Here’s an interesting experiment to try out if you’re bored and into electronics. The next time you’re at a social gathering -a cocktail party, Christmas party or maybe a family reunion- bring up the topic of custom transformers or switch mode transformers. Unless you’re in the middle of an Engineering convention, I’m willing to bet you get a blank look from ninety percent of the people around you, with the odd person assuming that you must be talking about the cartoon robots and wondering which one was “Switch Mode.” Then again, maybe its better you didn’t bring it up. Engineers are already having a reputation to rival that of accountants when it comes to reputedly being awkward conversationalists.
It’s too bad, because transformers (the magnetic components, not the movie robots) can actually be a fascinating topic. I suspect that most people have no idea what a switch mode transformer is, or where they might find one. Given that lack of knowledge, the lengths that a company like South Dakota-based Custom Coils goes to in an effort to ensure the reliability of their transformers would probably be lost on them. These little gizmos are not something that you’d like to have fail.
Transformers are a key component of many electronic devices. Industries as wide ranging as aerospace, telecommunications and biomedical rely on switch mode transformers which are used in RFI filters, low power isolation power supplies and switching regulators. There is also widespread use of customized versions. A batch of custom transformers manufactured for a specialized application may include modifications like flame retardant or glass-filled bobbins, orienting the core mounting to be vertical or horizontal, customized terminals and the type of wire used (everything from super fine wire to super heavy wire). In order to meet any specific requirements for isolation or protection, sleeving can be changed to a variety of different materials including Teflon, vinylglass or PVC heat shrink.
Given the wide range of end applications, huge variety of variables related to construction and the impact of faulty or improperly designed transformers, it makes sense that companies needing to source custom transformers for use in their products should take the time to work with their preferred vendor starting from the design stage. Doing so leads to a much smoother testing cycle and quicker time to production.
Robert Young has worked in the electronics field for close to four decades. After studying electromagnetic devices through college, he starting his career as an Electrical Engineer, designing custom transformers for a company that supplied many of the components used in the aerospace industry. He wrote a series of articles about the superior performance of ferrite compounds in the manufacture of a switch mode transformer, pointing out that the mix of iron oxides with carbonates made of nickel, magnesium or zinc resulted in a superior magnetic core. Robert remains active in the industry and is always available to consult when needed.
