The concept of coupled inductors, or transformer coils, is fundamental in the field of electrical engineering. Coupled inductors are used to transfer energy from a primary circuit to a secondary circuit, allowing for efficient and reliable power transmutation while providing some unique advantages not seen with other power conversion methods.
What is a Coupled Inductor & How Does It Work?
Coupled inductors are imperative in the electrical engineering field. They function in DC-DC convertors by transferring energy from one winding to another. It uses a gapped magnetic core, which converts the voltage between primary and secondary coils. This process allows the inductors to deliver power in controlled intervals, which is unique and not seen in other methods.
Understanding how coupled inductors work is necessary to know how they can be applied to various applications. Fortunately, we have an in-depth understanding of the technology and the different industries so that we can provide the best possible solution for your project requirements.
Coefficient of Coupling
The coefficient of the coupling is defined as the fraction of magnetic flux from the current in one coil that links with the current of another coil. It’s represented by the (k) symbol and expresses the amount of coupling between two inductively coupled coils.
The coupled inductor equations formula is K = M/√L1+L2. L1 refers to the first coil’s self-inductance, L2 refers to the second coil’s self-inductance, and M represents the mutual inductance between the two coils.
Benefits of Utilizing a Coupled Inductor
The ability of coupled inductors to deliver power in a controlled interval is the physical space that it can save since it uses a single core while having the power of two. Due to this design, many industries are enticed by it.
Another advantage is that it has a more significant efficiency gain in performance due to the lower winding losses. Even though this efficiency isn’t as notable, it’s still a benefit.
Finally, a coupled inductor’s ripple is divided between two inductors, allowing the inductance also to be halved. The design naturally has a small input capacitor with a more straightforward EMI filtering.
Common Applications of Coupled Inductors
A coupled inductor is designed to increase or decrease the voltage and current of numerous electrical applications. They’re used in myriad industries for various applications, from automotive and aerospace to medical, industrial, and consumer appliances.
Frequently, coupled inductors are seen in power supplies where noise reduction is necessary or interference between two circuits is required. Additionally, they’re also used as filters in RF design.
With the numerous applications coupled inductors have, it’s crucial to have reliable and safe products from a trusted manufacturer, such as MPS Industries, to guarantee your project’s success.
Why Choose MPS Industries for Your Inductor Needs?
Our Coupled Inductors are specially designed to save on space and cost, while meeting your requirements for electrical performance and reliability.
We have extensive experience designing and manufacturing custom and standard inductors at MPS Industries, so we can quickly achieve customer satisfaction and success. If you have any concerns or questions about what is coupled inductor and our products, don’t hesitate to contact us today.
You may also request a quote, and our staff will get in touch with you shortly to help with your project’s needs.
As energy efficiency becomes more important in modern electronics, resonant power conversion is becoming a prominent technique for minimizing energy loss in power electronics applications. The resonant inductor is an important component in resonant power conversion systems.
The importance of resonant inductors in these systems and their application in zero voltage switching (ZVS) technology, which is extensively employed in power controllers, will be discussed in this article.
What Is Zero Voltage Switching?
Power switches are turned on and off when the voltage across them is zero or close to zero using zero voltage switching. This reduces switching losses and improves efficiency, particularly in high-frequency applications. To reduce the energy losses associated with switching transients, ZVS is extensively utilized in many power conversion systems, including resonant converters.
Resonant Power Conversion
Resonant power conversion systems are designed to achieve high efficiency and minimal switching losses by utilizing the inherent oscillation of circuit parts such as inductors and capacitors. Working in intricate concert with other components, the resonant inductor plays a fundamental role within these circuits, creating an active tank that determines both system frequency and performance parameters.
Resonant Inductors in ZVS Applications
Resonant inductors are key elements in ZVS applications, as they act like a buffer that stores and releases energy based on an established pattern to generate the requisite resonance waveform for clean switching. Though not exclusive to zero voltage switched converters, their inclusion is essential for optimal performance.
By meticulously defining the inductance and quality factor of the inductor, it is possible to adjust the resonant frequency so that maximum performance can be achieved from your power converter. This optimization will guarantee a smooth transition between each switching cycle at its most beneficial point, reducing energy loss significantly.
