Custom Transformers are usually required when a transformer needs to be able to perform special functions or requires unusual features. If untraditional construction, rare material, or high voltage coils are involved, a custom transformer may be the safest option to pursue.
There are several common problems and requisites that custom transformers can offer potential solution for, including:
- Unusual input or output voltage
- Line and load reactors are essential parts of regeneration and power factor control
- Protective enclosures are needed
- Ripple filters and armature chokes are required to reduce DC drive noise
- Unusual wiring
When in the market for a custom transformer there are several things a manufacturer should be able to provide, as well as several key pieces of information to keep in mind.
- A positive relationship with the design and engineering staff can help guarantee efficient and effective product manufacturing, by ensuring important concerns are being addressed.
- The engineer and design team should be able to design a new part, and alter or replicate and already existent one.
- Make sure that when using CAD for prototypes or for designing a solution they are able to offer you service while also keeping cost reasonable.
- When negotiating price, a quote should be available within three days to one week, depending on the specific complexities of the transformer. Attempts should be made to respond appropriately to requests for a faster quote.
- Development of a prototype can usually be completed within a few days. Appropriate software (CAD, for example) should ensure that the prototype is dimensionally accurate.
- An effective manufacture should be able to provide a wealth of options when it comes to concepts, materials, and technology, and should be up to speed with recent developments and trends.
- In terms of price, an aluminum wound core is more affordable, but copper is more energy efficient and can save money spent on electricity. Additionally, copper is strong and highly corrosion resistant, meaning it can outlast aluminum, and connections remain nice and tight.
- A transformer with an oval shape wound core (as opposed to the traditional square core) can help reduce core loss by ensuring the flux moves in the same direction as the grain.
- A certain amount of noise can be expected with all transformers, and is produced by the flux of the core. A manufacturer should present sounds levels that match the standards of the American National Standards Institute and are subsequently certified. Anti-vibration isolators are also a good way to help minimize the transformer hum.
- A transformer should be designed to achieve a temperature within the appropriate range for the type of insulation. Not only does this help a transformer reach its maximum lifespan, it can also prompt other design issues to be considered before manufacturing actually begins.