Size plays a major role in transformer design, especially when it comes to efficiency, power rating and equipment lifespan. Balancing a compact transformer design with high voltage capacity is a crucial part of most equipment today. R-core transformers are one type of transformer core that achieves a good balance of small, compact size and high power, without sacrificing performance.
Size and Power Ratings in Transformers
Sizing is crucial in transformers. Proper sizing helps to ensure the highest possible efficiency, reduces failures, overheating and maintenance needs and maintains system reliability.
Transformer size almost directly correlates to the voltage that it can handle. Larger cores, thicker wires, more windings–all of these features allow the transformer to handle more current and higher voltage. However, higher frequencies allow for smaller, more compact cores and designs, leading to the high-capacity transformer cores used across a wide range of equipment today. One of the more innovative designs for high-capacity, compact transformers is the R-core transformer.
Powerful and Compact: R-Core
R-core transformers are valued for their balance of size and power rating. They are known for being compact, with low losses and quieter operation than other transformer cores, as well as longer lifespans due to the minimal amount of heat generated. The rectangular, silicon-steel core eliminates the gaps in the magnetic field, dramatically reducing leakage flux and noise. The symmetrical coil windings on either side of the core mutually cancel out each other’s magnetic flux as well, minimizing leakage flux even further for quieter, more efficient operation. These characteristics have made them popular in high-performance audio equipment, medical device systems and high-accuracy industrial systems.
Unlike other common transformers, such as toroidal and EL type, R-cores feature an inherently thin, light-weight design and simple shape. Its compact size expands mounting options and reduces its spatial footprint as well. The major downside of R-core transformers is their cost, as they require specialized equipment to manufacture.
About Custom Magnetics, Inc.
Custom Magnetics is a leading manufacturer of custom transformers and high-performance magnetic components. If you’re looking for a contract manufacturing partner specializing in high-end transformers, consider working with us–request a quote today to get started.