This type of inductor is especially beneficial for applications operating at frequencies between 20KHz and 1MHz. To get the most efficient operation from a resonant inductor, it should be designed with Litz wire. This reduces copper losses and ensures that current flows evenly through all players of the wire during operation.
MPS Industries’ ZVS Resonant Inductors
MPS Industries is proud to be a leading provider of reliable and high-performing resonant inductors. Our inductors are the perfect addition to your power conversion system, thanks to their incredible saturation currents, minimal capacitance interference, and low core losses.
When constructing your unique design, MPS Industries’ ZVS resonant inductors come in a range of sizes and inductance values so you can select the most suitable component. Our engineers can help you choose an optimized solution or provide a fully customized design to meet your specific needs. Additionally, these components utilize Litz wire which suppresses skin and proximity effects that may reduce performance when dealing with high frequency applications.
Applications of Resonant Inductors and ZVS
Resonant inductors and ZVS technology are used in a wide range of applications where energy efficiency and high-frequency operation are critical. Among these applications are:
Electric vehicle chargers
Renewable energy systems
Resonant inductors are essential components of resonant power conversion systems, allowing for great efficiency and low switching losses. The use of ZVS technology in conjunction with resonant inductors allows for even more energy loss reduction and increased performance in a variety of power electronics applications.
The ZVS resonant inductors from MPS Industries are an excellent example of a component intended to satisfy the demands of modern power conversion systems, delivering dependable and efficient solutions for a wide range of industries and applications.
This year from March 4-8, San Antonio, Texas is going to be a popular destination for more than just the San Antonio Spurs or the Alamo. These dates are set aside for the premier global event for everything related to power electronics, APEC 2018. Held at the Henry B. Gonzalez Convention Center, this 44,995 sq. ft. center will have speakers, sessions, workshops, committee meetings, and seminars on all the practical and applied aspects related to the power electronics business. This conference is more than just a ‘what’s new’ type of expo; it has a little something for anyone who works in power electronics and its related industries. MPS will be at Booth 526.
Speakers, vendors, and attendees come from a wide range of backgrounds in the industry, such as equipment OEMs, designers, manufacturers and suppliers, engineers, marketing, and sales. There are professional plenary, technical, and RAP seminars. This year, there will be over 300 registered exhibitors, all showcasing solutions in power electronics for a number of categories, such as: assemblies, magnetics, power converters, semiconductors, software and services, and more. Exhibitor seminars provide a close and upfront look at their products and services, delivered in half-hour increments.
As a leading manufacturer of magnetic components, MPS Industries, Inc. is excited for this year’s show. We offer power transformers, inductors, LAN/RJ45s, common mode chokes, broadband magnetics, custom designed magnetics, and a wide range of transformers. We’re looking forward to networking with other industry professionals and talking with experts from the industries we service, such as: automotive, renewable energy, industrial, military and aerospace, medical, consumer electronics, and telecommunications.
To learn more about MPS Industries and to keep up to date on all things related to power electronics, you can read our blog, follow us on Twitter, and connect with us on LinkedIn. To learn more about how we can help you with our wide range of products or with a custom design, we invite you to contact us today.
With 2017 officially closed, now is the time to look towards industry predictions in the new year.
Industry Outlook Predictions
Projections for 2018 show positive outlooks for three of the main industries MPS serves.
The renewable energy sector, both globally and within the U.S., will always be at the forefront of debate and conversation. Renewables (in particular, wind and solar) will continue to increase their share of the power mix.
Industry experts have predicted that the medical market will continue to grow in the upcoming year, given the fast pace nature of technological advancements and increasing role of tech in medical devices. Our design team ensures our magnetic components meet industry requirements, such as UL544 standards.
In the global consumer electronics industry, the forecast is for a healthy demand in 2018, particularly for Smart TVs, 3D TVs, smartphones, and tablets. Connected devices that use magnetic parts continue to provide potential opportunities, especially as new data sources come to fruition.
