Designing Electromagnetic Components for Aerospace

Aerospace technologies have such unique demands that call for precision. This means that aerospace has developed, essentially, a separate field of magnetics that relies on many different electrical systems and components. Modern avionics integrates magnetic components in alternators, generators, inverters, rectifiers, and transformers to create and distribute electricity. Current and voltage convert this electricity to each receiving system’s needs, which is essential in controlling altitude, monitoring flight paths, and tracking location. Some aerospace electromagnetic components are more important than others; however, they play key roles in keeping these systems operating. Without electromagnetics, these flight systems would be impossible. Electromagnetic components are designed for various aerospace specifications and depending on the unique needs of different aircraft types, such as weight, available space, and size. These factors are often uncompromising, and even different aircraft of the same type will have different needs due to differences in applications. This means electromagnetic components must be uniquely integrated with electrical systems. Magnetic components are valuable throughout various military applications and are used for missile defense, jamming, or protecting signals (infrared, ultraviolet, visible light; radio), radar, etc. For example, the Electromagnetic Aircraft Launch System (EMALS) system helps aircraft launch from carriers. Unique Aerospace Magnetic Components:

• Air-Core Conductors: These conductors are set apart from many other kinds of electromagnetic parts due to their unique design. Conductors are applied to materials like PTFE and glass, making them lighter than components wound around centerpieces of ferromagnetic material. They can even be applied to just air. In aerospace, every ounce of weight factors into flight. This makes having a lighter component key to efficient weight distribution. Conductors are designed and produced for very-high-frequency (VHF) and ultra-high frequency (UHF) radio frequency applications.
• Isolation Power Transformers: They protect users and sensitive aerospace electronics by separating primary and secondary windings. This is vital for aerospace systems, as electrical shorts can be incredibly problematic. Any issues with various systems pose dangers to the flight crew, passengers, and others.
• Transformer Rectifiers: These units operate on 3-phase AC power sources. They support many aerospace systems; they’re available in different sized models with an output that ranges between 10 and 400 amps and in both 12-pulse and 24-pulse models. Transformer rectifier units output a range of DC voltages, usually 28V DC. Their output power is clean and can be up to 88% efficient.

Syrma: Magnetics Manufacturer We provide a full range of custom magnetic assemblies and magnetic products. Our advanced and scalable production resources enable us to meet your cost and performance specifications. Magnetic components (chokes, inductors, and transformers) are key aerospace, automotive, computers, consumer electronics, defense, home appliances, and lighting. Our Ferrite core transformers, both through-hole and SMD type, have up to 500 watts with a frequency of up to 300 kHz. Our inductors operate over a wide range of frequencies, input voltages, and inductance values. Our chokes protect circuits from high-frequency alternating current and allow for low-frequency direct current. Our engineering team draws upon over 20 years of experience at the forefront of analog design and manufacturing to ensure a streamlined end-to-end product cycle, from prototyping and testing through high-volume production. Our localized supply-chain ecosystem enables us to seek lower costs among trusted suppliers constantly. Core materials used in magnetics include cobalt alloys, ferrite, metallic glass, nickel alloys, and silicon iron. The construction of coil devices varies widely in the number of turns of the magnet, tefzel, and litz wires. Most windings are automatically wound on thermoplastic or thermoset bobbins, which offer excellent ground insulation, the most effective use of window area, and the greatest amount of control for through-hole or surface mounting. Backed by 40 Years of Expertise Syrma SGS has been the preferred value creator for its customers over the last 40 years through innovative and efficient electronic system design and manufacturing (ESDM). We provide high-mix, adjustable volume, precision OEM manufacturing with a rich supply chain ecosystem that catalyzes growth in the electronics manufacturing industry. Our one-stop-solution electronics manufacturing services include product design, assembly (PCBA & box build), quick prototyping, repair & rework, and automatic tester development services. In November 2020, Syrma acquired SGS Tekniks, an equi-sized pure-play EMS company, to become an Rs.1000 Cr. entity. This merger enhances our geography, capacity, and capability footprints possessing a total plant area of 450K sq ft area with 14 SMT lines across our 11 facilities across India. Syrma SGS also offers OEM solutions for RFID tags & inlays, high-frequency magnetic components, and electro-mechanicals for all Industries. We serve over 140 OEMs in 20+ destinations and have supplied hundreds of million units in the last decade. To learn more about this topic, please contact us.