⚙️ Rugged & Military Power Supply Solutions

🔹 Electrical Architecture – Inside the Converter

The internal design of Gilgal’s rugged converters is based on synchronous switching topologies optimized for high efficiency (>90%) and minimal EMI radiation.

Core design elements:

• Isolated topology: Each converter features galvanic isolation between input and output to prevent ground loops in multi-system configurations.

• Synchronous rectification: Improves efficiency at low voltages (3.3 V, 5 V) and minimizes heat dissipation.

• Wide input stage (10–36 VDC): Supports 24 V and 28 V defense buses with tolerance to ±40% variations.

• Input surge protection network: A combination of TVS diodes, LC filters, and active MOSFET crowbar protection ensures immunity to MIL-STD-1275F transients up to ±250 V.

• Reverse polarity protection: Automatically recovers after incorrect connection — no fuses to replace.

• Multi-stage filtering: Common-mode chokes and differential LC sections achieve compliance with MIL-STD-461G CE102 noise emission limits.

• Thermal design: Conduction-cooled aluminum housing dissipates heat efficiently without fans or moving parts.

This robust architecture guarantees stable DC output under pulsed or dynamic loads, even during system startup surges or generator noise typical in armored vehicle environments.

🔹 Mechanical and Environmental Engineering

Each unit is built in a fully enclosed aluminum housing (85 × 40 × 19 mm), treated with an anti-corrosive anodized finish.
Connectors are industrial/military grade and available in horizontal (H) or vertical (V) configurations to match PCB or chassis mounting requirements.
All models are designed for operational temperatures from −40 °C to +70 °C, with full power delivery across the entire range.

The compact size and weight (~70 g) make them ideal for embedded systems with tight mechanical envelopes such as UAV payloads, communication terminals, or sensor pods.

🔹 Series Overview – Tailored Power by Application

1️⃣ Single Output – Up to 20 W

Compact, lightweight converters optimized for low-power control systems and sensors.
Typical outputs: 3.3 V, 5 V, 12 V, 15 V, 24 V.
Used in telemetry units, small communication boards, and tactical electronics.

2️⃣ Dual Output – Up to 20 W + 20 W

Two isolated outputs for systems requiring separate analog/digital rails or redundancy.
Examples: +5 V and +15 V for mixed-signal circuits, ±12 V for operational amplifiers.
Ideal for RF front ends, servo controllers, and instrumentation modules.

3️⃣ High Power – Up to 60 W

The flagship converters, delivering up to 10 A continuous current at 3.3 V or 5 V,
and up to 60 W at 12–24 V outputs.
These supplies power mission computers, communication gateways, and power amplifiers.
Each model maintains full MIL-STD-1275F surge compliance and includes active feedback for tight load regulation (<1%).

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🔹 Testing, Qualification & Quality Assurance

Before release, each unit undergoes:

• 100% burn-in testing under full load and temperature.

• Hi-Pot insulation test at 500 V between input and output.

• EMI/EMC verification using MIL-STD-461G compliant test setups.

• Thermal drift and regulation testing at cold, ambient, and hot conditions.

• Vibration and shock simulation per MIL-STD-810H Method 514.8.

This ensures every delivered unit is field-ready, verified, and reliable, even in mission-critical environments where downtime is not an option.

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🔹 System Integration – Beyond the Converter

These rugged converters can operate standalone or as part of a comprehensive protected power architecture.
They integrate seamlessly with Smart Power Protectors (SPP-F330A family) and with external EMI filters or surge absorbers to form a complete, MIL-qualified 28 V DC subsystem.

Common configurations include:

• Vehicle DC bus → Surge Filter → SPP → DC/DC Converter → Load

• AC/DC front-end → Rugged DC/DC modules → Isolated control circuits

This modularity allows system designers to meet MIL-STD-1275F, 704F, and 461G simultaneously — achieving both electrical safety and signal integrity at the system level.

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🔹 Practical Applications

• Defense platforms: AFV, APC, C4I shelters, weapon stations

• Aerospace: UAV avionics, radar power interfaces, communication links

• Industrial: Robotics, heavy automation, field sensors

• Hybrid military-medical systems: where isolation and noise immunity are vital

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⚙️ Why Engineers Choose Gilgal Power Engineering

• Proven field record with major defense OEMs and system integrators

• Design flexibility – horizontal or vertical mounting, custom voltages

• Reliability-focused engineering – no derating tricks, full load operation guaranteed

• Support and availability – local technical assistance and documentation via Amironic Ltd.

• Scalable architecture – single, dual, or high-power models share identical footprint