Meeting Demands in 2018
Our broad product offerings will carry on into 2018 as our MPS team continues to manufacture magnetic components, including transformers and inductors, for industrial applications across a wide range of industries.
Having a diverse product line enables our team to effectively serve multiple markets worldwide from our headquarters in Gardena, California. Our high-quality lineup solves client needs across industries such as automotive, industrial, renewable energy, medical, military and aerospace, telecommunications, and consumer electronics.
Moving into the New Year
At MPS Industries, we embrace opportunities to fulfill customers’ visions and possess the skills to move quickly as industry demand increases across the sectors we serve. Our agility, both in strategy and operations, and excellent customer support, makes us a great choice for your magnetic components manufacturer this year.
Contact us today for your next project or any questions you might have. Also, follow us on Twitter, LinkedIn, and our blog to receive the latest industry and in-house updates.
As 2017 comes to a close, we’re highlighting some of our best products that we’ve shared with you over the past 12 months! These great features (& more!) will be available for your specifications come 2018 too… Don’t miss out!
If you’re looking for a high-power inductor with a quick turnaround time for design approval, you’ve found the right spot. Our HWI57A2 and H1300 series models can help you test your capabilities without the hassle of waiting for a full custom design. Avoid NRE’s, tooling, and long lead times with our ideal-for-your-requirements components. Their modular design allows you to connect each in series or in parallel for higher inductance and/or current.
Here are some of the advantages to keep in mind:
Units are semi-customizable
Lead connections can be optimized
Thermal potting available in 1,2, or 3 w/mk depending on requirements & targeted cost
Units arrive ready to bolt down, connect, and install
No need for an NRE
Shorter lead times than other fully customized inductors
High Current HEW™ Inductor in low-profile compact form
Inductance Range: 3.3 µH to 15 µH
Very low DCR
True 30 Amp handling capability on the wire
Dummy 3rd pin for mounting stability
As you’re designing keep in mind that our engineers are more than that. They are experts of the inductors, magnetics, battery, and energy fields, no matter what industry you’re purposing! We serve: automotive, industrial, medical, military, aerospace, telecom, and consumer electronics — and that’s only naming a few!
MPS is no stranger to quality and efficiency when it comes down to you high-power magnetics. Our continuous goal is to find ways to push the envelope when it comes to magnetic designs. The aim is to provide our customer with the most optimized solutions. When developing our high power standard product lines, we strive to improve both the efficiency and heat dissipation of our parts. MPS engineers understand that quality, compact size, and low DCR are crucial requirements for our customer base.
That’s why we’ve created series like the HWI34. Here’s a closer look at its profile:
Low profile, small footprint, compact form
Inductance Range 4.7 uH to 29uH
Exceptionally low DCR
Great heat dissipation
True 45-55 Amp wire handling capacity
Powered cores with distributed gap for soft saturation
For high-temperature environments – up to 125°C ambient (max temp 180C)
Higher current available
Different mounting available
We look forward to new product developments in the upcoming year.
Keep an eye out for our next entry on what is to come throughout 2018. We can’t wait to implement our own creations alongside those of our customers as well!
Remember that we know the importance of providing maximum support for your supplies. MPS’ engineers work closely with you to not only design based on your electrical specifications, but your mechanical requirements as well, including hardware selection and mounting optimization for your specific system.
You’ve selected an inductor, but how can you tell if a high current inductor truly is high current? It’s crucial to confirm that the inductor you’re using matches the specifications you need and that they are capable of performing accurately.
Certain manufacturers use data sheets to mention the saturation current on the inductor “can be up to almost 100 Amp with 30% drop in inductance.” If you ask us, that’s a relatively vague description. It’s hard to tell if this explanation means that your inductor can actually be used at 100 Amp when the copper size can only carry less than 30 Amp and a 40°C rise in temperature. Power engineers often misinterpret the fact that these inductors are rated at the saturation temperature.
As a leading industry expert in high current inductors, MPS Industries manufactures high current fixed inductors in compact size packages with varying inductance ranges. We also provide full customization options for any of our products. Our inductors can be used as a true high current (>100 Amp RMS) rated inductor.
