Power Transformer Reliability is a Major Concern of Transformer Manufacturers

Around the globe different sectors share a growing concern over the reliability of the power transformer in operation. It would be a mistake to imagine that only power generation authorities or companies have any kind of need for power transformers . This is understood by all transformer manufacturers . Within power systems anywhere transformers form a substantial part of the asset costs. So it is critical that the power transformer in use is reliable too.
Transformer manufacturers prefer to use national standards like ANSI, NEMA and others which address many of the elements influencing operating environment of the transformer and provide recommendations or standard values wherever applicable. Weather conditions, location, electrical loading, operating methods, system parameters and application are various elements of the operating environment that need to be documented thoroughly while designing any power transformer .
The design engineer must get all the needed information within the specifications and any clarification, if needed, must be obtained from the user or use parameters detailed in the national industry standards. Failure to do so could result in decreased service life and premature failure. It should be kept in mind that heat and moisture related contamination are the two greatest enemies of a power transformer's operation.
Quality control measures used by transformer manufacturers will influence the finished product as distinguished from the prototype created during design. The transformer manufacturers understand the importance of ensuring that the manufacturing process does not deviate from the design in terms of materials used, processes, handling, machines and personnel. The manner of shipment and installation will also determine the longevity of the power transformer . This is because any mishandling during shipment and installation can lead to failure of the product at an early stage.
One way of ensuring the reliability of a power transformer is to have scheduled or regular maintenance, not just repair maintenance. With energy needs spiraling the world over it is essential that the key components of power distribution networks — transformers — are equal to the challenge of assuring uninterrupted power supply.

Reliable Transformer Manufacturers Can be Found Right Here

There are all kinds of transformer manufacturers in the market. The trick is to find the reliable ones. This is particularly true if you are looking for manufacturers of all types of toroidal and bobbin wound components, and associated assemblies. You could do a search online or else check in the local Yellow Pages for such transformer manufacturers . Just check out what attention they pay to their customers' requirements, how far they are willing to customize their products as well as what quality control measures they have in place. Ensure that they can offer you options on laminated transformers, toroidal transformers, E and C-cored transformers, ferrite cored components as well as a range of UL Approved toroidal transformers.
The most reliable transformer manufacturers would be able to manufacture and supply any quantity from one off to many thousands off and are able to design to meet customers' electrical specification, or can build to print. If their manufacturing unit is geographically located far from where you need to set up transformers or other related products, they will normally be able to put you in touch with transformer suppliers . Ever since the transformer principle was demonstrated in 1831 by Michael Faraday it has been used to transfer electrical energy from one circuit to another. Over the decades since then transformers have been put to many uses which impact power level, frequency range, voltage class, cooling type, application function, end purpose, winding turns ratio.
There are various kinds of transformers like the current, isolation, power, electric, audio, fly back, high voltage, low voltage, step down, push pull and isolation transformer. The best transformer manufacturers can offer you options on each of these kinds. High voltage transformers are used in CRT displays, medical equipment and in amplifiers too. Laminated transformers are widely used for lighting, power-driven gates, control of alarms, air conditioning and vending mechanisms. Just ask your transformer suppliers as what would be the most appropriate for your application in case you don't have a readymade blueprint.

Power Transformers are Critical to Modern Living

The world has come to be increasingly driven by electricity which makes the power transformer critical in every aspect of modern living. This is because power transformers are used in varied applications, not just by the manufacturers of electricity. These are the major transport systems like the railways, aviation, aerospace and underwater navigation. In their own unique ways these industries need power transformers to utilize electric power within their unique specifications and convert into mechanical power. In this manner they are different from electronic transformers, which are basically transformers used for electronic purpose.
A power transformer is differentiated by end usage. A linear power transformer is mostly used in radio, project kits, VCD and etc while the switch mode power transformers can be found in computer monitors, TVs, fax and so on. A transformer consists of two or more coils wound on the same core. Power transformers can be manufactured in a wide range of sizes. They can be small enough to fit into a microphone, or they may be extremely large units that weigh hundreds of tons and used to interconnect national power grids.
Iron is usually used as the core material of power transformers. The basic property of a power transformer is to change AC voltage. A transformer cannot change direct current voltage. A step down transformer has a lower AC output voltage at its secondary winding than the AC input voltage to its primary winding. Conversely, a step up transformer has a higher secondary than primary voltage.
The transformer lamination or coating of shellac, enamel or varnish is to insulate adjacent turns from shorts between winding. Power distribution transformers may include highly efficient amorphous metal core transformers, package substations, battery chargers, switchgear and associated electrical equipment. These need to be checked periodically to ensure uninterrupted power supply. Checking a linear power transformer is quite straight forward. Apply the a/c voltage to the primary winding and expect output voltage at the secondary side. No or low output voltage means the transformer winding has open or shorted winding. Look for any evidence of overheating, such as darkened or blackened areas or a burnt smell.

Preserve the Safety of Equipment with Medical Isolation Transformers

Everyone knows that transformers have a special application in medical equipment. Therefore maintaining their safety quotient becomes paramount to protect patients and healthcare personnel from things like electric shock or even electrocution and noise pollution. A medical isolation transformer serves precisely that function since a medical isolation transformer provides galvanic isolation that is utilized for protection against electric shock, suppression of electrical noise in various receptive and sensitive gadgets, and transmission of power among two circuits. Laboratory gadgets and other electronic equipment thus get electrostatic shields from such medical isolation transformers between windings that are used for power supplies.
Custom wound transformers take into consideration needs like thwarting capacitance that enhance the primary and secondary winding linkage causing a higher frequency sound or increase of energy voltage levels from one stage to another through induction of electrical energy from one winding to another. These custom wound transformers often utilize unconnected bobbins on both coil windings in which the windings are only wound on top of each other with insulation in the middle. The purpose of opposing the interference caused by ground loops and minimization of the coupling of the coils is served by this kind of isolation.
Custom wound transformers have to be used wherever you need to separate the source of the power from the actual user or device while maintaining the supply of current from one circuit to another. Power spikes are one of the main threats to sensitive electronic equipment. An isolation transformer which may or may not be a custom wound transformer helps to ensure that the electrical system is fully protected against transients. You certainly need to have voltage stabilizing equipment to protect against sudden surges or drops in voltage which can damage or even put sensitive devices out of order.
Just remember that custom wound transformers have more applications than in medical isolation transformers. Whatever be the industry you need it for – aerospace, railways, general electronics or test equipment – get in touch with a reliable manufacturer.

