How To Customize A Toroidal Transformer?

While there are a number of high quality standard toroidal products available, many want to request customized designs for their specific applications. This is so because customized designs are specially tailored to meet the size, capacity, and performance required by the application, which means a perfect ideal fit.

When you’re looking for such customizable solutions, there are two ways you can work it out – first being where you provide with all the details and have the product only manufactured; the other being where you just convey your requirements and have the entire design-to-manufacture task taken care of by the manufacturer.

When you want to provide your own drawing

If you are the first sort, where you provide a specification or detailed drawing depicting all that you need within your transformer, it doesn’t mean that the drawing will be blindly followed. The manufacturer will first analyze the information, working on every detail, to see that the purpose of the transformer is served, without any chances of error. In case any such doubtful specification is seen, it will be brought to your notice, after which the required changes will be made. Only when both the manufacturer and the client are satisfied with the drawing, will the transformer be put into production.

When you want the entire process to be outsourced

If you’re not too sure about the specifications or drawings, you can have the entire process taken care of by a manufacturer. All you have to do is convey what your application is about, what purpose you want the transformer to serve, any specific environments the transformer will need to work in, any space constraints or other limitations, and the quantity and deadline. Once every such detail is conveyed by you, it becomes the duty of the manufacturer to design and manufacture the perfect toroidal product for you.

Do you want a prototype?

It’s absolutely alright if you want to see a prototype first, before putting the entire production into practice. Whether the design is made by you, or the manufacturer, you may be unsure of the outcome, and want to first look at a prototype. Manufacturers can use a software to create the plan for such a prototype, by inputting all the information on the drawing, and crafting a digital design of the product you need. This practice is a more accurate way of ensuring that the final product will be appropriate, and meet your specifications. Any adjustments required in the prototype are made, before moving on to manufacturing the complete project.

Where to get your toroidal transformers? Miracle Electronics’ highly-trained engineers oversee every step of the manufacturing process, right from designing to prototyping to production to testing. Only when the final product is proven to be effective, is it shipped to the client. With everything being done in-house, it saves on a lot of time that may otherwise be spent collaborating with different facilities. This not only avoids shipping delays, but also helps in carefully monitoring the entire manufacturing process. You’ll thus get toroidal transformers that enable the highest level of accuracy and reliability, meeting any regulatory requirements. So, when you need one-of-a-kind toroidal transformers for your applications, look no further than Miracle Electronics, where everything will be carried out within their ISO-certified facilities. Whether you’re in the manufacturing, medical, audio, energy, or any other industry, you can ensure that the final product is effective, efficient, reliable, and safe.

For more information, visit: https://www.miracle.net.in/

 

Making The Correct Toroidal Transformer Choice

When you’re looking to buy toroidal transformers for your application that can step up or step down a voltage, or for isolating an electronic equipment from a source of voltage, while allowing power to be transferred from the primary to the secondary coil, you need to make the right choice.

What is a toroidal transformer?

Constructed using a ring-shaped metal core, on which a wire is wound to form the primary input coil, overlaid with insulation, over which a secondary output wire is wound, toroidal transformers offer a neat and small variation of other kinds of transformers that require more space to be installed, and are also comparatively heavier.

Pros and cons of a toroidal transformers

Toroidal transformers have several advantages over other equivalent traditional devices, such as –

• Overlapped coils that allow for much smaller devices, unlike in the case where there are two separate coils
• Smaller number of turns required per coil, resulting in higher inductance relative to a similarly-sized traditional transformer.
• Magnetic flux limited to the toroidal core, having the transformer to shield itself from producing electromagnetic interference

Nevertheless, just like anything else, toroidal transformers also come with a disadvantage, which is that with each winding to be passed through the center hole, automated winding becomes difficult, or may require a dedicated winding machine specific to toroidal devices, resulting in cost additions when such toroids are manufactured.

Applications where toroidal transformers are the best choice

Because of the peculiar kind of construction and winding that a toroidal transformer is made with, as the size of the transformer increases, the advantages tend to diminish. For this reason, toroidal transformers are best suited for signal applications, like audio and radio frequency applications. They are also well suited for applications including security systems, LED lighting, inverter systems, industrial control equipment, power distribution equipment, isolation equipment, automotive electronics, and telecommunication systems.