At MPS we carry a wide range of products. Our team is dedicated to increasing our offerings year after year to better serve your magnetic component needs.
Be sure to browse our inductors and contact us to speak with an Applications Engineer or Sales Representative regarding your inductor requirements.
If you’re in need of magnetic components, we can support you!
As the first Friday in October, National Manufacturing Day 2017 will happen on October 6th. As a prominent electronics component manufacturer, MPS Industries is happy to spread the word about NMD. This year the event promises to be a day full of education and encouragement for all attendees.
What MFG DAY Means for the Industry
Produced by the National Association of Manufacturers, National Manufacturing Day is a way to halt common misconceptions about the industry. Facilities across the nation will open up their doors to connect with the next generation and present the truth of the industry as it is today. Along with providing this educational opportunity, the annual event also provides manufacturers with a platform to speak about positive industry attributes, as well as shared challenges, and to connect with the community.
These efforts help ensure a strong future for the United States manufacturing industry that is enjoying a comeback following the Great Recession of 2010. Inviting students, businesspeople, journalists, teachers, and politicians onto industry shop floors across the US can help influence public views about manufacturing.
Bridging the Skills Gap and More
National Manufacturing Day is important as it provides firsthand the opportunity to see the tech-savvy present-day manufacturing force. MFG DAY is a vehicle to combat current issues facing the manufacturing industry, such as the skills gap and the shortage of girls in STEM (Science, Technology, Engineering, and Math) subjects in comparison to boys.
MFG DAY also is in favor of reshoring or bringing manufacturing jobs back to the organization’s headquarters rather than outsourcing overseas. Our MPS team supports reshoring, STEM education, and efforts to bridge the skills gap.
Inspiring Future Generations
Inspiring younger generations to seek manufacturing careers is something we are passionate about here at MPS. Our clients span many industries including: industrial, military, telecom, aerospace, automotive, and consumer electronics. Learn about each field by attending National Manufacturing Day events in your community.
MPS Industries designs and manufactures top-quality magnetic components, including a range of inductors and transformers. Stay current on relevant industry developments by following our blog and by connecting on Twitter and LinkedIn. For electronic components from an ISO 9001:2008 certified company, MPS has your best interests at heart. Contact us for your next order.
The first week of August is “National Simplify Your Life Week.” As industry leaders in magnetic component manufacturing, it is our team goal to provide our customers with nice, clean, and easy-to-mount packaging solutions. Customer feedback continually reassures us that our method works, keeping both your mechanical and electrical engineers in tip-top shape and spirits.
As other magnetic companies fail to keep up, we’re eager and ready to pick up the slack. We understand that our customers are looking to invest in higher frequencies and greater product performances. But what do we have that sets us apart?
The Benefits (& Simplicity) of Working with MPS
Simply put, we help you easily manage your power conversion application needs by simplifying your power conversion process.
Our customizable packages include:
Packaging optimization based on cooling method and mounting configuration
Heat sink integration (per request)
Can provide 3D STEP files upon request
Low-cost CNC machine cutting resources for enclosures/brackets for prototype purposes
Embedded temperature sensors (per request)
Low or no NRE
Domestic engineering support (in both CA and TX)
Domestic and off-shore manufacturing
Domestic and off-shore prototyping capabilities
Ability to package “drop-in” solutions for standard inductors, like the HWI4427series or the HWI4434series (these can be put in series or paralleled)
MPS Industries is on the leading-edge of design for high-efficiency magnetics, from micro-grid to utility, low kW to MW systems. We construct custom and semi-custom high-performance magnetics for automotive, aerospace, industrial, medical, defense, military, telecom and consumer electronics. Call or e-mail us today for your industrial magnetic needs! Or request a sample/quote.
Keep in Touch!
If you missed our email blast on easily managing power conversion applications, sign up for our newsletter today! Contacting us (above) will bring you one step closer to staying in the know. By clicking on the image below you will be able to follow or subscribe to our company blog.
Or simply add and interact with us on Twitter and LinkedIn for the latest industry updates!
