX FXW Series 1000 W DC/DC converter was selected as the key power conversion module.

The FXW Series provides an isolated, regulated DC output in a compact industry-standard footprint. With a wide 4:1 input voltage range, high power density and efficiency of up to 96%, the converter is well suited for demanding applications where performance, reliability and thermal management are critical.

The selected CALEX FXW DC/DC converter supports compact system integration while helping to reduce heat generation inside the device. Its metal baseplate and thermally optimised design enable efficient heat transfer to the surrounding mechanical structure, making it suitable for passive cooling concepts when properly integrated into the customer’s enclosure and thermal design.

System Integration and Benefits

Within the drone jamming device, the DC/DC converter serves as the central power conversion stage for the high-power electronic subsystem. The compact footprint allows efficient use of the available installation space, while the high conversion efficiency supports stable operation with reduced thermal load.

Key benefits of the implemented solution include:

1. High power density with 1000 W output capability
2. Compact converter design for space-limited military electronics
3. High efficiency for reduced power losses and lower heat dissipation
4. Thermally optimised metal baseplate supporting passive cooling concepts
5. Galvanic isolation for improved system safety and reliability
6. Robust protection features including over-current, short-circuit and over-temperature protection
7. Suitable for demanding mobile and defence-related environments
8. Scalable solution for serial production volumes
9. Scalability option using the CALEX FXP Series 1000 W DC/DC converter, offering similar features and performance with the additional capability of parallel operation for higher power requirements

The CALEX FXW Series was selected because it combines high output power, compact dimensions and strong thermal performance in a proven DC/DC converter platform.

Result

The implemented DC/DC power conversion solution fulfils the electrical, mechanical and thermal requirements of a compact drone jamming device in serial production. By using the CALEX FXW 1000 W DC/DC converter, the system benefits from high efficiency, reliable isolated power conversion and effective thermal performance for passive cooling.

The result is a compact and robust power conversion architecture suitable for demanding military electronics applications, supporting reliable operation and scalable production with an estimated annual quantity of 400–500 units.

For future power expansion requirements, the design can also be scaled using the CALEX FXP Series 1000 W DC/DC converter. The FXP Series offers comparable electrical and thermal performance characteristics while providing parallel operation capability, enabling higher system power levels without significant redesign of the power architecture.

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