Product Design Meets Engineering:
A Toroidal Transformer for Deep Sea Underwater Use
Case Study
5 min read
Type:
Customer:
Challenge
Product Design
One of the largest Marine /Defense OEM Equipment Manufacturers in the World
To design a toroidal transformer that has a smaller footprint, better thermal management, and improved performance to replace their current transformers.
The Need For Custom Transformer Designs
Power electronic components, especially magnetics, are a vital part of any electronic device. These magnetic parts, which include transformers provide a steady supply of power which transfer energy from one circuit to the next while stepping up or stepping down the voltage. Highly specialized machines require complex custom magnetics to optimize their performance for use in unique industrial applications. They span every industry including medical instrumentation, power supply equipment, aquaculture, satellite communications etc. Some of these applications require the electrical components to be able to withstand very corrosive environments and settings.
A toroidal transformer is a type of electrical transformer that uses a donut-shaped (toroidal) core made of a magnetic material, typically iron or similar material. The core is constructed as a closed loop, with primary and secondary winding wires wound around it.
Some key features and characteristics of toroidal transformers are:
Donut-Shaped Core
The design minimizes air gap within the core, making it more efficient at transferring electrical energy.
They are known for high efficiency and low electromagnetic interference (EMI) due to their compact, symmetrical design. The closed-loop core design reduces magnetic leakage and minimizes loss of energy.
Because of their low EMI and reduced magnetic field interference, toroidal transformers produce less electrical noise and hum.
The toroidal shape allows for a more compact and lightweight design compared to other types of transformers, which can be advantageous in space-constrained applications.
Higher Cost
While toroidal transformers offer several advantages, they tend to be more expensive to manufacture compared to traditional laminated or EI core transformers. However the efficiency and performance benefits may justify the cost for specific applications.
Designing a Toroidal Transformer for a Deep Sea Underwater Application
A large OEM customer in the Marine/Defense industry approached Velatron Technologies to replace their current transformers with three main requirements. It had to have a
Smaller Footprint
Better Thermal Management
Improved Performance
The customers request demanded Velatron Technologies specialized expertise in designing transformers. Several of the company’s capabilities were put to work on this project, including computer-assisted design, precision toroidal winding, custom part fabrication, epoxy encapsulation and comprehensive computerized product testing.
This project’s product design took place over two stages. The first was at Velatron Technologies 18,000 sq ft facility in Kitchener, Ontario. Engineers at the facility first constructed computer models using the customer’s base requirements and key parameters. Simulations were then performed using the CAD model to iterate and finalize designs for prototype units.
Velatron Technologies’ method of operation is founded on continuous improvement. Once the prototypes were completed, they were then sent to the customer facility to test in their products and verify performance. The customer found that the prototypes exceeded the requirements which allowed Velatron Technologies to start manufacturing the part.
Manufacturing Process
Final Design
Outcome of the Design Process
The new toroidal transformers exceeded all the customer requirements. Velatron Technologies engineering team was able to significant decrease the footprint while simultaneously increasing thermal regulation efficiency and reducing full load voltage errors as seen in the summary below:
15% reduction in volume.
6% reduction in weight.
35% improvement in thermal management.
Improved voltage output accuracy from +.84% to +0.3%.
6% improvement in voltage regulation
“Throughout [our] 20+ years of working together , [Velatron Technologies] has consistently been recognized as one of our most valuable vendors. Their profound expertise in magnetics has been truly invaluable, and their commitment to quality and customer support remains unparalleled.”
Gary C, Site/Operations Manager
This case study required Velatron Technologies to design and manufacture a custom solution to client’s requirements that leveraged its capabilities in multiple different areas.
Some takeaways from the project were:
Transformer design impacts thermal management and performance.
Toroidal transformers offer a unique design solution for multiple product performance issues.
Velatron Technologies has been a leading designer and manufacturer of custom transformers, inductors, and wound coils for more than 78 years. If you are looking for help in magnetics whether it be product design or build to print, contact us below.
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