Mag Manufacturing: Driving Efficiency in Transformers
Transformers have long been a crucial component of any electrical system, helping to safely and efficiently step up or down voltage through the system. However, like any functional part, transformers are never 100% efficient when it comes to real-world applications–but they can get very close.
When it comes to custom mag manufacturing, getting the utmost efficiency out of a transformer is often a must, especially in industries that require high performance out of their electronics. And there are a few general ways that transformers can be improved through good manufacturing and careful planning.
Precision Coil Winding
Transformers consist of a solid core surrounded by two coils of wire, and everything about how these wires are wound about the core contributes to the transformer’s performance. The space between each individual turn around the core, the material, diameter, and length of the wires themselves, how the wires are actually wound about the core, and related factors all have a role to play in the performance and efficiency of a transformer. Coil winding has significantly improved over the past decades as well, with automation and CNC equipment allowing for a variety of styles and dimensions of coils
Proper Insulation and Encapsulation
Transformers tend to generate a lot of heat, which can impact their efficiency and even potentially damage individual components. Properly insulating the coils and the transformer as a whole helps with protecting the final product from this heat. Various types of encapsulation will also help insulate the transformer from its environment, especially in demanding applications like military and aerospace electrical systems. For instance, SI Manufacturing offers options for vacuum or pressure multi-compound encapsulation on request.
Looking for a supplier of custom mag manufacturing services?
SI Manufacturing offers full custom electronics solutions, providing each of our clients from design to delivery with over four decades of experience in custom magnetics, precision winding, and custom power supply manufacturing. If you’re interested in learning more about what we can do for you in mag manufacturing, contact a member of our team today.