When will high-frequency energy consumption end?
Product Overview
In the energy architecture of 5G base stations and new energy vehicles, high-frequency transformers are becoming a key driver of the energy efficiency revolution. Our third-generation nanocrystalline core transformers increase operating frequencies to the 200kHz-2MHz range, reducing the size by 62% compared to traditional silicon steel solutions while achieving peak efficiency exceeding 98.7%. This switching power supply transformer is specifically designed for 800V high-voltage platforms, successfully resolving the heat dissipation bottleneck in electric vehicle OBC modules.
Technical Specifications
- Rated Power: 2kW-150kW (free air cooling)
- Dielectric Strength: AC 4kV/60s (compliant with IEC 61558-2-16)
- Operating Temperature Rise: ≤45K (full load @ 25°C ambient)
- Core Material: Fe-based nanocrystalline (22μm thickness)
Product Features
- Three-Dimensional Winding Technology: Utilizes a 36-strand Litz wire braid structure, reducing skin effect losses by 73% at 200kHz.
- Intelligent Monitoring: Built-in Hall sensors monitor the magnetic flux saturation of the Ring Electronic Transformer in real time.
- Modular Design: Supports parallel expansion of up to four High Frequency Electrical Transformers.
- Application Scenarios
- Medical Equipment: Ring power module for a certain brand of 128-slice CT scanner, ripple factor <0.5%.
- PV Inverter: Dedicated version for 1500V systems, MPPT efficiency increased to 99.2%.
- Military Electronics: Customized vibration-resistant solution certified by MIL-STD-810G.
Production Process
At the Dongguan Intelligent Manufacturing Base, each high-frequency transformer undergoes the following:
① Vacuum pressure impregnation (VPI process, permeability > 98%)
② Helium mass spectrometry leak detection (leak rate <1×10^-9 mbar·L/s)
③ 72-hour aging load test (simulating 5-year operating conditions)
Certifications
It has passed the UL 60601-1 medical device standard and EN 50155 rail transit certification. A harmonic tolerance version compliant with ANSI/IEEE C57.110 has been specially developed for data center needs.
Customer Testimonials
A Shenzhen charging station company reported that after adopting the third-generation Switching Power Supply Transformer, the volume of a 30kW module has been reduced to 19L, with a power density of 1.58kW/L. Its CTO specifically noted: "The dynamic response speed of the Ring Electronic Transformer reduces charging curve fluctuations from ±3% to ±0.7%."
Customization Options
- Core Shape: Toroidal, Planar, or E-Shaped
- Winding Configuration: Supports multiple 4-72V outputs
- Special Requirements: Salt spray-resistant (>1000h) and radiation-resistant (>100krad) versions available
FAQ
Q: How to prevent EMI issues under high-frequency operating conditions?
A: We recommend using a sandwich winding structure and combining it with our patented EMI-absorbing magnetic ring.
