New Development! Magnetically Coupled Components from SMP


Graben-Neudorf, Germany – SMP Sintermetalle Prometheus GmbH Co KG (SMP), German manufacturer of soft magnetic materials and inductive components, has expanded its portfolio of inductive components with the development and design of magnetically coupled components. SMP will present this new development at PCIM 2015 in Nuremberg, Germany, international trade fair for power electronics, intelligent motion, renewable energy and energy management.



Magnetically coupled components have the following advantages over components that are not magnetically coupled: they are less expensive, they are made using less material, so they are more compact and weigh less, and their loss balances are lower than those of non-magnetically coupled components (eco-design). Faster clock frequencies are possible. The quality factor is set without exposing the choke to any thermal load, and EMC considerations are reduced. The magnetizing and leakage inductances can be specifically set by adjusting the magnetic coupling. This is done by varying the geometries of the injection molded parts and using different coil types, such as separately wound coils, bifilar coils or superimposed wound coils.



The range of magnetically coupled components is designed for currents up to 2000 A and frequencies up to 500 kHz, which can be increased to 2 MHz in special applications. SMP uses powder composite materials that have been developed and manufactured entirely in-house and feature lower eddy current and magnetic reversal losses. The three-dimensional isotropy of the materials results in compact, lightweight structures, because the magnetic circuits are minimized. This also lowers the magnetic field strength, and the quantity of winding material used can be significantly reduced. Special magnetorestriction-free materials ensure that components run very quietly. These materials, which are developed and produced according to individual customer specifications, have a high saturation induction, up to 2 Tesla. And the oscillation behavior of the choke can be adjusted specifically by using certain materials or appropriate, magnetically coupled constructions with multiple coils.



Depending on the application, the magnetically coupled components from SMP are constructed for use as transducers, medium-frequency transformers, flux-compensating chokes or controlling chokes. Controlling chokes are produced by adding another coil in the role of transformer. They are implemented, for example, for control signals, for monitoring choke saturation, to measure current, to adjust the quality factor with thermal relief of the choke, also with possible energy recovery, and for setting a specific induction by premagnetizing the magnetic material.



Magnetically coupled components are used in industrial applications in power electronics, automation and signal processing, in drive units for railway engineering, electromobility, maritime and medical engineering, for renewable energies as well as for energy supply, and in the aerospace industry.



The components can be manufactured with dimensions ranging from 19 mm to 300 mm, weighing from 0.05 kg to 130 kg, and up to temperature class H (up to 180°C). Protection classes up to IP66 are available according to the intended application. All components are RoHS and REACH-compliant, the materials used are UL listed. SMP has its own, UL-approved insulation system and in-house capability to issue UL certification up to 1000 A; for currents higher than 1000 A, certification is carried out externally.



This German medium-size, family-owned business develops and manufactures the materials needed according to individual customer specifications in-house. SMP has also expanded its production and development facility to include an injection molding department, so that it can design and manufacture customized insulation systems. Almost 100 percent of its products are custom-made for specific customers. Consequently, SMP can offer outstanding manufacturing depth, starting with its selection of raw materials and continuing through the production of powder composite materials to the finished end product. Over 50 percent of its goods are exported to destinations all over the world.



Summary:

Advantages of magnetically coupled components compared with non-magnetically coupled components:

- less materials used

- better loss balances than those of non-magnetically coupled components (eco-design)

- faster clock frequencies possible

- quality factor setting without thermal load on the choke

- specific setting of magnetizing and leakage inductances

- reduced EMC effort

- even more compact and lightweight construction

- less expensive



Spectrum:

- Currents up to 2000 A

- Frequencies up to 500 kHz, for special applications even as high as 2 MHz

- Saturation inductions up to 2 Tesla

- Compact dimensions with diameters from 19 mm to 300 mm



Depending on the application, magnetically coupled components are designed as:

- Transducers

- Controlling chokes created by adding another coil in the role of transformer, e.g., for:

        - control signals

        - monitoring choke saturation

        - current measurement

        - setting the quality factor with thermal relief for the choke and possible energy recovery

        - specific induction setting by premagnetizing the magnetic material

- Medium-frequency transformers

- Flux-compensating chokes



SMP at PCIM Europe 2015: 

PCIM Europe 2015, the leading international trade fair for power electronics, intelligent motion, renewable energy and energy management, 19 to 21 May 2015, Nuremberg, Germany: Hall B6 Stand 306 



Company information:

SMP Sintermetalle Prometheus GmbH Co KG develops and manufactures inductive components and magnetically soft materials, cores and mouldings. Based in Graben-Neudorf near Karlsruhe, Germany, the company was founded in 1982 by Vasilios Gemenetzis and today employs 150 people. Research and development have been key aspects of the company’s philosophy ever since its foundation. SMP’s product range includes low-loss inductive custom components based on in-house-developed powder composites, such as filter, commutating, step-up converter, power recovery and single-conductor chokes. Many of its products are used in the railway industry. The market for inverters for photovoltaic systems that feed solar energy into the electricity grid and for converters for wind turbines is also experiencing strong growth. SMP has become one of the key global suppliers of magnetically soft materials for industrial applications, serving customers throughout the world.



Contact in Germany:

SMP Sintermetalle Prometheus GmbH & Co. KG

Ottostraße 4

D-76676 Graben-Neudorf, Germany

Tel: +49 (0)7255 716 0

Fax: +49 (0)7255 716 160

E-mail: info@smp.de

Internet: www.smp.de

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