Challenges And Strategies For Improving Transformer Efficiency

 

Transformers being responsible for moving power between circuits quietly and effectively, industry leaders and researchers are now prioritizing maintaining their efficiency. Improving transformer efficiency lowers energy losses while also saving money and contributing to sustainability. This article examines the complex problem of increasing transformer efficiency and the creative solutions being proposed.

The pursuit of increased productivity

The efficiency of a transformer is important for a number of reasons, such as lowering operating costs, minimizing environmental effect, and eliminating energy waste. Transformers do, however, have a number of difficulties that affect their effectiveness. These are a few of the main challenges –

• Core losses: Hysteresis and eddy currents can cause energy losses in the core materials of transformers, which decreases the efficiency.
• Heat dissipation: Overheating can cause the transformer to become inefficient and damaged.
• Voltage regulation: Efficiency depends on the ability to maintain a constant output voltage even in the face of fluctuating loads and input voltages.
• Environmental impact: Efficiency and the environment may be impacted by the insulating fluid selection, such as conventional mineral oil.
• Ageing infrastructure: A large number of transformers still in operation today may not be as efficient as they should be. Upgrading or replacing them is a significant challenge.

Strategies to Increase Productivity

It will take a combination of cutting-edge technologies and solutions to solve the aforementioned issues. The following tactics have been devised to enhance transformer efficiency.

• Advanced core materials: Core losses can be considerably decreased by using advanced core materials, such as amorphous metals or nanocrystalline alloys. These materials are more efficient because they have less hysteresis and eddy current losses.
• Smart cooling systems: Modern cooling technologies, such directed-flow fans and more effective cooling fluids, can aid in the more efficient dissipation of heat. Maintaining efficiency and avoiding overheating require effective cooling.
• Digital monitoring and maintenance: Proactive maintenance is made possible by real-time transformer monitoring. By minimizing unplanned downtime, predictive maintenance keeps the transformer running as efficiently as possible.
• Load management: Improving transformer loads and making sure they run within their designated range can both lead to increased efficiency. Load management improves the system’s overall efficiency and reduces energy losses.
• Voltage regulation: One of the most important factors in transformer efficiency is voltage regulation. On-load tap changers (OLTCs) and voltage regulators are examples of sophisticated voltage control devices that can guarantee steady output voltage under a range of loads and input voltages. Efficiency gains are partly attributable to this stability.
• Load-tap changing transformers: These transformers enable voltage regulation under a range of load circumstances by adjusting the turns ratio. More effective operation can be achieved through proper load-tap changing, particularly in situations where loads fluctuate.
• Compact designs: By lowering copper losses, smaller, more compact transformers with better insulation materials can shorten conductor lengths and increase overall efficiency. Compact designs are very useful in confined urban spaces.
• Eco-friendly insulating fluids: Transformers can be made more efficient and have a smaller negative impact on the environment by using natural ester-based oils in place of conventional mineral oil. These fluids have improved fire resistance and heat dissipation.
• Smart grid integration: Real-time control and communication are made possible by the incorporation of transformers into smart grids. Smart grids reduce energy losses by optimising their functioning for efficiency and load management.
• Lifecycle cost analysis: Making well-informed judgements concerning transformer selection and operation can be aided by taking into account the total cost of ownership over a transformer’s full lifecycle, including efficiency and maintenance expenses.

Enhancing transformer efficiency is essential for contemporary electrical systems. Although there are significant challenges, there is a way forward using the techniques mentioned above. We may expect even more creative ideas and a greater emphasis on efficiency as technology develops. We are getting closer to a future in the transformer industry where sustainability is valued, expenses are minimized, and energy conservation is achieved. This is not just about making transformers better, but about creating a more responsible and efficient power distribution system for the future.

While we move into the future slow and steady, when you’re looking for efficient transformers in the present, you can always approach reputable transformer suppliers in India, one like Miracle Electronics, where you are guarantees to receive only authentic products and high quality transformers that comply with RoHS and REACH, which ensures dependability and credibility at every step.

