Tag Archive: transformers

  1. The Complete Guide to Flyback Transformers

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    When a power converter doesn’t require very high power – i.e. 200 watts or less – flyback converters are good choices due to their lower cost, decreased quantity of components, and simple design. Flyback converters are used in a variety of equipment, including televisions, LED lighting arrays, telecommunications, and industrial systems. 

    One of the main components within a flyback converter design is the transformer.

    The primary distinguishing feature of a flyback transformer is a gapped core that holds energy from each input cycle. The energy stored in the transformer’s core allows it to efficiently increase or decrease the voltage as needed for equipment operation.

                         

    How Does a Flyback Transformer Work?

    A flyback transformer circuit looks similar to other isolated transformers, and it uses many of the same components, including a switch, output rectifier or diode, and input and output capacitors. Unlike other isolated transformer designs, however, flyback transformers store energy within the core without the need for a separate output inductor. This highly efficient construction facilitates cost-effective power usage by ensuring circuit isolation and allowing both positive and negative output voltage. 

    Switch

    The most common switch design for flyback converters is the metal oxide semiconductor field effect transistor (MOSFET), which consists of three terminals that modify the intensity of and redirect electronic signals. Switches for flyback converters may also be composed of bipolar transistors, gallium nitride (GaN), or silicon carbide (SiC). 

    When the switch is closed (or in the on position), current flows through the primary coil and gets stored in the core. When the switch is off, the current flows through the secondary coil and is transmitted to the output load. The output voltage is modified by adjusting duty cycles and turn ratios between the primary and secondary coils.

    Coupled Inductor

    The coils that transmit and store energy in a flyback transformer form a coupled inductor. The two coils are linked by mutual electromagnetic inductance—when energy flows into the primary coil, it creates a magnetic link and generates voltage in the second coil.

    Coupled inductors are used to modify voltage. They can also be used to isolate circuit components to enhance the efficiency of electrical flow. When the switch is on, energy flows into the primary winding and gets stored in the core. The stored magnetic flux flows into the secondary winding when the switch is turned off, and the energy is then distributed through a diode.

    Output Diode

    Current may be increased, decreased, or modified as it flows from the second coil. Diodes ensure that the current flows unidirectionally toward the output and keep the voltage as necessary to meet the needs of the application. Since current from the transformer can fluctuate based on the input voltage, the diode and output capacitor help to keep the outflow of current steady.

    Input and Output Capacitors

    Capacitors in flyback transformers can be installed on both the input and output ends of the current flow. They are used to store energy so that it can be released in controlled amounts. Input capacitors control the flow of energy into the primary coil, while output capacitors manage the output to ensure a smooth flow of energy at the desired voltage and current.

    Applications of Flyback Transformers

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    The Complete Guide to Flyback Transformers

    Flyback transformers are highly efficient, compact, and cost-effective, which makes them ideal for numerous applications and industries. Some of these uses include: 

    • DC-DC and AC-DC power supplies. Flyback transformers are used to facilitate the conversion of AC to DC and DC to DC in power supplies for a variety of devices that require current and voltage modification.
    • Televisions and computer monitors. The first flyback transformers were invented for use in televisions, and they continue to provide a reliable source of steady voltage for computer monitors, televisions, and other visual displays.
    • Aerospace components. The compact size, efficiency, and accuracy of flyback transformers make them perfect for use in electrical equipment found in aerospace applications.
    • Telecommunications equipment. Flyback power converters are often used for DC to DC power conversion in telecommunication systems. 
    • LED lighting systems. Flyback transformers are used in LED drivers to regulate the output current from the power supply. 
    • Capacitor and battery charging systems. Flyback transformers convert current and transmit energy in capacitor and battery chargers. 
    • Converters and inverters. Since electrical converters and inverters operate at varying frequencies, flyback transformers adjust the voltage and current levels for a consistent power supply.
    • Industrial systems. A broad range of industrial equipment uses flyback transformers to enhance operational efficiency and improve the performance of electrical components. 

    Advantages of Using Flyback Transformers

    Flyback transformers offer numerous advantages over other converters, including:

    • Circuit isolation. A key benefit of flyback transformers is their circuit isolation, preventing electrical hazards and providing improved safety, particularly for those in the vicinity of high energy electrical systems.
    • Compact size. The simple design of flyback transformers makes them smaller, lighter, and easier to install than comparable transformers – meaning they are likely to be a better fit within your overall electrical system. 
    • Cost-effectiveness. Flyback transformers are generally about the same investment as other transformers. However, flyback converters – of which flyback transformers are a key component – are typically less expensive than comparable converters, since they are made up of fewer components. This is important to keep in mind if you are considering flyback transformers and their application within flyback converters. 
    • Convenience. You can use flyback transformers to isolate and manipulate multiple output voltages from one control. 

