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How to Get the Best Toroidal Transformers

Custom toroids and custom coil winding are ideal for many situations where a small, high-powered transformer is needed. Toroids are not generic devices, which means customization is essential for accomplishing desired applications. To get the best possible toroid, engineers must first decide several things.

What core material should you use?

High-performance scores are manufactured from premium-grade steel strips that leave no air gaps. Steel is one of the most used materials for a core because it provides toroids with solid and reliable magnetic fields. Remember that steel produces eddy currents that make the core less effective. Two other popular options include laminated silicon alloy and amorphous steel. The laminated silicon variant of a toroid is ideal in devices that require 50/60/400Hz transformers. Engineers rely on laminated silicon alloy for robust magnetic propagations that reduce heat dissipation. This is an excellent material choice when looking to minimize the effects of eddy currents.

Does Magnetic Wire Selection Matter?

Just as different materials affect performance, so does the magnet wire selection. Aluminum and copper are two of the most popular choices for magnetic wire; although, copper is preferred for custom winding toroids. Copper has better size, cost, and carrying capacity when compared to aluminum. Copper also has higher electrical and thermal characteristics compared to aluminum. It is crucial to remember that although copper might be best in many situations, it should not be used in every scenario.

What are winding techniques?

Another vital aspect of creating toroids is custom coil winding. The winding process determines leakage inductance, so special care and consideration must be used for this portion of the construction process. Each winding technique depends on the toroid being created and its function within an electrical device or system.

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