Power Transformer Efficiency – Why It Matters

 

Power transformers, the colossi of our electrical infrastructure that guarantee the dependable delivery of electrical energy, are responsible for the transmission and distribution of electricity across cities and nations. However, not all of the energy is transformed; some energy is lost, therefore the efficiency of a transformer cannot be said to be 100%. These losses, which can be mainly ascribed to two things—copper losses and core losses—lead to a decline in the efficiency of the transformers that falls between 95% and 99%. This efficiency of a power transformer holds paramount importance in various aspects, making it a critical factor to consider in the design, selection, and functioning of power transformers in India.

Why does transformer efficiency matter?

• Reduced network losses: As electricity moves from power plants to end customers, electrical networks experience energy losses. Transformers along the transmission and distribution lines that are efficient cut down on network losses, resulting in a reduction in the need for energy generation.
• Energy conservation: Optimizing the consumption of energy is a universal necessity in a time when energy resources are limited and environmental concerns are at the forefront. In order to conserve precious resources, efficient transformers reduce energy losses during power transmission and distribution.
• Heat reduction: Transformers run cooler when their losses are reduced. Cooler transformers are safer and less likely to catch fire because they are less likely to overheat and have insulation degradation.
• Load handling capacity: More powerful loads can be carried by efficient transformers without overheating. The improved load handling capability supports the resilience and stability of the grid.
• Voltage regulation: More dependable and constant voltage regulation is provided by energy-efficient transformers, ensuring that electrical devices receive a steady power supply. This enhances the functionality and durability of the connected equipment.
• Reliability and longevity: When operating, efficient transformers produce less heat, which results in reduced thermal stress. By doing so, the operational lifespan of a transformer can be substantially extended, resulting in fewer premature replacements and the corresponding environmental effects.
• Environmental impact: Each megawatt-hour of power produced leaves behind a certain amount of environmental damage. Reduced energy losses caused by efficient transformers equate to lowered greenhouse gas emissions, carbon emissions, and environmental deterioration. This makes a big difference in maintaining the ecosystem.

The financial impact of transformer efficiency

If the foregoing wasn’t enough, we’ve created a separate section to show that transformer efficiency isn’t only about being environmentally responsible; it also has a direct impact on the financial aspect, which affects utilities, businesses, and consumers equally.

• Lower operating costs: Efficient transformers lower operating costs, such as electricity costs and maintenance costs, for businesses, utilities, and data centres that depend on transformers to power their operations.
• Fewer downtime costs: Less heat generation and more dependable performance lead to less downtime and lower expenses related to operations that are disrupted.
• Reduced energy bills: The most immediate and obvious advantage of efficient transformers is a decrease in energy bills. Consumers simply pay for the energy they use, not for any that is wasted, thanks to the lower losses.
• Incentives and rebates: Many local governments and utilities offer rebates and incentives for utilizing energy-efficient equipment, which may further lower the initial cost of purchasing efficient transformers.

Energy efficiency regulations and standards

You can see how governments and regulatory organizations around the world have come to recognize the significance of transformer efficiency. Transformers must adhere to a number of standards and laws that have been developed, with IEC serving as the Indian standard. International standards have been produced by the International Electrotechnical Commission (IEC), such as IEC 60076, which outlines power transformer efficiency classes. These guidelines are extensively used in many nations, including India. IE1 (Standard Efficiency), IE2 (High Efficiency), IE3 (Premium Efficiency), and IE4 (Super Premium Efficiency) are the four efficiency classes for power transformers as defined by IEC 60076. With each class corresponding to a specific efficiency range, IE3 and IE4 are the most energy-efficient classes.

More than merely a technical need, transformer efficiency is a key element of an ethical and sustainable approach to energy. Effective transformers are essential for resource conservation, cutting carbon emissions, and lowering energy prices since they minimise energy losses. They are crucial elements in the shift to a future with clean Ultimately, by putting efficiency first, we improve the durability and dependability of our electrical infrastructure and help to create a more sustainable and profitable energy landscape. At its core, choosing to invest in energy-efficiency transformers is a decision to sculpt a more efficient and sustainable future. Choose wisely and select only the highest-efficiency power transformers in India offered by Miracle Electronics, one of the most reputed transformer manufacturers both in India and abroad.er and more sustainable energy sources.

