Is An EI Transformer A Good Choice For You? – Miracle Electronics

With every transformer performing the same task of trading voltage for current in a circuit, without affecting the total electrical power, different types of transformers work differently to achieving the same goal. Also, different types in regards to the shape, size, material, etc. also affects the quality of performance. In this blog today, we’ll speak about one particular kind of transformer – the EI transformer.

What is EI transformer?

As the name itself suggests, EI transformer is one whose core is combined by laminations shaped “E” and “I”. A traditional and economical transformer, the EI transformer is widely used in a variety of electronic equipment and audio applications. The air gap between the E and I laminations can be easily adjusted by filling it with a suitable medium, making it suitable for building output transformers and chokes. This is the reason why many audio output transformers and chokes are designed with the EI transformer.

Why should you opt for an EI transformer?

EI transformers have a very simple structure, making it absolutely easy to manufacture, which is why most transformer factories are able to manufacture these transformers.

It is very easy to find the components required to build an EI transformer in the market, making it an easy-make as well as economical solution. With everything being available easily, the prices automatically go down.

EI cores are flat stampings with no need of any kind of bending or forming, which makes it very economical to manufacture.

The laminations can be removed from a single rectangular sheet without substantial wastage.

The mounting method of the EI transformer is simple.

EI transformer cores are more preferred than other U, C, and L core types, mainly because more surface space is protected by the winding in these cores.

The make of an IE transformer is such that the whole thing can be held together conveniently with simple corner fixings, or just vacuum impregnation with lacquer.

There is very good magnetic coupling between the two ends of the core.

Are there any disadvantages of using an EI transformer?

Just like anything else, EI transformers, in spite of having so many good qualities, also have drawbacks. One major drawback is that these cores don’t have self-shielding quality in them.

After going through the blog, it’s time you decide as to whether you would want to use an EI transformer for your application or not. Despite the fact that an EI transformer doesn’t have self-shielding, there are so many other benefits associated with it. So, whether it is for differential, power, or telecom inductors, converters, or inverter transformers, if EI seems to be the right choice for you, you could approach Miracle Electronics for the same. They’re the most reliable EI transformer manufacturer in India, where you can get durable and highly efficient transformers that come with superior wiring, varnishing, and connection terminators, all of which provide excellent regulation with minimal temperature rise. You can thus make the most of your electrical devices by buying such RoHS and REACH compliant EI transformers that can lower the voltage exactly to a value that is required by your appliance, while keeping it running right and safe.

 

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.

Evaluating The Quality Of Control Transformers - Miracle Electronics

If you’ve gone through the multiple blogs that we’ve written about how transformers help transfer electrical power between two or more circuits effectively, you already know that transformers are highly effective in saving your projects from getting hampered, and helping production to take place without disturbance; thus becoming an integral part of our everyday lives . A control transformer is mainly created for purposes that demand electromagnetic and solenoid devices. Such transformers have an in-built capacitor that helps reduce variation in output and lets your machine do its work without any difficulties. But, this is possible when you have a good quality transformer that best fits your requirements.

How to evaluate the quality of a control transformer?

Winding material type – The two main materials used for winding are copper and aluminium. Copper is certainly the better choice as it is a better conductor, and also provides higher mechanical strength, while making the size of the transformers smaller. Aluminium windings are comparatively more affordable, but they are lower in conductive properties. Copper thus is certainly more efficient, but many applications choose aluminium because of their significant cost advantage. You must thus make your choice depending upon your individual application; and choose a transformer manufacturer who is apt at manufacturing both kinds of transformers so that he can work to fulfill your specific demands at any time.

Voltage and frequency – What Ampere or Wattage does your application load need? Considering this, you’ll be able to pick the best size and voltage rating device for your production. You need to determine the voltage and frequency of both the primary and secondary, in order to make a rational choice.

Life expectancy – The life of the insulation system is another important factor to consider. Insulation life is equivalent to the temperatures being experienced by insulation across the process. Hot spot temperatures are determined by adding the total of the winding angle, maximum ambient temperature, and standard winding temperature increase. Another factor you need to consider is the kVA rating that signifies the amount of kVA charging that occurs in the measured temperature increase. When used in standard operating conditions, including the allowed hot spot temperature with suitable insulation class, a standard life expectancy can be determined.

With the above aspects considered, you can guarantee the best fit control transformer for your application. After all, determining the best type of transformer that you need for your application is an important thing to do. More than that, you can approach a genuine transformer manufacturer in India, one like Miracle Electronics, who can provide you with only genuine high-quality products, and also advise you on the best kinds of transformers that can suit your requirements and applications. We specialize in manufacturing transformers of export quality that are acclaimed for unique features of excellent voltage regulation, durability, and compact design. You can get every kind of transformer here, like power, toroidal, medical isolation, audio, EI, UI, SMPS, and more. You can purchase from off-the-shelf products, or have your own transformers especially customized for your requirements .

The Efficiency And Losses Of Transformers Explained - Miracle Electronics

We cannot neglect the importance of transformers , as we’ve become so dependent on every kind of electrical and electronic application, each of which requires a transformer to bring in safe amount of power for effective and safe performance. But, it is absolutely important that the transformers are efficient in their functioning so that any kinds of problems can be avoided. One important factor in transformer efficiency is “transfer loss”. Here’s all you need to know about transformer efficiency and transformer losses, so that you can get hold of the right kind of transformer.

What is transformer loss?

