High Frequency Transformer 30kHz

A transformer’s function is to change the entry current/voltage level to another level while keeping the same power.

Electrical Functions

• Voltage transformation : V1 → V2 
• Isolation
• Measurement

Example : 

SMPS Transformers : Flyback, Forward, Push Pull, Half Bridge, Full Bridge, Dual Active Bridge, LLC transformers.
Pulse Transformers

• Gate Drive Transformers

• Data Bus 1553

   

Current  Transformers

Multi Pulse Transformer for “400Hz” Power Supply 
50/60 Hz Transformer for Niche Markets
 

Exxelia SVM designs inductors and chokes to block high-frequency ripple currents. Examples include filter inductors (5 mH, 15 A rms at 40 kHz; 10 mH, 10 A; dimensions specified). They also provide LCL filter inductors using rectangular Litz wire rated for high current (e.g., 100 µH, 360 A continuous, 510 A peak, 50 Hz–3.5 kHz).

Exxelia SVM develops SMPS transformers in multiple topologies (flyback, push–pull, forward converter, gate drive, pulse), supporting up to 500 kHz. They cover various core geometries (EE, EFD, ETD, PQ, RM, ER, Pot, Toroid…) with conductors such as enameled copper, triple-insulated wires, Litz, and twisted wires.

Exxelia SVM designs high-frequency transformers operating up to 100 kHz and 500 kW. Custom units are also available, such as dry-type transformers (30 kVA at ~30 kHz, up to 50 kV DC) and high-voltage models (80 kVA, 20 kHz, ±25 kV outputs).

Yes. Exxelia SVM serves high-reliability markets such as defence, medical, EV, and communications, ensuring compliance with strict safety and regulatory standards.

Exxelia SVM provides a wide portfolio of magnetics components, including high-frequency transformers, SMPS transformers, linear power transformers, inductors & chokes, reactors, current transformers, and custom magnetics—covering both high- and low-frequency applications.

Exxelia SVM offers linear isolation transformers with high efficiency that comply with IEC and UL safety standards, e.g., a 3 kVA isolation transformer at 230 V / 50 Hz.

To convert your concepts in to reality in Magnetic Components. Exxelia SVM can play a significant role in your Product Design where Magnetics is a vital component; in simple words Exxelia SVM can be your Strategic Solution Provider for your Special Magnetic components.

Exxelia SVM Design and Technology group works as an extended arm of customers Innovation Team in understanding the Specification, Criticality and the time lines of the Project implementation.

Design Organization

• Electrical, Electronics, Mechanical (Bobbin, Clamps and brackets)
• Design and simulation Capability for Inductors, Transformers, Hall Effect Current Transformers, Actuators, Solenoids.
• Power Converters, Stabilizer for Medical Equipment’s.
• Design and Development for Molded , Laminated , Epoxy powder coated , Nickel& Golde plated, Silver Plated , Brazing&Tin Plated , Flexible busbars and other Press Components.

Knowledge, Expertise & Techniques

• The Team at Exxelia SVM can Engineer your ideas and convert them into End use Components
• MATLAB, FEMM Modelling and Thermal Simulation of Magnetic components
• Reliability of components evaluated using Thermal Cycle, Random Vibration Test and Packaging Drop Test for Shipping and Handling
• Load Test for High Current Inductors and Linear Power transformers to check the temperature rise at actual loading pattern

Support for End use and Application

• The Team at Exxelia SVM Interact with Customers and provide solutions for End use and Application

Functional test set up developed for Variable Frequency High power test bench to test the transformers and inductors
Topologies – Full Bridge, Half Bridge, Push-Pull, Forward with loading facility.

Flyback Transformer Testing Set up

• Frequency – Up to 133 kHz
• Rating - Up to 250VA

High frequency Transformer Testing set up

• Frequency – Up to 100 kHz
• Rating - Up to 25kVA

Waveforms:

Lab Facility as per UL Safety Requirements

• Partial Discharge Test up to 100kV AC
• Impulse Testing Facility upto 100kV DC (Both Lighting and Switching Impulse)
• Load Test up to 50kVA (50HZ operating frequency)
• Dielectric Strength Test both AC and DC
• Precision LCR Magnetic Analyzer for measuring Inductance, Capacitance and Resistance
• DC Bias Test up for Inductors
• Temperature Data Logger

Magnetics Manufacturing Facility

• Multi spindle CNC Winding Machines
• Automatic Test equipment’s (ATE)
• Copper Foil Winding Machines
• Vacuum Impregnation plant

Busbar Manufacturing Facility

• Automatic Pressure Gelation Machine ( Resin Cast)
• Amada CNC Turret Punching Machine
• Amada CNC Bending Machine
• AIDA Pneumatic Press for Blanking and forming
• CNC PET Film Cutting Machine
• Hot Press for Lamination
• Powder Coating Plant
• Plating Plant
• Resistance Brazing and Pressure Welding Setup
• PEM Nut and Stud insertion Machine.

Backward Integration

• Round Litz Wire up to 350A Current Rating
• Rectangular Type 8 Litz wire up to 350A Current Rating
• Press Components
• Bobbin manufacturing both Thermoset and Thermoplastic
• Sophisticated Tool room
• Lamination Stamping Facility
• Thermoforming Packaging Trays

Special Purpose Machines (SPM)
Builds special jigs, Fixtures, Machines to bring out Customized Products