Ensuring Optimal Performance With The Right Transformer Maintenance Procedures

Transformers serve as unsung heroes in the field of energy conversion and distribution, ensuring the efficient and secure transmission of electricity around the world. But if they aren't properly maintained, they won't be able to deliver the steady stream of power they are built for, for a very long period of time. Even if you bought high-quality transformers from a reputed and genuine transformer manufacturer in India like Miracle Electronics, the longevity, reliability, and safety of your transformers may still depend on diligent maintenance. This blog explores the nuances of transformer maintenance, including its importance, types, challenges, and innovative strategies to overcome them.

Importance of transformer maintenance

• Transformer upkeep is essential for avoiding catastrophic failures. Unexpected failures that could result in a lot of downtime are avoided by scheduled maintenance. Power supply interruptions and service interruptions are reduced by addressing possible issues including insulation deterioration, overheating, and contamination before they escalate.
• The best performance and safety are also guaranteed by routine inspections, tests, and repairs. The lifespan of transformers is increased, energy efficiency is improved, and the dependability of power distribution networks is protected with proper maintenance. Transformers will continue to operate at their peak levels for a long time if problems are promptly identified and fixed.
• Transformers are guaranteed to operate within safe limits through maintenance, lowering the possibility of faults that can jeopardise the distribution of energy. An effective and reliable power supply is made possible by well-maintained transformers, which increases the dependability of electrical grids and systems.

Therefore, transformer maintenance helps to ensure continuous energy supply by proactively identifying and fixing possible issues, reducing hazards to both infrastructure and public safety.

Types of transformer maintenance

Transformer reliability is improved, downtime is reduced, and potential failures are proactively handled by implementing a complete maintenance approach. There are several ways that can be used for this, and the choice of approach depends on the criticality of the transformer, the resources that are available, and the desired balance between cost and reliability. Preventive maintenance, predictive maintenance, and corrective maintenance are the three fundamental maintenance approaches for transformers.

• Preventive maintenance includes routine inspections, cleaning, and testing, including dielectric tests, winding resistance measurements, and oil analysis, to keep transformers in top working order. Preventive maintenance reduces risks and prevents significant failures by discovering potential problems early.
• Predictive maintenance makes possible real-time transformer health evaluation by utilizing data and monitoring systems. Sensors gather performance information, which enables analysis to foresee possible faults. Dissolved gas analysis (DGA) techniques can identify gas changes in the transformer oil that indicate problems such overheating or deteriorating insulation. Through targeted adjustments made possible by this proactive strategy, maintenance efforts are optimized.
• Corrective maintenance involves responding to unanticipated failures or irregularities. The problem is identified and fixed quickly, resulting in the least amount of downtime possible. Preventive and predictive maintenance methods are preferred since corrective maintenance is frequently more expensive and disruptive than other types.

Common transformer challenges

Using transformers and maintaining them doesn’t come without challenges. Even though you execute the right maintenance procedures, there may be certain challenges you may face, depending upon the installation, the environment, and many other factors. Let’s take a look at the most common transformer challenges encountered, and how they can be dealt with.

• Challenge 1 – Transformer insulation materials may become less effective over time as a result of temperature changes, electrical stress, and moisture exposure. Insulation is weakened as a result, raising the possibility of electrical malfunctions and failures.

The solution – Insulation health is evaluated through routine testing, such as dielectric testing and partial discharge measurements. Electrical failure is avoided and safe operation is ensured by prompt replacement of degraded insulation materials.

• Challenge 2 – Overheating during operation can cause insulating materials to become thermally stressed, and as a result, degrade. These effects are accelerated by overloading, which frequently results from increased demand. This could lead to insulation disintegration and shortened lifespan.

The solution – Thermal monitoring devices are used to keep track of temperature changes inside transformers. By using load management tactics and cooling procedures, overloading hazards are reduced and problems related to excessive heat buildup are avoided.

• Challenge 3 – Contaminants, such as dust and pollution, may get inside transformers and compromise their insulation and performance. Moisture intrusion makes things worse by corroding parts and hastening insulation degradation.

The solution – Effects of contamination and moisture are reduced by properly sealing transformers and developing adequate venting systems. Utilizing moisture-resistant materials, desiccant breathers, and routine cleaning help combat contamination and its damaging consequences.

