Choosing The Right SMPS Transformer – Miracle Electronics

A multitude of electrical and electronic personal daily-use products, such as computers, mobile phone chargers, automobiles, telecommunications, and security systems, involve the usage of SMPS transformers, making it one of the most in-demand transformers across the globe.

These transformers are used to provide galvanic isolation at the input, meaning a clear barrier that prevents dangerous high voltages from passing to the output, thus providing safety from electrical shock. However, one disadvantage of such isolated power supply is low efficiency, which can range between only 70 to 90%.

What causes low efficiency?

As the power supply is run at high voltage/current, strong magnetic fields are passed into the core of the SMPS transformer, which causes hysteresis in the magnetic core as the input AC signal oscillates. Further, because of such high input current, the core can saturate during operation, leading to even severe hysteresis and heat dissipation. Due to this, almost every SMPS transformer manufacturer in India supplies hysteresis curves with their components, allowing the designer to determine the limits on the input current.

What problem can low efficiency cause? How can it be resolved?

Lower efficiency of the SMPS units can cause heat up to higher temperatures when run at high voltage/current. This is why thermal management strategies are required to remove the heat. Heat sinks can help here, as they provide sufficient cooling when used with chassis-mounted fans.

How to place an SMPS transformer effectively?

SMPS transformers can be placed in one or more locations in a regulator circuit, in any of the multiple power conversion and regulation stages. But, one very common location for the transformer is between the output regulation stage and the switching stage. However, the exact location for the SMPS will depend on the power supply topology – two common topologies being flyback converter and forward converter.

How to choose your SMPS transformer?

There are a variety of SMPS transformers that use different core materials, coil numbers, and winding directions. For instance, different core materials saturate at different magnetic field strengths, which determines the highest voltage that can be used with the transformer. Generally, 2 coil transformers are the most common, while 3 coil transformers are used to provide multiple output power levels from a single SMPS circuit. In this way, you must be able to determine the exact specifications that you require. You must be able to choose the ideal SMPS transformer for your application. It must be one that operates within the linear hysteresis range for your supply, in order to minimize heating and power loss.

Partnering with a professional SMPS transformer manufacturer in India, one like Miracle Electronics, can ensure that every minute detail about designing the transformer is taken care of. That’s because they are skilled and capable of designing unique customized SMPS transformers for your particular application, delivering RoHS and REACH compliant solutions that guarantee minimal power wastage and highest possible efficiency. Miracle Electronics’ SMPS transformers have a high power-to-size ratio, with each segment topology having a unique V-in to V-out transfer function, leading to absolute efficiency. Hence, with a reliable transformer manufacturer  like Miracle Electronics, your transformers produce the desired output voltage, ensuring that the ripple is within your tolerances.