Why Are Toroidal Transformers A Better Choice? – Miracle Electronics

Like every transformer type, a toroidal transformer is designed to change the AC current, without the need for any type of movement or action, on the part of the component. But, what makes it different is that its doughnut shaped core is made of cold-rolled silicon steel, which boosts the performance of the core, as compared to any other traditional laminated core. 

The core is wrapped with a coil that generates magnetic field lines, which are completely coincident with the magnetic circuit of the core. This results in a reduced excitation energy and core loss. A toroidal transformer thus benefits the application by offering high electrical efficiency and less magnetic interference, packed in a small size, which also makes it absolutely light in weight.

Distinguishing the outcomes produced by a toroidal transformer

By using an efficient toroidal transformer, large amounts of energy can be saved. Let us take an example. You can take two different types of transformers for the same application; for instance, one being an EI-core transformer 2 x 24V 50 VA, and the second being a toroidal transformer 2 x 9V 50 VA. Loading both these transformers with several load resistors, and the loading power ranging from 5 to 40 Watts, the energy losses can be measured to find the remarkable difference between the two outcomes. The difference between the input and output powers is the energy loss that is converted into heat within the transformer. Moreover, dividing the output power by the input power can also bring to you the transformer’s efficiency. Calculating with different numbers of load resistors, you’ll be able to clearly see the significant differences in the outcomes. The toroidal transformer will result in much less losses than an EI transformer.

Where can you use a toroidal transformer?

Toroidal transformers are used widely in home appliances and other electronic equipment with high technical requirements, such as computers, lighting, telecommunications, audio equipment, medical equipment, and automatic control equipment. You can choose to use the same for your equipment too. And, to bring about even better results, you can opt for a customized toroidal transformer, manufactured by professional and expert toroidal transformer manufacturers in India.

Designing a customized toroidal transformer

Before designing a customized toroidal transformer, there are certain parameters that need to be considered; some of them being –

• The industry – With every industry having different requirements, the industry and equipment in which the toroidal transformer needs to be used should be thoroughly considered and understood.
• Input voltage – Generally, the toroidal transformer is designed according to 220V, but it can also be customized as per any special requirements regarding the input voltage.
• Output voltage and current – Whether the toroidal transformer is single or multi-wound, the output voltage and current of each winding needs to be considered well.
• Output power – The wattage obtained by multiplying the output voltage and the output current also needs to be contemplated.
• The installation method – The kind of installation method needs to be carefully decided upon, such as bracket installing, middle hole potting, full potting, etc.
• Any other special requirements – Any other special requirements such as the lead length, or whether the lead needs to be added with a terminal plug, and other such considerations, need to be reflected upon.

Whether standard or customized, whatever your choice may be, Miracle Electronics are the toroidal transformer manufacturers in India you can rely upon to satisfy all your requirements!

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.