Creative Solutions For Complex Specifications

 

Electronic Craftsmen has been designing and building Switch Mode Power Supplies for over 20 years. Understanding SMPS fundamentals is critical in optimizing transformer design to achieve:

 

  • Smaller Size - Cooler Operation - Lower Losses
  • Appropriate topology
  • Optimal materials – frequency dependent

 

Example Types of Switch Mode Transformers:

 

  • Switching Converter
  • Flyback
  • Forward Converter
  • Push-Pull
  • Full Bridge
  • High Current
  • Buck - Boost
  • Half Bridge

 

 

 

Recent Work

20kW Switching Transformer for DC-DC Converter operating at 20-40kHz (EC Custom Model 215027)

 

20kW Switching Transformer for DC-DC Converter operating at 20-40kHz (EC Custom Model 215027)

Nominal Power: 20kW

Switching Frequency: 20kHz (can also operate at 40kHz)

Primary-secondary ration: 7:5 (1.4:1)

Primary voltage: 720V

Nominal output current: 60A

Approx. dim: 2.75”W x 4.25”H x 5.50”D

Approx. weight: 10Lbs

Application:  Custom Test & Measurement Equipment

Electronic Craftsmen Custom Transformer Model 215027

 

 

 

Switching Flyback Transformer, 200kHz, 60W, discontinuous mode

 

Switching Flyback Transformer, 200kHz, 60W, discontinuous mode

Copper Foil Input winding; 7x34AWG output and 41AWG HV output. EER35 Core (PC44), Class B (130C) insulation system.

 

 

High Voltage Switching Transformer, 36.5kVA @ 25kHz

 

High Voltage Switching Transformer, 36.5kVA @ 25kHz

Model 215006. Designed for HV laboratory application. Input 5kV @ 400A; Resonant output 60kV @ 200A with 60kVdc isolation with 100ms on / 5 mins off time. Epoxy encapsulated Litz wire coils assembled on Ferrite Cores.

 

Reliable, Innovative Designs.

Custom built for your application, assembled with care and precision.

 

 

Get A Quote!

 

Switch Mode / High Frequency / Ferrite Custom Transformer Capabilities at Electronic Craftsmen

  • Power: From mW to 200kVA @ 20kHz (typical)

  • Working Voltage up to 12kV (depending on frequency); multiple stages possible for higher outputs

  • Frequency: To 500kHz (typical)

  • Temperature Class to 220C (155C / Class F typical)

  • Weight: 0.06 oz / 1g to 550 lbs / 250kg

  • Multiple taps as required

  • Dielectric Strength (hipot) to 30kVac or 20kVdc

  • Parts can be vacuum varnished or molded with a variety of hard or soft encapsulant materials with thermal conductivity.

  • Wire sizes from 1-45 AWG or Copper Foil to 0.050in thick (in multiple layers for higher current); Litz wire for higher frequency

  • Regulation to specification

     

  • Manufactured using all known state-of-the-art magnetic core materials, including but not limited to electrical grade steel laminations, ferrites & powdered iron, nickel-iron alloy, iron amorphous metal strip-wound cores, nanocrystalline cores and small toroids.

  • Antifungal and non-nutrient coatings available

  • Corrosion resistant coatings & platings available

  • Standard or custom terminations & leads

  • Mounting Configurations: pcb-mount (horizontal or vertical), custom or standard brackets or stacked configurations

  • Designed to meet CSA & UL (safety) or MIL PRF 27 (aerospace / military) requirements upon request

  • MIL PRF 27 Grade 5 & 6 encapsulation available