Custom Transformers or Toroid Transformer: The Choice is Yours

Custom transformers are those which are made to your specifications and customized to your special needs. Your needs could range from many different kinds of transformers and inductors including laminated transformers, toroid transformers , E and C-cored transformers and ferrite cored components. Just make sure that the manufacturer you deal with works very closely with its customers to establish long term partnerships the way SIGA does.
Customization relates to a number of factors like installation site, installation environment, even application. So when you order custom transformers obviously you are taking into consideration factors like where they are going to be installed. Strictly speaking custom transformers should remain functional even under severe weather conditions. If the area where they need to function is prone to dust storms or is simply very dusty under normal conditions, you need to underline the fact to the manufacturers. The safety of operations can be compromised by the fact whether the custom transformers are fire proof or not.
Some of the critical specifications of any custom transformers relate to output and input frequency and voltage. The input voltage may vary from few volts to hundreds of volts and even kilovolts. The output power rating is totally dependent on the kind of application you need the transformer for. Winding turns ratio, with popular choices like step-up, step-down, variable and multiple winding can also be customized. These transformers may be further described by their essential construction. A lot of existing transformers are lesion on toroidal cores. Toroid transformers are used because they offer multiple magnetic advantages and hence they are used as inductors in applications such as low-frequency transmitters and receivers.
The greatest advantage of a toroid transformer is that this component offers higher and better inductance. A typical toroid transformer would come in a feature resembling that of a doughnut. Unlike the other inductors toroids hardly interact with neighboring components. Not only is it a cost effective component, the Q values are also great. Add to that you can find them in different diameters and width. After all a toroid transformer comes in two different forms, namely ferrites and the powdered iron.

Be Kind to the Environment: Use an Isolation Transformer

There are experts who hold to it buckle and thong that the only way to eliminate common mode noise is to use an isolation transformer . This reduction of noise and other kinds of sound makes the isolation transformer critical in the prevention of any sound or noise created by connecting the signal of the audio amplifier to the speaker output circuit without any connection created between the two. It helps in separating the amount produced by the audio amplifier to the piece of module from the amplifier. It facilitates the connection of the amount produced by the radio frequency amplifier to the transmitted signals towards the direction of the antenna.
On the other hand, an isolating transformer is used both when sending power and signals. It has a built-in special insulation placed between primary and secondary windings which are discernible when holding out a high voltage of a thousand to four thousand volt range. Isolating transformers include very small transformers, such as four transformers in a minute dual in-line chip package that are used to isolate high-frequency low-voltage pulse circuits. The downside is that they can be quite expensive compared to conventional transformers.
An isolation transformer provides galvanic isolation that is utilized for protection against electric shock, suppression of electrical noise in various receptive and sensitive gadgets, and transmission of power among two circuits. Many don't realize it but telephone lines too need an isolation transformer because they use digital information which requires periodic amplification. Isolation transformers carry out the separation of direct current components from the signal to the control of every amplifier on the line. An isolating transformer can carry out the task in the input and output of each amplifier.
An issue with transformers is that they have an output voltage that is dependent upon the loading on the transformer. The output voltage of an isolation transformer under no-load is higher than the output voltage under full load. This leads to variance in the terminal voltage with varying loads. The isolation transformer comes into its own where there is a requirement to remove earth leakage.

Pick on Transformer Manufacturers Who Pay Close Attention to Customer Needs

There are all kinds of transformer manufacturers out there. You need to be certain that the transformer manufacturers you deal with actually pay close attention to your specific requirements. The most reliable are the ones who are involved in the production of an increasingly wide range of high quality transformers and inductors. With some of them special coil assemblies have formed a significant proportion of the production. The experience and expertise which has been accumulated by these transformer manufacturers has enabled many ingenious development ideas to be brought to the production stage.
Check to see whether the transformer manufacturers you are negotiating with can produce a large variety of non standard assemblies. The best are the ones who have the expertise to apply to the construction and winding techniques for standard type assemblies where special performance or test parameters have been specified. Many of these companies will assess any specific individual power requirements and aim to supply cost effective and reliable power solutions that work for the customer and the environment.
If you don't want to deal directly with transformer manufacturers, then you can look for transformer suppliers . The savvy transformer suppliers know what kinds of choices must be offered to the buyers in the market. Parameters for transformers may differ as to installation site, installation environment, applications and specifications. Reliability is a key function of transformers and transformer suppliers understand that very well. Ask them about the safety factor involved. Depending on the geographic location you need to ensure that the transformers are heat proof, weather proof and/or earthquake proof.
Trustworthy transformer suppliers know that with no moving parts, transformers require minimal maintenance and are capable of withstanding overloads, surges, faults, and in some cases even superficial physical damage. While transformers can withstand a lot of electrical fluctuations, they do deteriorate with age, and thus need constant monitoring to detect and correct problems before they escalate into expensive repairs. So ask whether the transformer manufacturer will offer an AMC. More than other assets, transformers cannot afford to beak down.