High-Quality Custom Components for Toroidal Power Transformers

   

A toroidal coil transformer, as the name suggests, is toroidal or ring-like in shape. It has a magnetic core made of laminated iron, ferrite or powdered iron. Owing to its unique shape, it has minimal electromagnetic interference, thus increasing the efficiency of the equipment. Custom Coils is a toroidal transformer manufacturer and offers these transformers in highly compact configurations and for various applications. Custom Coils has more than 50 years of experience in custom toroidal power transformers. We offer toroidal cores made of various materials such as silicon steel, nickel, ferrite, powdered iron, and moly-perm alloy. We also help you choose the one that suits your requirements.

Toroidal Transformers: Features and Specifications

Our unique toroidal transformer design with no air gaps and an even winding come with all these features and formats:

Additional Features

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Toroidal Transformer Design Elements and Working

As we all know, a transformer helps change the voltage levels as required. But, a custom toroidal power transformer has some definite advantages owing to its shape and size. The input of a toroidal transformer is connected to the primary winding. As the current passes through the winding, it develops a positive magnetic field. The voltage eventually drops and the positive magnetic field becomes negative. This is the first part of the entire cycle. These positive and negative magnetic fields pass through the secondary winding and an output voltage is generated. So, in this case, the amount of voltage generated is proportional to the turns-ratio between the primary and secondary windings.

The core of this transformer helps the magnetic fields to build and collapse which induces the maximum voltage in the secondary winding. This improves the transformer efficiency.

Toroidal Transformer Construction

These transformers are available in a plethora of sizes and configurations. Custom Coils offers equipment that can wind toroids ranging from 0.5”OD to the ones that are 6.5” in diameter.

The usage of different shuttles and heads further improves the performance of these winders. Shuttles enable winding of wire gauges from 13GA up to 40GA. Toroids are usually wrapped in Mylar or tape for a higher insulation values. Thus, the toroidal transformer cores are insulated from the windings and the windings are insulated from each other.

Despite being small in size, in volume, and in weight, these transformers have a large surface area that enables it to dissipate heat more efficiently. The donut shape core reduces external magnetic flux that results in reduced leakage inductance.

Benefits of Toroidal Transformers

A toroidal coil transformer has an extremely flexible as well as a compact design which offers many benefits. Here, we have listed a few of them.

• Low offload loss:Since, the magnetic field is well shielded, the energy required to maintain the same in the core is less. So toroidal coil transformers have far lower excitation power than other types.
• Minimal external magnetic flux:Toroidal transformers radiate much lesser magnetic field than other types. The windings here act as a shield and hence no special shielding is required to minimize dissipation.
• Lower winding resistance:Toroidal transformer windings are uniformly distributed over the core; this helps reduce the winding resistance.
• Lower noise:The mechanical hum is far lesser in toroidal transformers than most other types. So, this functions quietly as the noise due to magnetostriction is reduced here.
• Smallest size by volume/weight:Although toroidal transformers are available in all sizes, the smallest size is significant and serves many application areas. Also, they are flexible, lightweight, and handy. This makes them easy to mount.
• Lower leakage inductance:Toroidal transformers have applications in power electronics, wherein a specific leakage inductance value of the transformer is required.

Applications of Toroidal Transformers

A custom toroidal power transformer has many applications, and it is especially used in sensitive devices such as amplifiers, clock and timer circuits, industrial processing, and medical equipment. Here are a few application areas of toroidal power transformers.