• Challenge 4 – The structural integrity of a transformer may be impacted by vibrations from surrounding machines or other outside influences. Winding displacement or insulation damage can be caused by mechanical stress during transit or during improper installation.

The solution – The effects of vibrations are lessened by mounting transformers on platforms that absorb vibrations or by employing resilient mounts. Using suitable shipping methods and cautious installation techniques will reduce mechanical stress and protect the integrity of the transformer.

By proactively addressing the challenges, you can enhance the reliability and longevity of your transformers. Regular maintenance schedules, data-driven insights, and cutting-edge diagnostics allow for a complete solution to the problems, ensuring that the transformers run as efficiently as possible and stay resilient to the challenges they encounter.

Transformers are the foundation of our electrified world, paving the way for a brighter future and serving as the engine behind industries and contemporary infrastructure. And with that, maintaining transformers is essential to ensure a consistent and effective supply of power. Transformer maintenance entails staying on top of problems and embracing contemporary methods, from preventive measures to creative initiatives that make use of technology.

Follow us on: Facebook & LinkedIn

Transformers: The Unsung Heroes Of The Electrical Power Industry

The transformer is an essential component in supplying electrical power for everyday needs. These amazing machines support the entire electrical power sector by facilitating the effective transmission and distribution of electricity to buildings, commercial buildings, and industrial facilities. Yet, these heroes frequently go unseen! But here, in this blog, we’ll shed some light on these amazing equipment, giving them the respect they ought to receive!

Transformers facilitate power generation

Transformers are crucial for integrating power plants with the electrical grid, and converting generated electricity to appropriate voltage levels for distribution. They also integrate renewable energy sources like solar and wind power into the grid, and enable the generation of sustainable energy.

Transformers provide for effective power distribution

Transformers make it easier to change electrical voltage levels, enabling electricity to be delivered across great distances with little loss. They also enable dependable power supply by stepping up the voltage for effective long-distance transmission, and stepping it down for safe distribution to end consumers.

Transformers enhance energy efficiency

By working at high voltage levels, transformers reduce power losses during transmission, thus increasing the total energy efficiency. Furthermore, distribution transformers ensure that power is delivered at the proper voltage levels, reducing waste and maximizing energy efficiency. This ultimately optimizes power utilization.

Transformers ensure reliable power supply

Transformers maintain a constant voltage level, compensating for fluctuations in the power grid and guaranteeing a steady supply of electricity to consumers. They also assist in reducing problems like voltage sags, harmonics, and power surges, which improves the quality and dependability of the electrical supply.

Transformers support industrial and commercial applications

Transformers supply the necessary energy for heavy machinery and equipment used in a variety of industries. In addition, they also help the efficient operation of commercial applications by supplying dependable electricity for lighting, heating, cooling, and other operational requirements.

Transformers promote safety and protection

Transformers provide electrical isolation, preventing humans and equipment from electric shocks and short circuits. Also, transformers integrate protection devices including fuses, circuit breakers, and surge arresters, to guard against damage from electrical faults and guarantee safety.

As you can see, transformers quietly deliver electricity to homes, offices, and industries in a safe and effective manner. It is impossible to emphasize their critical importance in voltage transformation, power generation, energy efficiency, dependability, and safety. With such an extraordinary role that transformers have played in sustaining the convenience of electricity in our daily life, they are yet often neglected. This clearly shows why we say that transformers are the unsung heroes of the electrical power industry.

To get your hands on these silent heroes, you can get in touch with Miracle Electronics, the leading transformer manufacturer in India, who has been offering a number of different types of transformers to clients across the globe since almost three decades now! Power, toroidal, EI, three phase, SMPS, encapsulated, UI, and planar are only some of the finest transformers on the list. Choosing any of these transformers will ensure an investment in quality.

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

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.

 

When Building Electronic Box Assemblies – Miracle Electronics

An electronic box assembly is an electromechanical assembly process that includes enclosure fabrication, installation of sub-assemblies and components, and routing of wires and harnesses. It could mean anything from a PCB assembly in a cabinet fill or wires, or a complex fully integrated electromechanical system with pneumatics and electronics. 

