Custom transformer design requires advanced engineering capabilities to meet unique application requirements. Our engineering team uses sophisticated design tools and methodologies to develop optimal custom transformer solutions.
Electromagnetic Design
Our electromagnetic design process uses advanced software to optimize core dimensions, winding configurations, conductor sizes, impedance, losses, and efficiency. Finite element analysis (FEA) is used for detailed electromagnetic field analysis, especially for high-current and special designs.
Thermal Design and Analysis
Thermal design is critical for transformer reliability and service life. Our engineers use computational fluid dynamics (CFD) and thermal network analysis to optimize cooling systems, calculate temperature distribution, and ensure all components operate within safe temperature limits under all expected conditions.
Mechanical Engineering
Our mechanical engineering team designs robust structures to withstand electromagnetic forces, thermal stresses, vibration, shock, and transportation loads. Finite element structural analysis is used to verify mechanical integrity and optimize material usage.
Prototyping and Testing
For new and complex custom designs, we can build prototypes for validation testing. Our comprehensive testing capabilities include routine tests, type tests, and special tests to verify performance and reliability. Test results are carefully analyzed and compared with design calculations to ensure the transformer meets all requirements.
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Need a custom transformer for your application? Send us your technical requirements and our engineering team will provide a custom solution within 24-48 hours.