TRAFOPSU
POWER COMPONENTS
High-Frequency Power Transformers and Inductors
for Industrial and Renewable Energy Applications
www.trafopsu.com
Power Components Overview
This document introduces the TrafoPSU Power Components family — a comprehensive range of high-frequency electromagnetic components engineered for modern power conversion systems. Drawing on extensive industry expertise in switch-mode power supply (SMPS) design and manufacturing, TrafoPSU operates as a custom transformer and inductor manufacturer in China, delivering end-to-end solutions that span the entire product lifecycle: from initial specification and custom design through prototyping, validation, and volume production.
Our power components are purpose-built for demanding applications where reliability, efficiency, and electrical safety are non-negotiable. Whether deployed in industrial welding equipment, uninterruptible power supplies, renewable energy inverters, or EV battery charging infrastructure, every TrafoPSU component is engineered to perform consistently under the most challenging operating conditions.
Every TrafoPSU power component is backed by a rigorous quality management system, fully automated production lines, and a commitment to using only certified raw materials — ensuring repeatable quality at competitive costs.
Development Process
The development of a custom power transformer or inductor at TrafoPSU follows a structured, collaborative methodology designed to translate customer requirements into optimized, production-ready components. Each phase builds upon the last, ensuring traceability and technical rigor at every step.
Custom Specification Review
Every project begins with a thorough analysis of the customer's specification. Our engineering team evaluates key parameters — rated power, switching frequency, topology, input/output voltage ranges, isolation requirements, thermal constraints, and mechanical envelope — to establish a clear design brief. This phase ensures alignment between customer expectations and technical feasibility before any design work commences.
Electromagnetic Simulation & Analysis
Following the initial specification review, our R&D team employs advanced electromagnetic simulation tools based on the finite element method (FEM) to model and predict transformer behaviour within the target application circuit. This simulation-driven approach enables precise characterization of:
- Core and winding power losses under actual operating waveforms
- Dynamic magnetic field distribution and flux density mapping
- Current distribution in conductors, including proximity and skin effects
- Thermal behaviour and hot-spot identification
- Leakage inductance and parasitic capacitance estimation
By simulating the complete electromagnetic and thermal behaviour before cutting metal, we dramatically reduce the number of physical prototype iterations and accelerate time-to-market for our customers.
Design Optimization
The transition from simulation to final design involves a systematic optimization process that balances technical performance against manufacturing efficiency and cost. Our engineers evaluate multiple winding configurations, core geometries, and materials to identify the solution offering the optimal quality-to-price ratio. Key considerations include:
- Minimizing total power losses (core + copper) at the rated operating point
- Achieving target leakage inductance and coupling capacitance specifications
- Ensuring adequate creepage and clearance distances for the required isolation voltage
- Optimizing for automated production to reduce labour cost and improve consistency
Rapid Prototyping
Prototypes are built and tested in our in-house laboratory using production-grade materials and processes. Each prototype undergoes a comprehensive electrical test regime, including inductance measurement, turns ratio verification, insulation resistance testing, and partial discharge analysis where applicable. We actively encourage customers to evaluate prototype samples in their own application circuits, and we provide full engineering support during this critical validation phase.
Power Factor Correction stages present unique inductor design challenges. The PFC choke must handle a current waveform composed of the low-frequency (50/60 Hz) mains component modulated by a high-frequency switching ripple. TrafoPSU PFC inductors are designed with careful attention to both low-frequency core utilization and high-frequency loss mechanisms, using optimized core geometries and winding techniques to deliver high efficiency across the entire operating envelope.