Which Transformers Are Best For Electrical Isolation In Medical Devices - Miracle Electronics

 With a multitude of transformer options available, identifying the best one out of the lot becomes difficult, for every individual application. And, the application that we are going to speak about in this blog is a critical one – medical devices. No kind of fault can be afforded in the case of medical applications. This is why only the most ideal kind of transformer that can offer safety and protection against electrical surges should be used. So, which one is it?

Toroidal transformers is the answer. Toroidal transformers are ideal for electrical isolation in medical equipment as they are compact, have low stray fields, and can be encapsulated when required. Hence, these transformers are less likely to cause electromagnetic disturbances. Isolation is when two parts of a circuit are physically and electrically separated, which is achieved by using electromagnetic field coupling between the two circuits. Isolation provides several safety advantages like breaking ground loops, improving common-mode voltage rejection, and permitting the two parts of the circuit to be at different voltage levels. For an isolation method to be safe enough for use in medical equipment, it needs high-integrity isolation components and a safe insulator barrier. The three most commonly used isolation methods include transformers, capacitive couplers, and optocouplers. But, in this blog, we will focus on the use of transformers to electrically isolate medical equipment.

A transformer transfers energy between two or more circuits through electromagnetic induction. They increase or decrease the voltages of alternating current in electric power applications, by passing a varying current through the primary winding to generate a magnetic flux in the transformer’s core, which in turn induces a voltage in the transformer’s secondary winding.

Toroidal cores are made form a continuous strip of silicone steel wound like a tight clock spring, with the ends tacked into place with small spot welds to prevent the coiled steel from unwinding. The core is insulated with an epoxy coating or a set of caps or multiple wraps of insulating film. The transformer’s windings wound around the core require additional insulation to be isolated. However, the construction of a toroidal transformer is very labour-intensive. But yet, these transformers are preferred more than any other transformer because of its performance. With the continuous strip of steel used in the core, the transformer becomes smaller, lighter, more efficient, and quieter than other kinds of transformers. These qualities are the most apt for sensitive medical electrical equipment; and clearly justify the additional expense.

Thus, to conclude, toroidal transformers are ideal for electrical isolation in medical equipment. So, if you are looking for the perfect transformer for your application, just get in touch with Miracle Electronics, a reliable and reputed medicaltransformer manufacturer in India, who can provide you with the most ideal toroidal medical isolation transformer . And, you can rest assured about the quality of transformers you will get here because every medical isolation toroidal transformer you’ll get will be RoHS and REACH compliant, adhering to the regulations under UL 60601-1 standards.

Why Should You Opt For Core Cap Transformers - Miracle Electronics

The typical method of manufacturing a transformer involves creating a core, insulating it, winding a magnet wire around to create a primary winding, insulating it, winding a magnet wire over the insulation to create a secondary winding, and finally insulating it too, to complete the transformer.

What are core caps?

To support the primary and secondary windings, and to reduce leakage current, segmented core caps are used in alternate sectors. Several modular electrically insulating segments snap or join together to form core caps for covering the transformer core. These core cap modules insulate the windings from the core over the full range of windings, allowing double-wall insulation between adjacent windings, significantly reducing leakage current. They also help in direct cooling of the core by ambient or forced air, without interfering with the insulation. The segments of each module include a pair of spaced insulating walls between which a core-covering panel portion is connected. The walls are inclined at a predetermined angle to each other, typically 30, 45, or 60 degrees, which is what determines the number of segments required to complete one core cap.

Benefits of using core caps

Reduced time invested – With the installation of core caps, there is no need for ground and inter-winding insulation and outer wrap. Also, both the primary and secondary windings can be wound on one machine only. In addition, providing the core cap includes mounting holes, which means that the time to fill the center of the transformer with epoxy is not required. All of this results in lesser time invested to manufacture and handle the transformers.

Reduced weight of the transformer – As mentioned above, there is no epoxy required to fill the center of the transformers if core caps are installed. Besides, no mounting washer will also be necessary. Hence, the weight of the transformer is also considerably reduced.

Reduced costs – Assembling core caps requires lesser skill levels that other core insulation techniques. Also, the cost to tool a smaller part for injection moulding is lesser than the cost of tooling a larger part. Thus, the cost to tool and assemble the core caps is way lesser. This means that the overall manufacturing costs of the transformer will be lesser too.

Reduced temperature rise – With core caps, there is a direct path for heat to escape into the environment. There is also no inter-winding insulation and outer wrap that traps heat. Thus, with all windings having a direct path for heat to transfer to the environment, then the temperature rise of the transformer is also reduced.

As you can see, core cap transformers help with reducing the time, weight, and costs of the transformer to a considerable extent, while also reducing the heat buildup. So, it can be clearly seen why core cap transformers are much better than standard transformers. You now know which kind of transformers to opt for, for your next application.

No matter what industry you are working in, and what kind of transformers you need, Miracle Electronics is your one stop destination to design all your transformer requirements. You can get all kinds of bundles of massive energy from this power, toroidal, EI, UI, SMPS, audio, and medical transformer manufacturer in India. And, every transformer you receive will always be RoHS and REACH compliant, having you to worry less about its quality and performance.