Transformers are manufactured in a variety of designs and in relatively short batches to meet the demands of customers who always have different expectations. There are a range of solutions that can be applied to build different collections of transformers. For example, different magnetic materials can be used to change the induction and density; or the ratio of copper to steel quantities can be altered from 1:2 to another relevant ratio. All these variations result in fluctuations in the cost of transformers. Miracle Electronics is a leading power transformer manufacturer in India that undertakes requests for custom design and development of its products, while providing transformers that are RoHS Compliant, Reach Compliant, and available with CE and UL marks with request. So, you can tie up and get the most appropriate power transformers that suit your application type and fit your budget. There are many components that define the cost of a transformer. Listed below is a detailed record of the factors that affect the cost of power transformers.
Material and measurements of wire used
Copper is the most fundamental material used in a transformer that plays a significant role in its price. The weight of copper used in the transformer decides the cost. For a 50 watt transformer, there is no significant representation of the weight of copper in the price, but when there is reinforced insulation in the wire, the length of the wire defines the cost. Insulation in the wire keeps the cost low when used for low turn count winds. With the current going higher, the cost of the wire increases. Similar to the length, the cost increases even with the diameter of the wire. Larger reinforced insulated wires are more expensive as compared to the basic wires. Another major factor that adds up to the wire cost is the amount of power the wire handles.
Flying lead connectors
Flying lead connectors are connectors with a set of wires attached to one end while the other end being loose or flying. Since these connectors reduce the size of the extended rail bobbins, they are also one important factor that play a role in the price. Because these flying lead connectors are manually installed into the board, they add to the production cost for additional manual labour.
Utmost care must be taken while manufacturing transformers. Especially the process of winding insulated wires must be done with special care so as to avoid any kind of damage. Coils that are made with human precision assure reliability and better quality. The process involves soldering which adds up to overhead costs of the transformer.
A margin tape is used for every single wind in order to correspond with clearance distances. This also adds up to the overhead category just like soldering because it is a part of the production procedure.
Most of the cost of power transformers is related to the production procedure and the manual labour involved in the construction. Since copper is a scarce material, the size of the wire is closely related to its price too.