Toroidal Transformers – The Making, The Working, And The Advantages - Miracle Electronics

Toroidal transformers that are so widely used in a variety of applications like home appliances, automatic control equipment, audio equipment, telecommunications, medical equipment, and more, have so many benefits over other transformers because of their construction and working. Let’s take a look at the making and working of a toroidal transformer that brings with it so many advantages.

The construction of a toroidal transformer

ü The core of a toroidal transformer is made of high quality cold-rolled silicon steel sheet with a thickness generally below 0.35 mm, which is seamlessly rolled to have the core perform better than other traditional laminated cores.

ü Then, the coil is wound around the core. The primary is first wound; a high quality high strength enameled wire with a diameter similar to the original wire is taken and double-wound on the I-shaped wire shuttle. The double thread head is then adhered to the outer circumference of the ring shaped core with double-sided tape, and the thread shuttle is wound in the inner circumference of the core. This first layer is insulated, after which a second layer is then wound over it.

ü After winding, the heads and tails of the two coils are connected to make them in series; and the other two wires are soldered out with a soft wire and insulated. After all the windings and insulation are done, the transformer is let to dry well.

The working of a toroidal transformer

With the primary and secondary coils wound around the toroidal core, the current that flows through the primary induces an electromotive force and a current in the secondary, thus transferring power from the primary coil to the secondary coil. The coil wound around the core produces a magnetic field whose direction is almost completely coincident with the core magnetic circuit. It is the unique shape of the transformer that  allows for shorter coils, reducing resistive losses or winding losses, and improving overall efficiency.

The benefits of a toroidal transformer

ü Compact and lightweight – The construction of a toroidal transformer makes it compact, and also lighter in weight. A toroidal transformer is in fact almost half the weight of other traditional type transformers.

ü High efficiency – The electrical efficiency of a toroidal transformer can be as high as 95%, or even more, with the no-load current being only 10% of other laminated-core type transformers.

ü Less magnetic interference – With no air gap in the core of a toroidal transformer, and the windings evenly wound around the core, the magnetic leakage is absolutely small, thus resulting in a very low electromagnetic radiation too. This particular property makes toroidal transformers ideal for usage in high sensitive electronic and medical equipment.

ü Lesser noise – Toroidal transformers produce very less noise with a wider frequency response, thus improving the sound quality of a power amplifier.

With all these performance and benefits, don’t you want to install a toroidal transformer into your premises or application? Then, hurry up and get in touch with experts like Miracle Electronics, one of the most experienced and reliable  toroidal transformer manufacturers in India, who have the understanding and skill of manufacturing transformers for almost every industry and requirement. You can also have customized transformers made depending upon your industry, application, input voltage, output power required, installation method, size, and any other special requirements.