Magnetics set for military
power supply
We were commissioned to design
magnetics for a military biphase power converter. We designed
for high reliability, low temperature rise and long life. By
working with the customer we were able to combine two inductors
into one, thus reducing cost and space requirement. Our client’s
customer confirmed that our designs were the highest performing,
and lowest temperature running, they had tested: “I must start
by saying thanks…works absolutely brilliant. We ran the PSU last
night for some time, and were very pleased with the results
(noise/ temp/performance etc). These are the best parts we have
seen as yet.”
Miniature safety-critical
audio transformer
A client’s customer needed to
reduce the size of his TX/RX telephony system, and needed high
performance safety isolating transformers to work with a variety
of different microphones. Traditionally, two different designs
of transformer were required for TX and RX channels; however, we
introduced an impedance concept we had refined to enable a
single design to be used for both channels. The final part
measured 13mm x 9mm x 7mm HT with 3000V rms isolation and
approval for safety-critical applications throughout the world.
Planar transformers
We have designed a large number
of planar devices for power applications to 300W. We produce all
the track layouts, drilling guides and gerber files. Designs up
to 4oz (140um) copper, 14 layers. Our designs have been approved
by large multinational companies.
Miniature high power ultra-low
leakage inductance transformer
We used a special winding method
with copper foil to give almost ideal coupling between windings
in an isolating DC-DC converter switching at high frequency. A
ratio of 1000:1 was achieved between primary inductance (80uH)
and leakage inductance (80nH). By mounting the part on a ceramic
substrate, customer comfortably achieved 30 watts power transfer
through the transformer, which was only 5mm high. Customer (one
of the largest telecoms equipment suppliers) confirmed that it
was the best solution they had ever tested.
Component characterization
We were commissioned by a large
multinational telco to characterize some legacy apparatus so
that it could be modelled as part of the design process for a
new generation of telephone exchanges. Results at different
excitation levels and frequencies were derived and compared to
standard circuit models.
RFID coils
We have designed coils for 125kHz
and 13.58MHz RFID applications, including complex shapes to fit
around components in densely-packed housings, and improved the
production tooling in order to be able to eject the complex
shapes without damage.
Documentation
For all designs we use 3-D CAD
models and have supplied toolmakers with 3-D CAD data suitable
for cutting metal without the need for interpreting complex 2-D
drawings. Of course, we also produce standard engineering
drawings for documentation, assembly, test and measurement.
By creating 3-D models we have
been able to produce high-quality realistic rendered images for
marketing purposes, and a variety of orthographic projections,
pictorials, cross-sections, exploded views etc or for handbooks,
datasheets, patent applications etc.
