Industrial 5V Online UPS

A high-efficiency industrial 5V Online UPS designed to provide uninterrupted power for embedded and industrial systems using intelligent battery management, seamless power switching, and advanced protection architecture.

  • Automation, Industrial, Power Electronics
  • Project Overview The Industrial 5V Online UPS is a high-performance power management platform developed to deliver continuous and reliable 5V power for industrial controllers, embedded systems, IoT devices, networking equipment, and mission-critical electronics. The system automatically switches between the primary power source and a rechargeable Lithium-ion battery without interrupting the output, ensuring uninterrupted operation during power failures. Built around a high-efficiency synchronous buck converter and intelligent power-path architecture, the platform integrates battery charging, automatic source selection, ideal diode switching, comprehensive protection mechanisms, and real-time system monitoring into a compact industrial-grade PCB. Designed for continuous 24/7 operation, the UPS delivers up to 10A continuous output, 12A peak current, and achieves approximately 92% power conversion efficiency. Client Requirements The client required a reliable industrial UPS capable of: Delivering uninterrupted regulated 5V output. Supporting high current industrial loads. Automatic switching between main power and battery. Fast battery charging. Wide input voltage compatibility. High conversion efficiency. Industrial-grade protection. Battery health monitoring. Real-time power status reporting. Production-ready hardware. Our Solution Metanoia designed and manufactured a complete industrial UPS platform including: Custom High-Current PCB Design. Online UPS Architecture. Intelligent Battery Management System. Automatic Power Source Switching. High-Efficiency DC-DC Conversion. Fast Lithium Battery Charging. Power Monitoring Interface. Protection Circuits. Embedded Power Electronics. Production-Ready Hardware. Main Features Online UPS Operation Automatically switches between external power and battery without interrupting the 5V output, ensuring continuous system operation. High Efficiency Power Conversion Utilizes a synchronous buck converter achieving up to 92% efficiency, reducing heat generation while maximizing power delivery. Intelligent Battery Management Integrated Lithium battery charging and protection system supporting: Fast Charging Overcharge Protection Over-discharge Protection Short Circuit Protection Current Limiting Industrial Protection Multiple hardware protection layers including: Reverse Polarity Protection Overvoltage Protection Overcurrent Protection Thermal Protection Crowbar Output Protection Inrush Current Limiting Real-Time Status Monitoring Provides dedicated outputs for: Battery Level Charging Status Main Power Detection Backup Mode Status Output Activity along with onboard LED indicators for instant visual diagnostics. Engineering Challenges Seamless Power Transition Designing an online UPS capable of switching power sources within microseconds while maintaining stable output voltage. High Current PCB Design Developing a compact PCB capable of safely handling continuous currents up to 10A with proper thermal performance. Efficient Power Management Optimizing converter efficiency while minimizing switching losses and heat generation. Industrial Reliability Implementing multiple hardware protection mechanisms to ensure long-term operation in demanding industrial environments. Development Process 1. System Architecture Designed the complete online UPS topology including battery charging, power-path management, and protection circuits. 2. Hardware Development Designed a custom high-current PCB integrating synchronous buck conversion, battery management, ideal diode controllers, and monitoring interfaces. 3. Power Electronics Optimization Optimized switching performance, thermal management, and power efficiency for continuous industrial operation. 4. Prototype Validation Validated efficiency, load regulation, protection mechanisms, battery charging, and automatic power switching under various operating conditions. 5. Manufacturing Prepared the hardware for production including PCB manufacturing, assembly, testing, and quality assurance.
  • Confidintial

Project Overview

The Industrial 5V Online UPS is a high-performance power management platform developed to deliver continuous and reliable 5V power for industrial controllers, embedded systems, IoT devices, networking equipment, and mission-critical electronics.

The system automatically switches between the primary power source and a rechargeable Lithium-ion battery without interrupting the output, ensuring uninterrupted operation during power failures.

Built around a high-efficiency synchronous buck converter and intelligent power-path architecture, the platform integrates battery charging, automatic source selection, ideal diode switching, comprehensive protection mechanisms, and real-time system monitoring into a compact industrial-grade PCB.

Designed for continuous 24/7 operation, the UPS delivers up to 10A continuous output, 12A peak current, and achieves approximately 92% power conversion efficiency.

Client Requirements

The client required a reliable industrial UPS capable of:

  • Delivering uninterrupted regulated 5V output.
  • Supporting high current industrial loads.
  • Automatic switching between main power and battery.
  • Fast battery charging.
  • Wide input voltage compatibility.
  • High conversion efficiency.
  • Industrial-grade protection.
  • Battery health monitoring.
  • Real-time power status reporting.
  • Production-ready hardware.

Our Solution

Metanoia designed and manufactured a complete industrial UPS platform including:

  • Custom High-Current PCB Design.
  • Online UPS Architecture.
  • Intelligent Battery Management System.
  • Automatic Power Source Switching.
  • High-Efficiency DC-DC Conversion.
  • Fast Lithium Battery Charging.
  • Power Monitoring Interface.
  • Protection Circuits.
  • Embedded Power Electronics.
  • Production-Ready Hardware.

Main Features

Online UPS Operation

Automatically switches between external power and battery without interrupting the 5V output, ensuring continuous system operation.

High Efficiency Power Conversion

Utilizes a synchronous buck converter achieving up to 92% efficiency, reducing heat generation while maximizing power delivery.

Intelligent Battery Management

Integrated Lithium battery charging and protection system supporting:

  • Fast Charging
  • Overcharge Protection
  • Over-discharge Protection
  • Short Circuit Protection
  • Current Limiting

Industrial Protection

Multiple hardware protection layers including:

  • Reverse Polarity Protection
  • Overvoltage Protection
  • Overcurrent Protection
  • Thermal Protection
  • Crowbar Output Protection
  • Inrush Current Limiting

Real-Time Status Monitoring

Provides dedicated outputs for:

  • Battery Level
  • Charging Status
  • Main Power Detection
  • Backup Mode Status
  • Output Activity

along with onboard LED indicators for instant visual diagnostics.

Engineering Challenges

Seamless Power Transition

Designing an online UPS capable of switching power sources within microseconds while maintaining stable output voltage.

High Current PCB Design

Developing a compact PCB capable of safely handling continuous currents up to 10A with proper thermal performance.

Efficient Power Management

Optimizing converter efficiency while minimizing switching losses and heat generation.

Industrial Reliability

Implementing multiple hardware protection mechanisms to ensure long-term operation in demanding industrial environments.

Development Process

1. System Architecture

Designed the complete online UPS topology including battery charging, power-path management, and protection circuits.

2. Hardware Development

Designed a custom high-current PCB integrating synchronous buck conversion, battery management, ideal diode controllers, and monitoring interfaces.

3. Power Electronics Optimization

Optimized switching performance, thermal management, and power efficiency for continuous industrial operation.

4. Prototype Validation

Validated efficiency, load regulation, protection mechanisms, battery charging, and automatic power switching under various operating conditions.

5. Manufacturing

Prepared the hardware for production including PCB manufacturing, assembly, testing, and quality assurance.