Whatever it may be, you need to have your components placed in a project box that protects, as well as makes your product truly useful and accessible.

Designing electronic box assemblies in India presents its own challenges, which is why you need a manufacturer who goes ahead with the right approach. You need one who specializes in the capability you want to build, and has experience in building the particular product and components you’re looking for. Outsourcing your electronic box assembly is an easy task when you have such a reliable manufacture partnered with. But, while you outsource, you also need to consider a few basics to help the build process go smoothly. There are certain instructions you need to send to the manufacturer for building the box appropriately. These include –

Bill of Materials (BOM)

The Bill of Materials gives the manufacturer an idea of all the key components, with a clear mention about the materials that you will be providing, and those to be sourced by the manufacturer. You may also define every tiny detail like the adhesives, tie wraps, nuts and bolts, washers, heat shrink, etc. if you wish to avoid even the smallest confusion or misconceptions in the future. You should also clearly specify the tolerances and finish of each component if you want anything particular to be considered. All in all, it is best to specify every minute detail just exactly how you need it. If you’re too confused as to what materials or specifications should be used for your particular requirement, you can also communicate all your ideas and purposes to the manufacturer, and help him decide the best solution for you.

Assembling

Once all the materials and components are decided and discussed upon, along with all the specifications and details mentioned, it’s now time to move on to the process of assembling them. if possible, you can provide a 3D CAD model to help the manufacturer visualize the final product like you want it to be. Or, at the least, you must provide the assembly drawings with every detail clearly mentioned. However, if you’re not too sure, you can always define the purpose and requirement, and leave the job of designing and prototyping to the manufacturer. This can also help when there are large amounts of space, labour, and specialist tools required for the build.

Testing

Testing is always an integral part for any product, especially when it is an electronic or electrical device. The basic electrical safety testing, such as earth bond and flash tests, need to be conducted, thus specified well in advance. Other tests may include visual inspection, functional testing, factory acceptance testing, etc., depending upon your specific product. If you’re not too sure again, your manufacturer can help decide as to what kind of testing is important, as they will have the proper knowledge and experience of what will work best for your particular product.

Outsourcing and electronic box assembly inevitable requires close cooperation between the client and manufacturer. By providing all the above information, and every other detail possible, there would be lesser confusion, lesser misunderstandings, and lesser wastage of time and money. Whether you require a simple box build assembly, or complex electronic box assemblies in India, you can get in touch with Miracle Electronics to ensure that your product is protected and looks good with the final assemble that proves to be a true reflection of your encased product. Dedicated to lean manufacturing techniques, Miracle Electronics will always offer maximized efficiency and a complete package, no matter what the product may be.

 

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!

Importance Of RoHS For Medical Isolation Transformers – Miracle Electronics

The term “medical” in itself indicates safety and caution. Medical transformers thus also need to be very carefully designed so as to keep both the operators and patients safe while they’re around the device. 

And, this is the reason why the transformers used in medical applications are always isolation transformers – those that isolate the patient and operator from electric shock, and protect the equipment from power surges and other faults. Such medical grade isolation transformers  thus need to maintain strict adherence to certain crucial standards; one of them being RoHS.

What is RoHS?

RoHS, or the Restriction on the use of Hazardous Substances, in itself states that no kind of hazardous substances are permitted to be used while manufacturing the particular device. The main goal of RoHS is to reduce the environmental effect and health impact of electronic equipment, by making electronics manufacturing safe at every stage of the electronic device’s life cycle.

When was RoHS introduced?

The RoHS restriction originated in the European Union in 2002, restricting the use of 6 particular hazardous substances found in electrical and electronic equipment. It was then officially adopted in February 2003. In 2005, on the 21^st of October, the European Commission decided to exempt the use of Cadmium and its compounds in electrical contacts. The next year, the European community established July 1 as the phase-out date for hazardous material in electronic products.

Why was RoHS introduced?

A wide range of materials were used to manufacture electrical and electronic equipment, such as radium, lead-tin allow, etc. But these materials, despite of the fact that the had many useful properties, were also discovered to be hazardous to both humans and the environment. It was thus a must to stop the usage of such harmful materials. For strict adherence, the RoHS was introduced, in order to improve the welfare of consumers, manufacturers, distributors, and the environment.

