Ferroresonant Transformer Manufacturing

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Custom Ferroresonant Transformer Manufacturer

To suit your unique application requirements, Leightner Electronics designs custom ferroresonant transformers (constant-voltage transformers) to your specifications. All unique ferroresonant transformers are engineered and manufactured in-house at our facility in McKinney, Texas, where we also maintain full control over all engineering, prototyping, design and development. To find out how Leightner may help your transformer needs, call 972-542-0176 or contact us!

Ferroresonant Transformer Benefits & Advantages

Ferroresonant transformers, also known as constant voltage transformers (CVTs), offer several significant advantages in power supply applications:

  • Voltage Regulation and Stability
  • Protection and Isolation
  • Current Limiting and Self-Regulation
  • Reliability and Durability
  • Power Quality Improvement

Ferroresonant transformers offer a combination of voltage regulation, protection, reliability, and power quality improvement, making them valuable in applications requiring stable and clean power supply, particularly in industrial and critical infrastructure settings.

Custom Ferroresonant Transformers Tailored to Your Requirements

Ferroresonant transformers can be tailored to suit almost any need by Leightner Electronics. Whether you need a simple design or a complex setup, we can make a transformer to fit your needs. Our design for your needs will vary on a few factors:

  • Power Rating: Typically ranges from 50 VA to 10 kVA for single-phase designs, with some clients needing support for three-phase configurations.
  • Input Voltage Range: Standard: ±15–25% of nominal voltage. Extended: Up to ±40% for specialized designs, enabling operation in extreme grid conditions.
  • Output Voltage Regulation: Standard: ±1–3% under load, even with input fluctuations. High-Precision: Controlled designs with electronic regulation achieve ±0.5% accuracy.
  • Frequency: Primarily 50/60 Hz, with custom designs available for 400 Hz (aviation) or 20 kHz (high-frequency applications).
  • Efficiency: Single-phase: ~75% Three-phase: ~85%.
  • Surge Protection: Attenuates transients up to 6 kV and filters line noise.
  • Waveform Output: Quasi-square wave: Reduces DC filtering needs. Low-distortion sine wave: <3% THD under load.
  • Temperature Tolerance: Operates reliably from -40°C to +85°C with optional thermal monitoring (RTDs or thermocouples).
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Ferroresonant Transformer Manufacturing Process

The core of a ferroresonant transformer is a critical component that distinguishes it from conventional transformers:

  1. Core Materials: The core is typically constructed using two different magnetic materials:
    • The center core piece is made of high-grade magnetic material, such as grain-oriented silicon steel (e.g., M6X-29 gauge).
    • The outer frame is formed of lower quality material, like low carbon non-oriented steel (e.g., 24 gauge Temp Core).
  2. Core Shape: The core often has a cruciform or similar structure:
    • It consists of a generally rectangular laminated outer frame.
    • A laminated center core piece is tightly fit within the outer frame.
  3. Lamination Stacking: The core pieces are created by stacking thin laminations of the chosen materials to the appropriate height.

Ferroresonant transformers have a unique winding arrangement:

  1. Primary Winding: Placed on the primary side of the transformer.
  2. Secondary Windings: Two secondary windings are typically used:
    • One for the load
    • One for the resonant capacitor (also called the tank circuit)
  3. Winding Placement: Both primary and secondary windings are often wound around different portions of the center core piece for simplified manufacturing.

A key feature of ferroresonant transformers is the magnetic shunt:

  1. Purpose: The shunt separates the primary and secondary windings, allowing for partial flux linkage.
  2. Construction: It typically consists of core legs and air gaps, carefully designed to apportion the magnetic flux between the outer frame and center core piece.

The resonant capacitor is a crucial component:

  1. Selection: The capacitor value is chosen in relation to the magnetic properties of the core material1.
  2. Connection: It is connected across the dedicated secondary winding.
  1. Core Assembly: The laminated core pieces are assembled into the cruciform or similar structure.
  2. Winding: The primary and secondary windings are wound onto the appropriate core sections.
  3. Shunt Integration: The magnetic shunt is incorporated into the core structure.
  4. Capacitor Installation: The resonant capacitor is connected to its dedicated winding.
  5. Final Assembly: All components are brought together in the transformer housing, with appropriate insulation and connections made.
  • Prototypes undergo rigorous testing for impedance, losses, and regulation (±1–3% accuracy).
  • Adjustments are made to meet performance benchmarks

Throughout the manufacturing process, quality control measures are implemented to ensure:

  1. Core Quality: Proper material selection and lamination stacking.
  2. Winding Accuracy: Correct number of turns and insulation.
  3. Magnetic Properties: Verification of desired saturation characteristics.
  4. Electrical Testing: Confirmation of voltage regulation, efficiency, and other electrical parameters.

Applications for Ferroresonant Transformers

Ferroresonant transformers have several important applications across various industries due to their unique voltage regulation and power conditioning capabilities:

  • Power Supply for Critical Equipment
  • Manufacturing and Production
  • Oil and Gas Industry
  • Petrochemical Industry
  • Power Generation Facilities
  • Pipeline and Transmission Systems
  • Power Quality Improvement
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Let Leightner Design Your Ferroresonant Transformer Today

With over 50 years of manufacturing and hundreds of thousands of transformers built to specifications, Leightner can handle any application of your custom Ferroresonant transformer needs. Request a quote to start the manufacturing process today!

Contact Us Today For Your Custom Transformer Needs

Leightner has over 50 Years of Experience Prototyping, Designing, & Manufacturing Custom Transformers For All Types of Applications

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