Transformer loss is the difference between output power and input power. There is no mechanical loss like friction or windage loss in an electrical transformer because it is a fixed device, but there are copper and iron losses present in a transformer. Also, there is the eddy current loss.

Copper loss/iron loss – In a transformer’s core, the process of magnetization reversal leads to hysteresis loss, which is dependent on the grade of iron, volume of iron, flux density value, and magnetic reversals frequency. The hysteresis loss or current loss of a transformer is dependent on the material’s magnetic property that is used for the construction of the core, which is why the losses are known as copper loss or iron loss. The windings in the transformer offer ohmic resistance, which also leads to copper loss. The copper loss for primary windings is I12R1, and for secondary windings is I22R2, where I1 and I2 are the currents flowing in the windings, and R1 and R2 are the resistances. Such copper loss is highly dependent on the load. 

Eddy current loss – The primary winding in a transformer is supplied with AC current, as a result of which magnetizing flux is set up, which in turn creates induced EMF in the secondary coil after coming in touch. However, some additional conducting parts like the iron body or steel core of a transformer also gets linked to the flux, which results in the circulation of small currents due to the induced EMF. This current is known as eddy current, which is responsible for energy dissipation in heat form.

What is transformer efficiency?

Transformer efficiency is important for economical functioning, which is determined by the ratio of output power to input power. A transformer can possess maximum efficiency when the iron and copper losses in it are equal.  You can get the most efficient transformers at Miracle Electronics, which is a reliable and recognized transformer manufacturer in India that offers transformers with maximum efficiency and minimal losses. This is possible as we have a team of skilled professionals using the latest technologies to be able to meet the highest quality standards and fulfill the demands of every kind of customer. You can buy all kinds of transformers here, such as power transformers, toroidal transformers, medical isolation transformers, three-phase transformers, EI transformers, UI transformers, SMPS transformers, and many more.

 

Wire Harnesses – What And How - Miracle Electronics

Wire harnesses are a group of wires or cables assembled together electrically and mechanically so that they can align, stay organized, keep the space neat, and transmit electrical power or electronic signals, depending upon the application. A wire harness generally contains cable lugs, plugs, connectors, heat shrinks, splices, strain reliefs, and more. Depending upon where and how it needs to be used, the components are decided upon.

Isolation Transformers – Why They Are Used - Miracle Electronics

Industrial applications require products that follow stringent rules and fulfill rigorous requirements. In such applications, the equipment used should not only functionally effective, but also safe. Highly regulated market sectors like industrial control, energy, and medical rely on the smooth functioning of their electrical devices. Any interruption in the working may cause critical delays and errors; and thus, unwanted outcomes. To help bring the required results in applications where high working voltages, surges, and transient voltages are present, high isolation transformers can help to meet the safety requirements. These transformers are designed to meet the most stringent safety standards.

How Do Stabilizers And Transformers Deliver Safe Power - Miracle Electronics

Every electric and electronic appliance relies ontransformers for their power supply, because transformers are the equipment that can increase or decrease the voltage to the required amount so that appropriate power supply is directed. If inappropriate power supply is directed, the equipment may either not work (if the power supply is insufficient), or it may cause disastrous results and breakdown of the appliance (if the power supply is higher than required). Stabilizers and transformers are thus ideal devices required for transferring appropriate amount of power supply to ensure safe and effective power-based operations.

How Can A Site Visit Help In Selecting The Best Electronics Manufacturer?

Site visits can help in better understanding electronics manufacturing servicing outsourcing options, and to look for operational capability, procedures, and culture of a prospective EMS partner. This gives you the opportunity to check for the best EMS manufacturer, if you are outsourcing for the first time, while also assessing whether this is a logical step for your business. Also, if you have already been outsourcing, and are considering alternative options now, then a site visit can help you decide whether it is t he right time to hand over the task to someone new. A site visit can also offer an insight that is better than what you can receive from brochures, websites, sales calls, and proposals.

Here, a site visit does not mean a complete site audit, but it can form a vital element of the rigorous research process that can help to guide your outsourcing decisions. When you ask them the right questions, you will be able to determine if they are a possible fit for your company. This blog will state some of the important questions that you will have to consider if you want to visit a prospective electronics manufacturer. You can also gather your own references, check for their ownership history, directorship, and financial health of the EMS provider. It can definitely take lots of effort and time to do all of this. It could take days or weeks together.

So, let us take a look at the most important questions that you must reflect on while considering 

electronicsmanufacturing services from India.

·        Does it feel right that you can work with the company? Can you see yourself working together with their management team? Can you imagine your product being manufactured in that environment?

·        Is their workforce skilled and dedicated about what they do? Do they have the capacity to meet your demands?

·        Will the people you are conversing with during your meeting be a part of the team that will take care of the production in the long term? If not, there may be misunderstandings and issues in regards to what you expect and what may be delivered. And then, it may be very time-consuming to correct the errors.

·        Is the electronics manufacturer service provider willing to answer all your questions that are concerned with their capabilities and operations?

Therefore, a site visit can help you get a first impression of the electronic manufacturing service provider and facility, along with the personnel, while also helping you build a picture of the potential assembly partner. Along with all the research you do, and results you get, your instinct also plays a very important role. So, even if everything seems right, but if it feels wrong, make a consideration again.

But, when you consider Miracle Electronics for your electronics manufacturing services fromIndia, you will neither get any negative results, nor will you get any negative instincts, as they are experienced and reliable manufacturers with EMS capabilities of product designing, system designing, value engineering, manufacturing, and logistics.