Custom magnetics have always been SI Manufacturing’s specialty. Precision windings for transformers are the heart of what we do, and have been since our humble beginnings in the 1950s. Today, we manufacture custom transformers for some of the world’s most demanding applications, helping our customers push the boundaries of what’s possible in electronics.
Transformers have always played a crucial role in any type of electronic device, no matter how big, small, simple, or complex. They are necessary for controlling voltage levels between different circuits, ensuring efficient power distribution and voltage regulation within the device, greatly impacting the performance of the end-use product. And because they have such a huge impact on the performance of the final electronic assembly, a lot goes into the design of a custom transformer, especially for high-reliability and high performance applications.
Design Considerations for Custom Transformers
When we help our customer design custom transformers and windings, we have to keep a lot of things in mind, like the application requirements for performance, the load characteristics expected of the final result, the environmental conditions the final assembly will encounter, and the industry regulations that the transformer needs to meet. We also have to plan for testing the finished transformer to ensure that it meets the specific performance criteria set out for it, such as voltage, power ratings, physical size, and thermal management.
Transformer Cores
The first thing we do when we collaborate with a customer on a custom transformer design is determine the best core material and the best configuration of the core. This decision will massively impact the transformer’s efficiency further down the line, as each material has its own unique properties that affect the transformer’s magnetic properties and core loss. As electronics become more and more miniaturized, especially in industries like Aerospace where weight and size constraints are increasingly more regulated, we also have to balance the size constraints of the core material with its performance. Certain materials may not meet the performance requirements of the initial design within the size constraints.
Transformer Windings
Once we’ve determined the core material, we then have to plan the winding around it. Transformer windings are the other crucial half of the custom transformer, as they ultimately have the most impact on its functionality. We have to consider the type of wire and determine the right wire gauge and insulation material to prevent overheating and short circuiting, and then perform the actual winding, which is an incredibly delicate task that requires significantly high precision to get the right amount of loops around the core. Proper and precise winding will reduce leakage flux and improve energy transfer, but even small mistakes can have a big impact on the transformer’s performance.
Final Thoughts
The final application of the transformer will often have the biggest impact on its design. Transformers are typically customized for very specific uses, which involves making difficult decisions of the winding configurations and materials, as well as determining the right core so that the final product meets industry requirements. It’s always important to keep in mind the end-use requirements of the transformer and the various conditions it will encounter when designing a custom one.
Are you looking for a custom electronics manufacturer specializing in the most demanding applications across Aerospace, Defense, and Industrial equipment? Contact us to learn more about what we can do for you!