Which materials are restricted for use under the RoHS restriction?

As per the RoHS, products compliant with the derivative must not exceed the allowable amounts of the restricted materials (with some limited exemptions). The 6 restricted materials include lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls, and polybrominated diphenyl ethers. This derivative applied to manufacturers, importers, distributors, and authorized representatives of a wide array of products. Some of the most common products that need to adhere to the RoHS standard include small and large household appliances, consumer electronics, lighting, computing equipment, communication equipment, power tools, and not to forget – medial transformers.

Why is it a must to adhere to the RoHS standard?

The 6 materials that fall under the RoHS derivative are hazardous to the environment, and also dangerous in terms of occupational exposure during manufacturing and recycling. Complying to RoHS reduces the amount of hazardous chemicals used in manufacturing electronics. This is why whenever you’re planning to purchase a medical isolation transformer in India, or any other electronic equipment for that matter, you should always approach a manufacturer whose products are all compliant to the RoHS certification. One such trusted manufacturer is Miracle Electronics, where every medical isolation transformer is not only RoHS compliant, but REACH compliant too!

 

Choosing The Right Power Supply For Your LED Application - Miracle Electronics

Discovering the right kind of power source for your LED lights and fixtures is absolutely important, may it be to build a new fixture, or retrofitting an existing one. What you’ll need is a constant current LED driver or a constant voltage power supply, or a combination of both, in order to make your LEDs work properly. Let’s help you know the different factors you need to consider when choosing a power supply for your LED lighting.

Most LEDs require a current-limiting device to prevent them from being over-driven. Such devices are used to regulate the current coming in to the LEDs, keeping them running safe, and maximizing their lifespan. If the current is not regulated, the LEDs may get heated up, thus changing their electrical characteristics to draw too much current, thus resulting in fluctuations or even failure. If your lighting fixture doesn’t have a current-limiting device, your first step should be to find a driver. But, if your LED product already has the current under control, you can move ahead to find a constant voltage power supply.

When the LED products already have current-limiting devices within the system, they call for a constant DC voltage, which is generally not available, and then you’ll need to find a power supply to convert your power to a safe DC voltage. But, in order to be able to effectively convert your AC voltage down to a safe DC voltage, there are many factors you need to consider, some of the most important ones being mentioned below.

Wattage and voltage

Identify the total amount of watts that all your lights combined will consume, and add to it a 20% cushion, or multiply the total wattage by 1.2. You’ll need to find a power supply rated for this calculated amount of wattage. Also, identify the output voltage that is compatible with the voltage of the LEDs. You also need to ensure that the power supply you select should be capable of handling the input power you have.

Temperature and environment

The area and the environment that you need the power supply in is also an important consideration. Power supplies operate efficiently only when they’re used within their temperature parameters. Installing a power system within a tiny enclosure, or where there is no ventilation system, is a bad idea. Rather, you should choose an area where it’s neither to warm, nor too cold, and where the heat produced cannot build up to damaging levels.

IP rating

Every power supply has an ingress protection rating, which is more popularly known as IP rating, consisting of a two-digit code that respectively indicates the size of solids and pressure of liquids that a power supply can resist. You need to ensure a power supply with an IP rating that will protect your source from the environment.

Size

The space that you have for installing the power supply should be well identified, and the right size of power supply device should be chosen. If the power supply is to be installed outside of the application, there should be a mounting possibility.

Using the above considerations, you should be on the right road to choosing the right power supply for your LED lights. There are a multitude of options to choose from, which is why you should take your time to consider every little aspect, so as to find the one that best fits your application, and is highly efficient in regards to how and where it needs to perform. And, when you’re done with all your contemplations, you’ll look for a place to begin your product search. This is where we suggest to you Miracle Electronics, a reputed brand where you can get standard as well as customized programmable power supply for LED light panel in India, each manufactured in dedicated work cells, using lean manufacturing techniques, to maximize efficiency.

Choosing Segmented Cap Transformers Over Conventional Ones - Miracle Electronics

When you’re operating a critical application, something involved with medical, aerospace, or military, you’re always trying to settle down on a few crucial decisions. One such decision may be determining the kind of transformers you want to use, upon which lots of electrical and signal-based outcomes will depend. 