    Considerations When Designing a Flyback Transformer

    Flyback transformers are available in numerous designs and configurations. Before attempting to select or design an appropriate flyback transformer for your needs, gather the following data about your application to present to your component provider: 

    • Maximum size and weight requirements
    • Switching frequency
    • Max duty cycle
    • Mounting type: surface mount, through-hole, etc.
    • Input voltage
    • Power and Output voltage (load)

    Quality Flyback Transformers at MPS Industries

    MPS Industries, Inc. is proud to offer an extensive range of quality electronic components for our customers in a wide range of industries, from aerospace and automotive to military, telecommunications, and renewable energy. We specialize in custom-manufactured inductors, power supplies, current sensors, and transformers. Our extensive experience in circuit design and engineering allows us to create unique electronic components to meet the most stringent industry standards and specifications. 

    To learn more, visit our Flyback Transformers product page, or contact our experts to discuss your magnetic component needs. 

  2. Switch Mode Power Supply Transformers FAQ

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    MPS Industries is a U.S.-based magnetic components manufacturer specializing in the design of custom transformers, inductors, common mode chokes, current sensors and many other custom magnetics. 

    Switch mode power supply (SMPS) transformers use different switching topologies, transferring the required power from input to output in the electronic systems. Here, we have answered some of the most frequently asked questions regarding this unique and efficient transformer technology. 

    How Does a Switch Mode Power Transformer Work?

    Switch mode transformers are used within switch mode power supplies to provide power to a range of commercial and industrial electronic systems. These transformers are highly efficient at converting alternating current (AC) main power to direct current (DC) output voltage. The AC main power is filtered through a capacitor when power is switched on, allowing it to be converted from AC voltage with rectifiers to unregulated DC voltage. Using a regulator, the switch mode transformer then converts this unregulated DC voltage into regulated DC output voltage at different voltage levels.

    What Are the Common Applications of a Switch Mode Power Transformer?

    Most modern electronic applications rely on power supplies that can very efficiently convert low-frequency main AC power to the well-regulated DC voltage required by the circuit. SMPS transformers are often preferred due to their ability to provide a tightly regulated output voltage. A few specific applications of these transformers include:

    • Medical devices
    • Communication devices
    • Commercial power supplies
    • Security systems
    • Support supplies for PLCs
    • Audiovisual products

    What Makes Switch Mode Power Transformers Different From Other Transformers?

    By internally switching the transistor between an on and off state, switch mode transformers can minimize a power supply’s energy dissipation, resulting in a higher efficiency with less heat produced when compared with those transformers used in linear power supplies. Linear power supplies typically require large power transformers to step up or down voltage before it can be applied to the regulator circuit. In general, linear power transformers tend to be bulkier and substantially less efficient than switch mode power transformers which are smaller and compact given their higher operating frequency.

    What Are the Different Switch Mode Power Transformer Topologies?

    The topology of a switch mode power transformer refers to its specific circuit configuration. A few of the basic topologies used in power design include:

    • Flyback: The flyback is an isolated topology in which energy accumulated and stored during the “on” state of the switch is transferred to the output during the “off” state. This is one of the simplest and lowest-cost isolated topologies and is best suited for lower-power applications.
    • Forward converter: Rather than storing energy in the core, forward converters directly transfer energy between the primary secondary sides. Like flybacks, forward converters are best suited for lower power applications.
    • Push-pull: The push-pull topology is basically a forward converter with a dual-drive winding, making it much more efficient at utilizing the core of the transformer when compared with flybacks or simple forward converters.
    • Half-bridge: The half-bridge is a type of forward converter topology. Half-bridge topologies are designed so that the load current can flow in two directions.
    • Full-bridge: The full-bridge topology is essentially two half bridges. It has similar switch ratings as the half-bridge but provides twice the output power.
    • Gate-drive: Gate-drive transformers are used in switch mode power supplies to control circuit timing through the delivery of electrical pulses.

    What Are the Advantages of Using a Switch Mode Power Transformer?

