Case Study:
High-Power LED Flash Controller for Freight Car Inspection
A 40-kW flash in a nutshell: Our LED pulse controller for freight car inspection
A Compact 16-Channel OEM Solution for Maximum Pulse Power in Six Months
To power and control the LED lighting for an automated freight car inspection system, we developed a 16-channel high-performance LED pulse controller in just six months. It delivers short, powerful, and reproducible current pulses to the LEDs, ensuring consistent image quality. This enables the reliable detection and analysis of graffiti and damage, as well as relevant markings such as car, container, or hazardous materials data.
Results at a Glance
After six months, the 16-channel solution was validated and ready for mass production, with an annual production volume of up to 100 units. A central controller replaces several individual devices, simplifies system integration, and supplies the LEDs with reproducible current pulses for consistently reliable image capture.
16 channels, 2.5 kW each
can be configured centrally
40 kW
electrical output power
6 months
Development time
50 A
Maximum pulse current per channel
50 V
per channel
50 µs
Pulse Duration
The Challenge
To ensure consistent image quality during the inspection of passing freight cars, the customer required short, high-power, and reproducible current pulses for 16 LED channels.
Our standard 4-channel controller had already proven itself in customer testing, but it was insufficient in terms of the number of channels and overall performance. Using multiple individual devices would have significantly increased the space required, the amount of cabling, and the effort needed for integration.
The Solution
Based on our standard 4-channel controller, we developed a central 16-channel OEM solution. An integrated power buffer supplies the energy for the short, high-power pulses. This allows the system to achieve up to 40 kW of peak electrical power with just 500 W of supply power.
All 16 channels can be configured centrally. This reduces cabling and simplifies system integration. We were responsible for the entire OEM development of the power supply—from electronics development and design, through thermal design and prototyping, to validation and transition to series production.
Benefits for the Customer
A central controller for all 16 channels
Less installation space, cabling, and integration effort
- Reproducible current pulses for consistent image quality
- A production-ready solution in just six months
Technical Implementation
- 16 high-power channels, each with up to 2.5 kW of pulse power
- Up to 50 A and 50 V per channel
- Pulse duration up to 50 µs
- Up to 40 kW total peak electrical power
- Integrated power buffer for a connected load of only 500 W
- Compact, thermally optimized design
AI-generated sample image illustrating the recorded measurement data
Do you need more than a standard LED driver?
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