Case Study: 24V 120W Power Adapter for Fanless Rugged Computer (MPC-3800 Series)

1. Project Background

A rugged computer manufacturer required a reliable external power solution for their fanless industrial computer system (MPC-3800 series) used in harsh environments.

The system supports wide DC input (9–48V) and is typically deployed in:

• Industrial automation
• Transportation systems
• Outdoor monitoring equipment

To ensure stable operation, the customer selected a 24V DC input architecture, requiring a high-quality external AC/DC adapter.

Learn more about our industrial power supply solutions.

2. Application System Overview

The rugged computer features:

• Intel® 10th Gen processor platform
• Fanless thermal design
• Wide operating temperature (-25°C to +70°C)
• Multiple I/O interfaces (LAN, USB, COM, DisplayPort)

👉 These characteristics demand a stable and low-noise DC power source, especially under continuous operation.

3. Power Requirements Analysis

Based on system design, the customer defined the following requirements:

4. Key Engineering Challenges

4.1 Wide Input vs External Adapter Compatibility

Although the system supports 9–48V DC input, using an unstable power source may lead to system resets or hardware damage.

👉 Required: regulated and stable 24V output

4.2 Thermal Constraints (Fanless Design)

Fanless rugged computers rely on passive heat dissipation.

👉 Power supply must:

• Maintain high efficiency
• Minimize heat generation

4.3 Electrical Noise Sensitivity

Multiple I/O interfaces and communication modules increase sensitivity to:

• Ripple
• EMI

👉 Required: low ripple & clean DC output

4.4 Connector Preference (Important Detail)

Unlike many industrial systems using terminal block input, this project required:

❗ Standard DC plug (non-terminal adapter)

Reasons:

• Easier installation
• Faster deployment
• Reduced wiring errors

5. XJK Power Solution

Shenzhen Xinjukang Technology (XJK Power) Co., LTD provided a 24V 5A 120W AC/DC power adapter optimized for rugged computing applications.

Key Features:

• Output: 24V DC / 5A
• Power: 120W
• Wide Input: 100–240V AC
• Efficiency: ≥ 88%
• Ripple & Noise: < 120mV
• Protections:
  • Over Voltage Protection (OVP)
  • Over Current Protection (OCP)
  • Short Circuit Protection (SCP)

Mechanical Design:

• Standard DC output connector (non-terminal)
• Robust enclosure for industrial environments
• Reliable cable strain relief

6. System Power Architecture

AC Grid (100–240V)
        ↓
120W AC/DC Adapter (24V 5A)
        ↓
Rugged Computer (MPC-3800)

7. Key Advantages

✔ Stable Power for Wide Input Systems

Provides regulated 24V output, eliminating instability from raw DC sources.

✔ Optimized for Fanless Systems

High efficiency reduces thermal stress inside the rugged computer.

✔ Low Ripple Output

Ensures stable operation of CPU, communication modules, and storage devices.

✔ Easy Integration

DC plug design simplifies installation compared to terminal block wiring.

✔ High Reliability

Designed for continuous industrial operation.

8. Results

After integration, the system achieved:

• Stable operation across full temperature range
• No unexpected reboot or power-related failure
• Improved deployment efficiency (plug-and-play adapter)

The customer successfully deployed the solution in multiple industrial projects.

9. Conclusion

For rugged computer systems like the MPC-3800 series, selecting a stable and efficient external power adapter is critical.

The 24V 120W power adapter from XJK Power provides a reliable, easy-to-deploy solution that meets the demands of harsh industrial environments. For more technical guidance, read our article on how to choose a power supply for industrial and rugged systems.

10. CTA

If you are developing rugged computers or industrial systems requiring:

• 24V / 120W power
• Fanless system compatibility
• Reliable external adapters

👉 Contact XJK Power for customized power solutions.

Q1: Why use 24V for rugged computers?
A: 24V provides better efficiency and stability for industrial systems compared to lower voltages.

Q2: Can I use a terminal power supply instead?
A: Yes, but DC plug adapters offer easier installation and faster deployment.