Toroidal Transformer Core

• Product Type: Ring-shaped core featuring a closed magnetic circuit with no air gap. Ensures continuous, uniform magnetic flow and extremely low magnetic resistance for highly efficient magnetic flux transmission.
• Material Selection: CRGO (Cold-Rolled Oriented Silicon Steel) / Amorphous Alloy. Material grades can be selected based on specific performance requirements for actual application scenarios.
• Silicon Steel Sheet Thickness: Standard thicknesses are 0.23mm, 0.27mm, and 0.30mm. Custom thicknesses available based on core loss, power output, and other requirements.
• Inner Diameter (ID): Customizable to fit equipment installation space with dimensional accuracy controlled within ±0.05mm.
• Outer Diameter (OD): Customizable to accommodate different power ratings and installation scenarios, with concentricity deviation not exceeding 0.03mm.
• Height: Customizable, covering thin-type, standard, and thick-type specifications to meet diverse equipment volume design requirements.
• Surface Insulation Treatment: Utilizes high-temperature insulation coating technology, achieving insulation class F or higher. Coating thickness ranges from 0.01-0.03mm, offering excellent temperature resistance and aging resistance to ensure electrical operational safety.
• Applicable Voltage Range: Compatible with AC frequencies of 50Hz-60Hz and voltage ranges from 0-1000V. Custom voltage specifications available based on specific application requirements.

• Continuous Magnetic Path Design: Utilizes strip-shaped iron core material formed through continuous winding without joints or air gaps. This ensures a complete magnetic path, significantly enhancing magnetic flux transmission efficiency, reducing magnetic resistance, and ultimately improving electrical energy conversion efficiency.
• Reduced Magnetic Losses: Synergistic optimization of material selection, magnetic circuit design, and precision annealing processes substantially lowers core no-load and load losses, delivering significant long-term energy cost savings.
• Ultra-Low Leakage Flux: The closed-loop structure effectively confines magnetic flux, typically achieving leakage rates below 1%. This significantly outperforms traditional EI cores, minimizing electromagnetic interference to surrounding electronic components.
• Low-Noise Operation: The gapless design eliminates vibration noise caused by magnetostriction. Combined with precision winding techniques, operational noise is controlled below 35dB, making it suitable for precision equipment applications.
• Compact Size: Compared to EI cores, it reduces volume by 30% and weight by 20-30% at equivalent power, significantly improving space utilization and facilitating miniaturized device designs.
• Higher Efficiency than EI Structure: Achieves over 95% electrical conversion efficiency, offering a clear advantage over traditional EI cores (85-90%). Its outstanding energy-saving performance aligns with “dual carbon” conservation goals.

• High-End Audio Equipment: Suitable for premium amplifiers, decoders, and professional audio systems. Its low magnetic leakage and noise characteristics ensure pure audio signal transmission, enhancing sound quality performance.
• Medical Power Supplies: Ideal for precision medical devices like patient monitors, ultrasound diagnostic equipment, and specialized medical power supplies. Electromagnetic interference-free and stable operation guarantee accurate medical device performance.
• UPS and Inverter Systems: Compatible with residential/industrial UPS units, photovoltaic inverters, and vehicle inverters. Shock-resistant and highly efficient, ensuring stable operation of emergency power systems.
• Industrial Control Power Supplies: Suitable for PLC control cabinets, frequency converters, and industrial rectifiers. Withstands high temperatures and heavy loads, enabling long-term stable operation in demanding industrial environments.
• Laboratory Instrumentation: Designed for precision measuring instruments and specialized laboratory power supplies, featuring high accuracy and stable operation to meet demanding laboratory testing requirements.

• Precision Winding Equipment: Equipped with fully automated precision winding machines, maintaining winding tension within 80-120N to ensure uniform internal stress in core materials. Winding accuracy reaches ±0.05mm, guaranteeing precise core geometric dimensions.
• Automated Annealing Process: Utilizes fully automated annealing equipment to perform annealing under nitrogen protection or vacuum conditions at 750-850°C with a 2-4 hour soak time. This effectively eliminates internal stresses and optimizes magnetic properties.
• Magnetic Performance Testing Equipment: Equipped with specialized magnetic property analyzers to precisely measure core loss, permeability, magnetic flux density, and other critical parameters. Ensures product compliance with specifications, maintaining magnetic flux density uniformity deviation below 2%.
• Monthly Production Capacity: Standardized production facilities and comprehensive quality control systems ensure stable monthly output. Capable of meeting bulk procurement demands with short-term high-volume supply capabilities to safeguard production schedules.
• Quality Control Process: Implemented a comprehensive quality control mechanism covering raw material inspection, production process monitoring, and finished product testing. This ensures quality traceability and batch consistency.
• Export Packaging Standards: Utilizes specialized anti-collision, moisture-proof, and rust-proof packaging compliant with international export transportation standards. Ensures safe delivery worldwide and prevents damage during transit.

• Customized by Drawing: Supports customer-submitted design drawings, manufacturing strictly according to specified parameters to ensure products perfectly match design specifications without secondary adjustments, tailored to meet exclusive equipment requirements.
• Customized by Performance Parameters: Provides professional engineering recommendations based on core performance needs such as power output, magnetic loss, and noise levels of customer equipment, optimizing core structure and parameters for precise performance matching.
• Special Material Requirements: Customize CRGO, amorphous alloy, or other specialized magnetic materials at specific grades to meet unique application scenarios and personalized performance demands.
• Special Insulation Treatment: Tailor insulation coatings with specific thicknesses and grades to meet customer equipment requirements, ensuring compatibility with extreme operating conditions like high temperatures or voltages.

Customization Process

1. Step 1: Provide Drawings or Parameters (Customer submits design drawings, dimensional parameters, performance requirements, and other core information)
2. Step 2: Engineering Evaluation (Professional engineers conduct technical reviews of requirements, optimize design solutions, confirm technical feasibility, and provide expert recommendations)
3. Step 3: Sample Confirmation (Rapidly produce samples based on the confirmed design, ship them to the customer for testing and evaluation, and confirm sample qualification)
4. Step 4: Mass Production (Initiate batch production upon sample approval, strictly controlling manufacturing quality to ensure products meet sample standards)
5. Step 5: Export Shipping (Complete packaging per export standards, coordinate with customers for customs clearance and logistics to ensure timely delivery)

• Magnetic Loss Comparison: Ring cores exhibit extremely low losses, with no-load losses reduced to below 0.1% of rated capacity. EI cores, due to air gaps, have higher losses—typically 1.5–2 times those of ring cores.
• Magnetic Leakage Comparison: Ring cores have leakage rates <1%, causing minimal electromagnetic interference. EI cores exhibit leakage rates of approximately 5-10%, potentially causing electromagnetic interference to surrounding electronic components.
• Noise Comparison: Ring cores operate at ≤35dB, falling within the low-noise range; EI cores produce 45-55dB operational noise with noticeable vibration-induced noise.
• Volume Comparison: For equivalent power ratings, ring cores reduce volume by 30% and weight by 20-30%; EI cores are bulky, heavier, and offer lower space utilization.
• Cost Differences: For small-batch custom orders, toroidal cores are slightly more expensive than EI cores due to their complex manufacturing process. In mass production, toroidal cores achieve over 95% material utilization, narrowing the cost gap. Long-term energy savings offset the initial cost difference.