DCR Loss Calculation for Inductors: A Practical Guide
DC resistance (DCR) loss is one of the two main loss components in any inductor—alongside core loss. At high DC current, DCR loss (I²R) often dominates total loss and is the primary driver of inductor heating. Getting DCR right is essential for efficiency and thermal design. This guide explains how to calculate DCR loss, what […]
How to Design a Custom Transformer: Step-by-Step Process
When standard off-the-shelf transformers don’t fit your application, a custom design is the answer. But designing a custom transformer from scratch can seem daunting—what information do you need? How does the process work? What can you expect from a magnetics supplier? This guide walks through the complete custom transformer design process, from specification to production. […]
Common Failure Modes of Transformers and Inductors
Magnetic components are among the most reliable parts of a power supply—but when they fail, it’s usually dramatic. Understanding the most common failure modes helps you design better, test smarter, and diagnose field failures faster. This guide covers the most common ways transformers and inductors fail, their root causes, and how to prevent them. Shaanxi […]
How to Reduce Transformer Audible Noise: Practical Guide
Audible noise from transformers and inductors is a common complaint in consumer electronics, industrial equipment and residential power systems. The 50/60 Hz hum from line transformers, or the higher-frequency whine from switching power supplies, can make products uncomfortable to live with. This guide explains why magnetics make noise, and the most effective ways to reduce […]
Isolation Transformer vs Auto Transformer: Which to Use?
When you need to step up or step down voltage, you have two main choices: an isolation transformer or an auto transformer. They look similar and both change voltage, but they have fundamentally different electrical characteristics, safety profiles and cost. This guide compares isolation and auto transformers, and helps you choose the right one for […]
Common Mode Choke vs Differential Mode Choke: What’s the Difference?
EMI filters use two types of chokes: common mode (CM) chokes and differential mode (DM) chokes. They look similar but serve completely different purposes. Understanding the difference—and when to use each—is critical for effective EMI filtering. This guide compares CM and DM chokes, how they work, and how to combine them in a complete EMI […]
Inductor Saturation: How to Calculate and Prevent It
Inductor saturation is the most common failure mode in power magnetics. When the core saturates, inductance drops sharply, current spikes, and the converter can destroy itself. Understanding saturation—how to calculate it, how to prevent it, and how to test for it—is essential for every power electronics engineer. This guide explains inductor saturation physics, calculation methods, […]
How to Choose Wire Gauge for Transformer and Inductor Windings
Wire gauge selection is one of the most important decisions in magnetic component design. Choose wire too thin and DCR loss makes the component inefficient and hot. Choose wire too thick and it won’t fit in the winding window. At high frequency, skin effect and proximity effect add another layer of complexity. This guide covers […]
How to Test Magnetic Components: Impedance, Saturation and Loss
Designing a transformer or inductor is only half the job—you need to verify it performs as calculated. Electrical testing of magnetic components ensures that inductance, saturation current, loss and thermal performance meet the design specification before production. This guide covers the key tests for transformers and inductors, the equipment needed, and what the results tell […]
Magnetic Components in Battery Management Systems (BMS)
Battery management systems (BMS) are the intelligence behind every lithium-ion battery pack—from electric vehicles to energy storage systems (ESS). While the BMS is known for its electronics, it also relies on magnetic components for current sensing, isolation and power supply. This guide covers the role of magnetics in BMS design and key component selection. Shaanxi […]