For instance, if you are into the medical industry, deciding upon the kind of medical isolation transformer in India you want to use for your applications, you may be unable to decide whether you should opt for a simple conventional one, or go in for a more radical one installed with segmented cap technology. If this is what you are unable to decide upon, you’re at the right place! We’ll help you know how a basic transformer is different from a segmented capped one, and how the latter can prove to be beneficial.

The basic construction of a toroidal transformer

A toroidal transformer has a basic method of construction which involves the following steps.

Creating a steel core – insulating the core – winding a magnetic wire around the core to create a primary winding – insulating the primary – winding a magnetic wire over the insulation to create a secondary winding – and finallyinsulating the secondary to complete the transformer.

Mounting the transformer

Once the transformer is manufactured, it is mounted either using a mounting washer and bolt, or by filling the center of the transformer with an epoxy, with a hole for a bolt.

The role of segmented core caps

Toroidal transformers are generally plain, but there are certain applications where additional segmented core caps are used. These core caps are mainly used to support the primary and secondary windings in alternate sectors to reduce leakage current. The insulating segments insulate the windings from the core over the full range of windings, allowing for double-wall insulation between adjacent windings, thus reducing leakage current to a great extent, as compared to conventional toroidal transformers. They also help to directly cool the core through ambient or forced air, without interfering with the insulation.

The construction of core caps

Several modular electrically insulating segments are snapped or joined together to form an annular or semi-annular core cap design to fully or partially cover the transformer core. The number of such segments that are required to complete a core cap is predetermined, based on the angle at which the adjacent walls are placed to each other. This is because the walls, which include male and female connector portions, are all disposed at a predetermined angle relative to each other, typically 30, 45, or 60 degrees. Typically, there are identical core cap segments in a single core, but there may also be groups of different segments spanning different arcs. The latter is basically seen in customized core cap designs that require certain particular properties and characteristics.

The benefits of a core cap design

Reduced costs – When a core cap design involves snapped segments, the cost to assemble the caps is reduced because the process of snapping requires lesser skill level than other techniques. Also, the cost to tool a smaller part for injection-moulding is lesser than the cost of tooling a larger part.

Reduced time – When a core cap design meets safety specifications for creepage and clearance, the manufacturing time is reduced because of no requirement for ground and inter-winding insulation and outer wrap. Moreover, the windings can be wound on one single machine, thus reducing the handling time.

Reduced temperature rise – When a core cap design allows airflow around the core and windings, while keeping creepage and clearance specifications safe, the temperature rise is reduced because there will be a direct path for the heat to escape from the un-insulated core into the environment, without having the windings and insulation to trap the heat within.

Reduced weight – When a core cap design includes mounting holes, the weight of the transformer is significantly reduced because there will be no center epoxy or mounting washer required.

As you can see, segmented cap transformers can offer significant reduction in leakage current, heat rise, costs, and time invested, in comparison to standard toroidal transformers. All of this combined, segmented cap transformers are lighter, faster, less expensive, and are rated for extended power for the same volume. This makes segmented cap transformers the ideal choice for critical applications like medical isolation transformers. So, whenever you are looking for an advantageous medical isolation transformer in India, you know what you have to choose. But, if you want a transformer that complies with applicable requirements, you need a manufacturer who you’re sure will provide you with only genuine standard transformers. One such reliable manufacturer  is Miracle Electronics, where every transformer is RoHS and REACH compliant, and also adhered to the regulations under UL 60601-1 standards.

EAF Transformers – Why & Where Are They Used - Miracle Electronics

EAF transformers – The name may make you think about them to be complex transformers with a complicated functioning. But, they aren’t so complex. EAF transformers are Electric Arc Furnace transformers that are generally used with electric arc furnaces or ladle metallurgy stations to transform high-voltage low-current electrical power to low-voltage high-current electric arcs inside an EAF furnace to melt scrap steel. The scrap steel is exposed directly to the electric arc produced by the EAF transformers inside an electrical arc furnace to temperatures up to 1800°C. 