MPS Industries, Inc. is happy to spread word of the annual National Safety Month this June. The initiative, run by the National Safety Council (NSC), is supported by thousands of businesses and organizations across the country. National Safety Month aims to promote workplace safety and reduce common risks of death and injury on the job, at home, and everywhere in between.
Our team is proud to be a part of this important event year-round. At MPS, we believe safety should be a critical concern in all processes, and we’re constantly looking for ways to innovate and improve our safety initiatives. To ensure optimal safety and health of our clients, we take into account the specific safety risks inherent in each industry we serve — from automotive, industrial, and military to medical, aerospace, and consumer electronics.
As part of our ISO, we closely monitor final product pass-rate, making sure we continually improve our quality processes, products, and procedures. We provide safety only using parts that pass final inspection and testing before they are shipped. We also make sure to store any failed parts in an isolated designated area so that they are never used. Needless to say, bad parts are extremely hazardous in our field. This is another reason we support speaking out during National Safety Month. Here at MPS, our staff works hard to provide our customers with quality parts to avoid any potential safety issues in your system or installation.
Making Safety a Year-Round Priority
As a manufacturer of magnetic components such as transformers and inductors, we place particular emphasis on electrical safety and the unique dangers posed by electrical applications. According to an OSHA report, electricity is responsible for 12% of all young employee workplace deaths, with about five workplace electrocutions occurring each week.
Electrocutions are primarily caused by accidental contact with overhead power lines, live circuits in panels, poorly maintained cords, and even the occasional lightning strike. Minimal electricity is needed to cause harm, making stringent safety precautions critical. Also, the risk of fire increases when electrical systems are not properly maintained and monitored. While the hazards of electric shock can never be fully eliminated, they can be controlled with the proper protection and training.
The NSC recommends having a certified electrician regularly inspect all tools and machines to ensure compliance with electrical code requirements, as well as only permitting trained and authorized personnel to work on your electrical equipment.
At MPS we stress the safety of our employees when it comes to operating the electrical machinery and tools used in all of our manufacturing processes. For more electrical safety tips that we use, check out the NSC’s full list of recommendations or browse the resources on their homepage.
If you’re interested in learning about any of our products or services, or would like to discuss how MPS Industries can help you meet your magnetic needs, contact us today. And don’t forget to follow our blog, Twitter, and LinkedIn to stay up to date on the latest industry products and trends.
It’s one thing to be a generic electronic component manufacturer, churning out the same identical transformers, inductors, and magnetic components on a day-to-day basis. There’s certainly a market for that – plenty of applications use off-the-shelf parts. But for custom components, you need a manufacturer who can combine a task-oriented sales force and a smart, driven engineering team that is up for solving any task you throw their way. This means coming to a manufacturer like MPS Industries.
Sales Driving Engineering
Sometimes, a component is purely customer-driven – a current or potential buyer has a specific need to be filled, and they need a great company to work with. Our sales staff will meet with the customer, discuss the needs and requirements of the component, and then work with the engineering team to develop a product that meets the need. The sales team can then help the customer tweak the product as needed, develop pricing, and work on prototypes and production quantities.
Engineering Driving Sales
Other times, our engineering team drives the sales of traditional and custom components through their innovative design. Maybe one of our team members hits on a component that fits an unfilled niche in the market, or has an epiphany over lunchtime on how to improve an existing component. Or, maybe one of those happy accidents occurs where a component seemingly wills itself into existence. In all of these cases, our team would produce a prototype, and place the product in our list of components on our website. If a customer then inquiries about a specific part on our website, the sales team can quote pricing and work with engineering on any customer requested modifications.
Working Together for the Customer
In the end, sales and engineering are working towards the same final goal – satisfying your needs as a customer, regardless of your requirements or industry. Here at MPS, we serve industries including (but not limited to):
Military and Aerospace
If you are interested in working with us here at MPS Industries, contact us today to talk to our staff and set up a meeting to discuss your industry needs. Even if you don’t have an immediate need, we’d be happy to hear from you and start developing a relationship. You can keep in touch and see what we are doing through our LinkedIn page, our Twitter, or by checking back here at our blog on a regular basis.