Transformers in the Transportation Industry

Posted by Bill Dull | April 24, 2023 0 Comments


Triad Magnetics is a worldwide leader in manufacturing high-performance magnetic components, transformers, inductors, and power supplies. Our quality products have set new standards in a broad range of commercial and industrial applications, which include:

  • Appliances
  • Computers
  • Automation Controls
  • Industrial Process Controls
  • Gaming Devices
  • Smart Meters
  • Lighting Systems

Supported by more than seven decades of design innovation and industrial automation, our automotive transformers provide many benefits for the transportation industry. Triad Magnetics produces transformers ideal for widespread use throughout the EV industry, utilizing advanced production techniques to manufacture high-quality transformers for EV charging.

The information below further explains how transformers for EV chargers work and the varying levels at which they perform. We will look at transportation applications that benefit from transformers and explore the availability of customizing transformers to meet the demands of specific applications.

EV Transformers Explained

As automobiles become more efficient with enhanced smart technology, the demand for transformers has significantly increased. From vehicle occupant comfort and safety to power train functions, automotive transformers play a vital role in the automotive industry as the increased use of electronics steadily grows and becomes more complex.

EV transformers are essential to the proper operation of electric vehicles, with the benefits of automotive transformers quickly expanding to use in boats, trains, jet skis, and more.

Electric vehicle charging stations also depend upon EV transformers with special considerations for the proper operation of the overall system. Improper use can lead to voltage and current distortion caused by a non-linear load on the power grid.

Transformer Levels

There are several  levels of electric vehicle charging that require transformer usage. These  include:

  • Level 1: A low voltage transformer (as small as 2kva) provides 2-5 miles per hour of charging for an electric vehicle using a 120V onboard car charger.
  • Level 2: A low-voltage transformer that provides approximately 10 miles per hour of charging using an onboard car charger at 240V or 280V.
  • Level 3: A fast charging station provides 50-1040 miles per hour of charging using single or three-phase sources to create 240V or 480V DC power.

EV Charging Transformer Applications

The demand for accessory products for electric vehicles is also increasing. While batteries demand a power source for charging purposes, a customized transformer maintains consistent monitoring to control the level of voltage used for charging. Innovation and advanced technologies have allowed Triad Magnetics to develop "smart transformers," which can efficiently charge several electric vehicles simultaneously.

EV charging transformer applications include:

  • Providing power to multiple Level 1 and Level 2 chargers at the same time
  • Powering one or two Level 3 fast chargers
  • Providing power to several Level 3 fast chargers at the same time

The automotive industry anticipates exponential growth of electric vehicle usage over the next decade. The EV charging infrastructure must expand to keep up with the demand.

EV transformers designed for smart grid (V2G and V2H) applications must maintain the power of 1,000 to 2,000W with large ferrites and C Core power toroids.

Custom Transformers from Triad

With transformers playing a significant role in the expanding EV market, many applications will require custom solutions. The engineering team at Triad Magnetics has a wealth of experience and knowledge that allows us to create innovative solutions to meet the demands of the transportation industry.

A recent case study describes how Triad engineers created a custom-made LLC transformer that works in the circuit allowing for a generous margin. We designed the unit to have specific inductance and leakage inductance in the same package, working in coordination with an external resonant inductor.

Finishing the custom transformer within budget and on time, the customer received a product that exceeded their expectations and met International Electrotechnical Commission (IEC) specifications.

Contact Triad Magnetics for All Your Automotive Transformer Needs

Triad Magnetics provides optimized design services to meet the specific demands of our client's applications. Our experienced engineering team offers prototyping and testing at our state-of-the-art facilities in Perris, California, backed by ISO 9001:2015 certification.

Whether you need us to create a custom automotive transformer or modify an existing product, Triad Magnetics can handle the demands of manufacturing transformers for use in various industries and applications.

Contact us to see how our global experience and dependable background in manufacturing can benefit your next project. Request a quote and Triad Magnetics can develop a detailed estimate to address the requirements of your specific application.