Custom Power Transformers
Custom Power Transformers
for Critical Applications
As a leading power transformer supplier, MPS Industries specializes in designing and manufacturing custom power transformers for aerospace, automotive, medical, and other sectors. We offer power transformers that can be customized to overcome complex challenges, such as multiple operating frequencies, countering proximity effects, or addressing differing impedance levels.
This comprehensive guide will detail the core types, materials, and functions of custom power transformers. Below, learn how these can be applied using manufacturing capabilities and cross-industry expertise to create optimized transformer designs for critical industries
The Importance of Custom Transformer Design
Standard transformers are designed to convert input voltage into output voltage. While they are generally engineered to conform to broad market specifications, these one-size-fits-all solutions may not cater to the exact technical, environmental, and space requirements of demanding industries.
Custom transformers eliminate these issues through meticulous engineering that matches precise power requirements, voltage levels, and load conditions. Aligning with specific end-use needs allows users to take advantage of the following benefits:
Efficiency Gains
Extending the Lifespan of Equipment
Optimizing Performance and Reliability
Electrical transformer manufacturers consider relevant physical, technical, environmental, and space configurations to offer an effective solution.
Lower Energy Consumption
Reduced Time and Costs Correcting Performance
Key Factors in Power Transformer Specification
From construction materials to mounting styles, many aspects of a transformer can be optimized to meet the application’s specifications. Some key factors to consider include:
- Board or chassis space
- Cooling requirements
- Energy losses
- Frequency ranges
- High dielectric and voltage designs
- Low-profile, sealed transformer, or toroidal design
- Mounting options
- Power and safety requirements
- Proximity effects
The process may involve selecting specific terminals, custom leads, and connectors to ensure proper integration. Key electrical parameters such as transformer ratings and desired voltage outputs must be assessed, as well as any unique power requirements. The transformer's operational environment dictates the necessary ventilation or ambient temperature ranges.
- Core Material and
Geometry SelectionCore Material and Geometry Selection
A successful transformer design must integrate high-quality, durable materials that can meet the unique demands of the given application. While a conductor can consist of aluminum or copper, the core material can include the following elements:
- Amorphous metals
- Metallic tape-wound cores
- Ferrite ceramics
- Powdered iron alloys
- Distributed gap powdered cores
- Silicone steel
The conductor wire geometry is broken down into the following categories:
- Litz
- Rectangular magnet
- Round magnet
- Square magnet
The core type can significantly impact noise rejection and overall performance. Laminated cores are a popular choice for low-frequency loads, and ferrite cores are often used for high-frequency isolation.
- Winding Configurations
and IsolationWinding Configurations and Isolation
The physical distance allocated between the windings, as well as the insulation materials used (i.e. insulaeted wire coatings, tapes, other insulation materials between windings) determines the insulation strength and is assessed based on several factors to optimize the performance of a custom power transformer, including:
- Litz
- Round magnet
- Rectangular magnet
- Square magnet
This is especially important for high-voltage applications with frequent or ongoing exposure to altitude, contaminants, or moisture. In addition to considering isolation, winding configuration can also impact leakage inductances, making it critical to factor into many differing applications.
- Thermal
ManagementThermal Management
Systems that operate in fluctuating climates or confined spaces will require materials that can handle thermal stress, some with an insulation rating up to 220 ºC, far exceeding the capabilities of standard power transformers. Cooling parts to reduce temperature rise is also an important part of meeting thermal management requirements. Encapsulation options are ideal for outdoor environments or applications prone to heavy vibration.
- Safety and Regulatory
Standard ComplianceSafety and Regulatory Standard Compliance
Adhering to safety and regulatory standards such as UL, IEC, or CE is crucial for custom power transformers to ensure the prevention of electrical hazards like fire and shock while meeting strict safety requirements for factors such as leakage current, clearance, and temperature rise.
Types of Custom Power Transformers We Manufacture
At MPS Industries, we design and manufacture custom power transformers with sufficient electromagnetic induction capabilities to transfer energy between circuits for conversion or voltage isolation purposes. They can be divided into the following categories:
Single-phase custom transformers. Utilizes a single-phase alternating current to lower or raise the voltage from each side of the transformer. The number of primary and secondary windings determines the change in voltage levels.
Three-phase custom transformers. Three single-phase transformers are wound onto a single three-legged core. Three coils are connected sequentially to match the input power, transforming the voltage from the utility to the desired level.
Switch Mode Power Supply (SMPS). A semiconductor switch regulates the flow of electricity to the DC power source, stepping the current up or down according to the specific application needs.
Our custom solutions minimize energy loss and have specific voltage transformation specifications.
Power transformers we can customize include:
Flyback transformers. Transformers that store energy in the magnetic field of the core and release it in controlled pulses. These are typically used in power supplies and high-voltage applications and are engineered for precise voltage regulation and efficiency.
Toroidal transformers. Transformers with a donut-shaped core. These designs minimize magnetic flux leakage, resulting in higher efficiency, lower operating temperatures, and very low noise.
Other types of power transformers can also be engineered according to exact specifications. These include current sense transformers and isolation transformers, as well as audio transformers, radio frequency (RF) transformers, balun transformers, and video isolation transformers.
The MPS Custom Design and Manufacturing Process
Our experienced engineers work closely with clients to understand your electrical and mechanical requirements, conducting an in-depth analysis to determine the best possible configuration of conductors and core materials. Our custom design and manufacturing process involves the following steps to accommodate the specific requirements of an application:
Analysis of Project Requirements
Design
Performance Testing and Validation
Customer Pre-approval
Production
Our custom power transformer designs accommodate demanding industries and high-sensitivity applications. We can provide transformers to power medical lasers and electroshock devices in the medical industry that require meticulous isolation and low leakage current for patient safety. In defense and automotive applications, our process works to ensure the transformer’s reliability in extreme temperature cycling and mechanical stress.
Partner With MPS Industries
With decades of proven experience as a custom transformer manufacturer, MPS Industries partners with clients across a diverse range of industries to develop custom power transformers for unique technical, environmental, and space requirements while meeting key quality and performance standards. MPS Industries maintains a certified quality system under ISO 9001:2015 and ISO 14001:2015, as well as environmental compliance with RoHS III, REACH, and similar requirements.
Contact us or request a quote today to learn more about our custom power transformer manufacturing capabilities and how we can meet your industry’s requirements.