    When it comes to modern electronic applications, SMPS transformers offer several clear advantages over alternative methods of converting DC power. These include:

    • Higher efficiency: The regulator’s switching action allows it to be in either on or off mode. Because of this, energy dissipation is minimal and power can be used extremely efficiently.
    • Lighter weight: Compared with linear transformers, switch mode power transformers are much smaller and lighter. This is possible due to their high operating frequency and highly efficient power usage.
    • Greater flexibility: Unlike linear transformers, switch mode power transformers are capable of creating high conversions in both voltage-boosting and voltage step-down applications.

    What Are the Design Considerations for an SMPS Transformer? 

    When designing an SMPS transformer, it is important to consider the following parameters:

    • Input and output voltage
    • Output power or current
    • Switching frequency
    • Operating mode
    • Maximum duty cycle of the IC
    • Safety standards
    • Temperature requirements
    • Size requirements

    Three primary design considerations are core shape, type, and size, all of which should be chosen based on your application’s power requirements, switching topology, and anticipated switching frequency. Certain core materials have properties that make them better suited for higher-frequency applications. It is also important to make sure the components and wiring do not go above their rated temperatures, as this will affect overall circuit reliability. Industry-specific safety requirements should also be kept in mind to ensure the compliance of your design with relevant regulatory standards.

    Are There Any Transformer Design Considerations for IC Chips?

    Generally, our customers’ design engineers will start with an integrated circuit/IC chip, which typically has some kind of reference design with suggestions on transformers and other components to be used with the chip. They can either start with the reference design and modify it to suit their application, or they might opt for their own custom design using the chip.  

    We currently work with several IC companies and are on some reference designs already. However, we can definitely work with the customer to supply transformers per their reference designs or create a custom design to meet their application needs.

    Contact MPS Industries for SMPS Transformer Guidance

    At MPS Industries, our electrical engineering team regularly provides magnetic component guidance and design assistance for even the most complex industrial systems. Whether you require minor modifications to a standard product or a complete custom design from scratch, our engineers possess the insight and resources to meet your exact specifications. We uphold a strong quality management system to make sure that every product we deliver meets or exceeds customer expectations and complies with all relevant industry standards.

    To learn more about SMPS transformers at MPS, check out the links below: 

    Contact us today about any of our magnetic component solutions or services!

  3. What is a Toroidal Power Transformer?

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    Transformers are electrical devices that rely on electromagnetic induction to transfer energy from one circuit to another. Among the most common types of transformers are power transformers, which are generally used in electrical systems to step up (i.e., increase) or step down (i.e., decrease) voltage levels between circuits. These transformers are available in several variations, each of which offers different performance characteristics. 

    The following article focuses on toroidal power transformers, including outlining what they are, what advantages they offer, what industrial applications in which they are used, and how they differ from standard transformers. 

    What Is a Toroidal Transformer?

    Similar to other transformers, a toroidal transformer operates under the principles of electromagnetic induction. It features a toroidal core surrounded by the primary and secondary windings. As current flows through the primary windings, it produces an electromagnetic force (EMF) that generates current in the secondary windings; this process allows power to be transferred from the primary coil to the secondary coil. 

    Advantages of Toroidal Power Transformers

    Compared to other types of power transformers, toroidal power transformers offer a number of advantages, such as:

    • Greater efficiency. The unique shape of these transformers accommodates the use of shorter coils, which allows for lower loss levels and, consequently, higher efficiency in the system.
    • Lower operating temperatures. As toroidal transformers are more efficient than other power transformers, they produce less heat during operations, which translates to lower operating temperatures. This quality, in turn, reduces the need for cooling devices. 
    • Smaller footprint. The coils in toroidal transformers can touch and overlap without interfering with performance, which allows these transformers to be more compact than conventional power transformers. 
    • Quieter operation. These transformers produce less mechanical hum than EI transformers. 
    • Better protection against EMI. The primary and secondary coils covering the core act as a shield against the magnetic field produced, which protects nearby sensitive electronic equipment from being affected by the transformer during operations. 

    Applications of Toroidal Power Transformers

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    What is a Toroidal Power Transformer

    Toroidal power transformers find application in a wide range of industries, including: 

    • Aerospace
    • Audio/visual equipment
    • Automotive
    • Consumer goods
    • Lighting
    • Medical 
    • Military and defense
    • Power generation and distribution
    • Renewable energy
    • Security
    • Telecommunications

    Due to their compact size, they are often used in electronic devices and systems such as computers. Their quiet operation makes them well-suited for use in amplifiers, audio equipment, televisions, and other audio/visual systems. These qualities, combined with their high efficiency and reliability, are among some of the reasons why they are regularly used in medical equipment. 

