Custom Transformer Design at Velatron Technologies

Introduction

Velatron Technologies, with a legacy dating Custom Transformer Designer is renowned for its expertise in designing and manufacturing custom transformers, inductors, and related assemblies. Formerly known as S.G. Smallwood Inc., Velatron has evolved to become a leader in the field, serving diverse industries with innovative and reliable magnetic solutions.

The Process of Custom Transformer Design

Designing a custom transformer involves a meticulous process that integrates advanced engineering principles and cutting-edge technology. Here’s a step-by-step overview of how Velatron approaches this complex task:

1. Define Design Parameters

   • Voltage and Power Ratings: Determining the primary and secondary voltage ratings and calculating the power rating to handle the expected load.
   • Frequency: Specifying the operating frequency, which influences core material selection and overall design.

2. Core Design

   • Core Type and Size: Selecting the appropriate core type (e.g., E-I core or Toroidal core) and calculating the core size based on the chosen material and required magnetic flux.
   • Winding Configurations: Optimizing winding configurations to minimize leakage flux and enhance efficiency.

3. Coil Design

   • Wire Selection and Insulation: Choosing the right wire size and material for both primary and secondary coils and selecting suitable insulation materials to prevent short circuits and breakdowns.

4. Cooling System Design

   • Cooling Method and Sizing: Deciding on the cooling method (oil-immersed, air-cooled, or water-cooled) and sizing the cooling system to ensure efficient heat dissipation.

1. Compliance and Standards

   • Ensuring the design complies with international standards such as UL, CSA, and IEEE to guarantee safety, efficiency, and environmental compliance.

2. Advanced Techniques

   • Computer-Aided Design (CAD) and Finite Element Analysis (FEA): Utilizing CAD for precise modeling and FEA for in-depth analysis of magnetic fields, thermal behavior, and mechanical stress. Emerging technologies like machine learning are also explored for predictive maintenance and performance optimization.

Applications and Industries

Velatron’s custom transformers are integral to various industries, including aerospace, defense, renewable energy, robotics, and scientific instrumentation. These transformers are designed to meet specific requirements, ensuring superior performance and reliability across applications such as switch-mode power supplies, energy storage, and RFI suppression.

Commitment to Quality and Innovation

Velatron’s commitment to quality is demonstrated through rigorous quality control measures and adherence to global certifications such as AS9100D and ISO 9001:2015. Their manufacturing capabilities include CNC precision winding, epoxy encapsulation, and varnish impregnation, ensuring that each transformer meets the highest standards of performance and reliability.

Why Choose Velatron Technologies?

1. Decades of Expertise: Leveraging over seven decades of experience in magnetic solutions.
2. Cutting-Edge Technology: Utilizing the latest advancements for innovative designs.
3. Global Certifications: Ensuring compliance with stringent international standards.
4. Customer-Centric Approach: Focusing on meeting and exceeding customer expectations.
5. Lean Manufacturing Principles: Enhancing efficiency, reducing waste, and ensuring timely delivery.

Conclusion

Velatron Technologies stands out as a premier designer Velatron Technologies and manufacturer of custom transformers, providing solutions that address the unique needs of various industries. Their dedication to quality, innovation, and customer satisfaction makes them a reliable partner for any project requiring advanced magnetic solutions.