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Designing demanding industrial magnetic components, such as ferrite transformers and inductors, for high-frequency switched-mode power supplies (SMPS), is a technologically intricate and critical process. These components are fundamental to the performance and efficiency of SMPS, particularly in high-frequency applications where size, power density, and electromagnetic interference (EMI) control are paramount. Here, we’ll provide a technology-oriented description of the design engineering process for these magnetic components:
The design process starts with careful selection of the core material. Ferrite materials are commonly used in high-frequency applications due to their high permeability, low core loss, and excellent EMI suppression characteristics. The choice of ferrite material depends on factors like operating frequency, temperature range, and desired inductance values.
The core’s physical geometry and size are crucial for achieving the desired electrical properties. Engineers must determine the core’s shape, dimensions, and core gap (if applicable) to optimize inductance, saturation current, and minimize core losses.
Designers must determine the number of turns and wire gauge for the windings. This decision impacts the inductance, current-handling capacity, and parasitic capacitance of the component. Proper winding techniques, such as interleaving, are used to reduce leakage inductance and improve performance.
Engineers account for parasitic elements like resistance (R), capacitance (C), and self-resonant frequency (SRF) in the component. These parasitic elements can significantly impact high-frequency performance and EMI.
It’s crucial to analyze and prevent magnetic core saturation, as it can lead to performance degradation and overheating. Saturation analysis involves estimating the maximum current the component can handle without saturating the core material.
High-frequency SMPS designs require minimizing core losses. Engineers calculate core losses, including hysteresis and eddy current losses, and select core materials and geometries that reduce these losses to achieve high efficiency.
Controlling electromagnetic interference (EMI) is essential in high-frequency SMPS. Engineers implement techniques like interleaved windings, shielding, and proper winding termination to minimize radiated EMI.
As high-frequency SMPS can generate significant heat, proper thermal analysis is critical. Adequate heat sinking and thermal design are essential to prevent overheating and maintain component reliability.
Prototyping and testing are essential to validate the design’s performance in real-world conditions. Engineers use network analyzers and impedance analyzers to measure component characteristics and ensure they meet the design specifications.
Magnetic components for demanding industrial SMPS are often customized for specific applications. Engineers may fine-tune designs to meet unique requirements, such as high current handling, high voltage isolation, or extended temperature ranges.
Components used in industrial applications may need to comply with safety and regulatory standards such as UL, CE, and RoHS. Engineers ensure that the magnetic components meet these standards.

In conclusion

In conclusion, designing demanding industrial magnetic components, like ferrite transformers and inductors, for high-frequency SMPS involves a comprehensive understanding of materials, electromagnetic properties, and thermal considerations. Achieving high efficiency, low EMI, and reliability is essential in these applications, as they play a pivotal role in the performance of power supplies used in critical industrial equipment. Careful consideration of core materials, geometries, winding configurations, and rigorous testing are key elements of the design engineering process for these crucial components.