    Toroidal Transformers vs. Conventional Transformers

    The main difference between toroidal transformers and conventional transformers is the core. 

    • Toroidal transformers have a donut-shaped core that is surrounded by the primary and secondary windings. This design allows for a more efficient transfer of power and more compact construction. Some of the other advantages these transformers have over conventional transformers include quieter operation and greater construction flexibility.
    • Conventional transformers—also knowns as EI transformers—have a core consisting of E-shape steel sheets and I-shaped caps. Compared to toroidal transformers, they come at a much lower price point. 

    Contact the Transformer Experts at MPS Industries Today

    MPS Industries is an ISO 9001:2015 certified manufacturer of standard and custom transformers. We offer toroidal transformers that accommodate between 50 to 30,000 VAC power and operating temperatures up to 70° C. Our products are made in the USA and comply with the following standards: RoHS, REACH, CE, CSA, UL, and ETL. To find out more about our toroidal transformers or other electronic products, contact us today.

     

  4. APEC 2018 is Just Around the Corner

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    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.

    Who’s Coming

    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.

    Networking Opportunities

    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.

  5. Manufacturing & Magnetics – An Important Industry Outlook

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    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.

    Clients will still be able to work with our experienced team to design and engineer custom electrical components as per request.

    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 TwitterLinkedIn, and our blog to receive the latest industry and in-house updates.

  6. Help the Manufacturing Industry Celebrate National Manufacturing Day!

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    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.

  7. The Automotive Recovery, Powered by MPS

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    Recent news and trends all point to a giant recovery for the American auto industry. Most major automakers saw moderate to large sales increases in 2012; one market research firm, Polk, now expects new car sales to increase by 6.6% in 2013, thanks to a recovering economy and growth in the pickup truck and midsize sedan markets.

    Last year, American auto company, Chrysler reported its highest sales since 2007. Meanwhile, the Japanese automakers have been recovering from the 2011 earthquake and tsunami that devastated factories and drastically decreased production; Toyota, for example, sold a record 9.7 million vehicles last year, and expects to sell even more in 2013.

    Whether you’re dealing with a German vehicle or an American one, a pickup truck or a compact car, quality products from MPS Industries are the best parts for automotive applications. We provide TS16949-certified manufacturing, and we also bring extensive experience with automotive requirements like IMDS and PPAP to the table. Our transformers and inductors are not only reliable and energy efficient, but they’re competitively priced to boot.

    No matter how severe the environmental condition or temperature, our magnetics are guaranteed to perform. We manufacture parts that can be used in fuel pumps, particulate matter sensors, and DC/AC inverters that can be used to power electrical devices inside of vehicles, like TV screens or DVD players. MPS Industries components are at work in every part of the car.

    2013 promises to be a one of the biggest year for vehicle sales in quite a while, and MPS Industries products will be there to make sure everything keeps running smoothly.

  8. Electronics and the eCommerce Revolution

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    With Black Friday and Cyber Monday in the rear-view mirror, the holiday shopping season has hit full stride. As expected, these two highly anticipated shopping days did not disappoint in 2012; in fact, Cyber Monday was most likely the busiest eCommerce day in history up 30% from last year.  In addition, both days proved that even traditional shoppers have become highly tech savvy consumers. As a leading manufacturer of electronic components for consumer electronics, MPS is thrilled about this latest trend. You will find our custom transformers, inductors, sensors, and power supplies in holiday gift favorites like laptops, printers, game consoles, DVR boxes, and just about anything, you plug in or charge. Tech focused companies like Best Buy, Amazon, and eBay had outstanding stock performances on Cyber Monday and most are expecting their strongest holiday seasons ever.  The way American’s shop and the products they shop for, has fundamentally changed.

    In order to take advantage of this massive retail paradigm shift MPS combines outstanding cost-effectiveness with the ability to support high volume production of your custom designed electronic components. Our team of design, production, and supply chain experts know how to get products to market fast. Therefore, you can get custom electronic components at the right price and in time to take advantage of the even the most chaotic holiday season.

    If you want to jump into the 21st century feet first, contact MPS today and let us show you the way to the future!