contact us
Leave Your Message

Conversion Transformers

At its core, a PCB conversion transformer operates based on Faraday's Law of Electromagnetic Induction. It comprises two or more windings (coils) wound around a magnetic core. When an alternating current (AC) flows through the primary winding, a varying magnetic field is generated, which induces a voltage in the secondary winding(s). The turns ratio of these windings determines the voltage transformation ratio, enabling step-up, step-down, or voltage isolation functions.


    PCB conversion transformers can be classified based on various criteria:

    By Function: Voltage transformers for stepping up or down voltages, isolation transformers for providing galvanic isolation, and auto transformers that use a single winding for both input and output to save on copper and size.   

    By Construction: Open-frame, encapsulated, or potted transformers, differing in their protection levels against environmental factors like dust, moisture, and mechanical stress.

    By Frequency Range: Low-frequency transformers (50/60Hz) for mains power applications and high-frequency transformers (kHz to MHz) used in switch-mode power supplies (SMPS).


    Manufacturing Techniques

    The manufacturing process of PCB conversion transformers involves several stages:

    Design & Simulation: Using software tools to design the transformer, considering parameters such as voltage, current, frequency, and desired efficiency.

    Core Selection: Ferrite or iron powder cores are commonly used, chosen based on the required performance and operating frequency.

    Winding: Automated machines wind the wire onto the core according to the designed pattern, ensuring precise control over the number of turns and insulation.

    Assembly: Windings are mounted onto the PCB, often using automated pick-and-place machines, followed by soldering.

    Testing: Comprehensive testing includes insulation resistance, dielectric strength, and functional tests to ensure compliance with safety standards.


    Performance Attributes

    Key performance attributes of PCB conversion transformers include:

    Efficiency: The ratio of output power to input power, with higher efficiency translating to less energy loss and heat generation.

    Voltage Regulation: The ability to maintain a stable output voltage despite changes in load or input voltage.

    Insulation Resistance: Ensures safe operation by preventing electrical leakage between windings and to ground.

    Frequency Response: Determines the transformer's ability to handle a range of frequencies without significant degradation in performance.


    Distinctive Advantages

    PCB conversion transformers offer several advantages:

    Compactness: Their integration directly onto PCBs significantly reduces the overall size and weight of electronic devices.

    Cost-Effectiveness: Mass production techniques and standardized designs lower manufacturing costs.

    Ease of Integration: Seamless integration with other PCB components simplifies design and assembly processes.

    Flexibility: Customizable to meet specific voltage and power requirements of diverse applications.


    Key Application Domains

    PCB conversion transformers find extensive use across a myriad of industries and devices:

    Consumer Electronics: In smartphones, laptops, TVs, and home appliances for power supply and voltage regulation.

    Industrial Automation: For control systems, motor drives, and PLCs, ensuring stable power supply and isolation.

    Medical Equipment: Vital in medical devices requiring precise voltage control and electrical isolation for patient safety.

    Renewable Energy Systems: Used in solar inverters and wind turbine controllers for efficient power conversion.

    Telecommunications: Essential in network equipment, routers, and base stations for power supply and signal transmission.