Considerations to be made while making a toroidal transformer choice

Configuration

A transformer’s configuration refers to the number of input voltages it can accept, and the number of leads it must include. As the number of leads and required copper wiring increases, the manufacturing and product costs also increase. Toroidal transformers come in two basic types of configurations – single and dual.

• Single configuration transformers include only one primary coil winding, thus being able to accept only one input voltage.
• Dual configuration transformers include two windings in the primary coil winding, thus being able to accept two different input voltages. Here, in order to switch input voltages, a two-lead voltage selector must be used in conjunction with the transformer.
• Multiple configuration transformers can also be manufactured; however, they’re required to be used with a switching device.

Mounting

Toroidal transformers can be mounted using one of the below mentioned methods.

• Screwing onto an internal framework using in-built tabs
• Securing to a flat surface using a rubber washer and metal disk
• Securing to a flat surface using an H-shaped frame
• Soldering to a circuit board using through-hole or surface mount technology

Considering all of the above, you can select the perfect toroidal transformer type for your application. Whatever your toroidal transformer type, you can always rely on the products offered by Miracle Electronics. Other than standard products, you can also have your toroidal transformers customized perfectly here. Understanding the electrical needs of the customers, these expert toroidal transformer manufacturers in India are able to offer the most apt customized solution to every client!

Visit our website: https://www.miracle.net.in/

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.

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.

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.

 

Switch Mode Power Supply Transformers _ What They Are - Miracle Electronics

 Switched mode power supply (SMPS) is an electronic power supply that incorporates a switching regulator to convert electrical power efficiently, by transferring power from a DC or AC source to DC loads. The pass transistor of an SMPS continually switches between low dissipation, full on, and full off states, spending very little time in the high dissipation transitions, which minimizes wasted energy. Also, by varying the ratio of on to off time, voltage regulation is achieved. This high power conversion efficiency with no energy wastage is an important advantage of an SMPS.

Unlike linear power supply transformers, SMPS are small and light due to the smaller size and weight of the transformers installed, which is why they are effectively used as replacements for linear regulators when high efficiency is required with lighter weight and smaller size. The transformers that are mainly composed of magnetic core and winding, are used for conversion, energy storage, and isolation. But, the materials used will affect the performance of the transformer, which will in turn affect the heat dissipation and working efficiency of the equipment. Thus, you need to be very sure about the materials that you are having installed in your SMPS transformer. This is why when planning on getting an SMPS transformer for your application, you need to approach only an expert transformer manufacturer in India, one like Miracle Electronics, who has immense knowledge about, and enough experience of manufacturing and working with SMPS transformers.

Advantages and disadvantages of using SMPS transformers

• One of the main advantages of using SMPS transformers is that you can have efficiency up to 96% because the switching transistor dissipates very little power when acting like a switch. Other advantages include small size, light weight, and low noise. Also, the standby power loss is very low.
• One disadvantage is that they are very complicated and they can cause electrical noise problems if not carefully suppressed; thus causing harmonic distortion.

Types of SMPS transformers

SMPS transformers are divided into two types – unipolar and bipolar. Unipolar transformers are characterized by a unipolar pulse as input voltage, and are divided into positive flyback voltage output. Bipolar transformers are characterized by a bipolar pulse as input voltage, with the output generally being bipolar pulse voltage. 

Materials used

As mentioned above, it is very important to choose the right materials for the SMPS transformer. There are three main components of an SMPS transformer – magnetic materials, wire materials, and bobbin materials.

Magnetic materials – These are soft ferrite which are divided into two categories according to their composition and application frequenct – MnZm and NiZn.

Wire materials – Polyurethane and polyester enameled wires are generally used to wind small electronic transformers, divided into thin paint and thick paint types, depending upon the thickness of the paint layer.

Bobbin materials – Bobbins of SMPS transformers are different from general transformers, as they play a dual role of mounting and positioning of the entire transformer, along with insulating and supporting the coil. Thus, the bobbin material needs to meet insulation requirements, as well as possess tensile strength and heat resistance.