These transformers help in maintaining a perfect balance in the electric circuit, as a lot of charge accumulation in one portion of the circuit can lead to load shedding or wearing down of the device. This advantage and functioning of an EAF transformer is what helps it to be used in a number of applications, such as in gas factories, steel plants, and in industries manufacturing calcium carbide.

Benefits of using an EAF transformer

There are a lot many benefits of using an EAF transformer, some of the advantages being mentioned below.

ü EAF transformers are industrially manufactured devices, each unit being sold by registered dealers, who procure complete details of the customer before making the sale. This is because these EAF transformers are highly expensive, which is why you must always purchase from a leading transformer manufacturer in India, to ensure safety and the guarantee of making a right purchase.

ü The details of EAF transformer manufacturers are always available online, which makes it easy to track them down. This means there is no possibility of any unscrupulous practices, which is why these industrial devices are rarely mishandled, thus saving you from any such problems, as you can be sure you’ve made a legitimate purchase.

ü An EAF transformer is manufactured with the help of machines, and each component is made by expert manpower, which means you can expect a strong-built device at your service. This means there is completely durability. And, if you purchase from a genuine transformer manufacturer in India, one like Miracle Electronics, you can rest assured of having the best after sales service too.

Applications of EAF transformers

Gas factories – Electricity is used in gas factories to perform the process of catalysis, that is, combining or breaking down the components of a gaseous mixture, which cannot be achieved by normal processes of applying heat and pressure. EAF transformers are useful to carry out such specific reactions.

Steel plants – Steel plants require melting of iron at high temperatures, and a sturdy furnace that can help them achieve a large amount of heat, which can liquefy the iron, so that the various components can be formed from it. This is where EAF transformers can help.

So, whether your application is that in a gas factory or steel plant, or even in an industry that manufactures calcium carbide, you can rely on EAF transformers to easily and effectively carry out your power transformations from high-voltage low-current electrical power to low-voltage high-current electric arcs inside an EAF furnace.

 

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.

Factors To Consider While Manufacturing A Switch Gear - Miracle Electronics

Electric power has become a basic necessity for each one of us today; and for electric power circuits to operate well, it is important that they are operated by the right switch gear controls, which can switch and protect individual components of the equipment. Composed of electrical disconnect switches, fuses, and circuit breakers to control, protect, and isolate electrical equipment, switch gears are used to de-energize equipment so hat work can be performed with zero faults down the line.

These equipment are thus directly linked to the reliability of the electric supply; and must be thus manufactured very cautiously. So, when you are looking to manufacture such important components for your application, it is crucial that you consider several factors so as to develop and implement these components properly.

The size of the switch gear

The first and foremost consideration is the size of your switch gear. What size of switch gear will be apt for your application? Especially, when maintenance is concerned, you need to have an appropriate switch gear, if you need to move it in and out of the enclosure at the base for repairs and upkeep.

The environmental factors it will encounter

Where are you planning to install your switch gear? What is the application? Where will your product be used or installed? What kind of environmental factors will the switch gear encounter? For example, if the environmental conditions are of extreme temperatures or humidity, you need to design your switch gear such that they can effectively perform under those circumstances.

The operation requirements

You also need to consider the general control action of the switch gear. Are there any special requirements you need your switch gear to perform? Whatever your requirements, you need to present the information to the manufacturer right at the beginning of the development phase. Depending upon all that you require from your switch gear, the design plans will be worked out; and based on the finalized plan, the manufacturing will be carried out. Hence, every tiny information should be communicated and clarified before moving into the manufacturing phase to ensure that every specification of the switch gear will complement your equipment operation requirements.

Typically, switch gear are located on both high and low voltage sides of large power transformers. The switch gear on the low voltage side of transformers may be located in a building, with medium voltage circuit breakers for distribution circuits, along with control, protection, and metering equipment. For industrial applications, transformers and switch gear are combined into one housing, known as a unitized substation. So, for any queries on switch gear and transformers, and their components, or to place an order, you can always get in touch with Miracle Electronics, the best transformer manufacturer in India , where you can communicate all your information with skilled technicians, and have only the best electronic components manufactured for you. You can have almost every kind of electronics manufacturing services offered here, right from product and system designing to manufacturing the best quality products.