• • • TRANSFORMERS & SWITCHGEAR • • •
TOROIDAL TRANSFORMERS: HOW ELECTROMAGNETIC COMPONENTS
ARE DRIVING INDUSTRY OF THE FUTURE The fusion of technology and mass-production has dramatically increased the scale of output in manufacturing. Industrial Internet of Things (IIoT) solutions are now commonplace on production lines, with sensors and robotic equipment elevating manufacturing capabilities by channelling live data from the source By Alex Deakin, Account Manager, Etal Group
ecause advanced digital industrial systems are critical to the future of manufacturing, high levels of service uptime are a prerequisite, with a specific electromagnetic component helping to power the smart factories of today – toroidal transformers. For modern day manufacturing to thrive, these components are critical, but what exactly are toroidal transformers and how are they helping shape the future of the sector?
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What is a Toroidal Transformer? A special type of electrical transformer, toroidal transformers provide increased design flexibility, efficiency and compactness compared to shell and core type transformers. They also known to be lighter in weight and smaller in size compared to conventional off-the-shelf transformers. Toroidal transformers operate under the principles of electromagnetic induction similar to a linear transformer. It features a toroidal core surrounded by primary and secondary windings. As currents flow through the primary winding, it produces an electromagnetic force (EMF) that generates a current in the secondary winding; this process allows power to be transformed from the primary coil to the secondary coil.
All windings are symmetrically spread over the entire core which makes the wire length very short. A higher flux density is also possible as the magnetic flux is in the same direction as the rolling direction of the grain-orientated core, allowing significant savings of volume and weight. A higher current density can flow through the wire as the whole surface of the toroidal core allows efficient cooling of the copper windings.
The Role of Toroidal
Transformers in Manufacturing The unique shape of toroidal transformers offers manufacturers superior performance compared to traditional alternatives. Typically, they are used for power conversion and electrical isolation in critical equipment such as Programmable Logic Controllers (PLCs), motor drives, machinery and Uninterruptible Power Supplies (UPS). However, the main benefit they bring to the
factory floor is high energy efficiency. The compact, lightweight design saves space, and the extremely low Electromagnetic Interference (EMI) is essential to ensuring the precision and data integrity required for modern automation.
As IIoT systems become more compact and densely integrated, the risk of EMI grows. Sensitive electronics operating near high-power components are particularly vulnerable. This is where toroidal transformers offer a distinct advantage. Toroidal transformers are specifically designed to minimise stray magnetic fields, which are a major contributor to EMI. Their circular core creates a closed-loop magnetic path that keeps the magnetic flux tightly contained within the core material. This design significantly reduces the amount of electromagnetic radiation that escapes into the surrounding environment. Additionally, the compact winding geometry of toroidal transformers helps reduce leakage inductance, further limiting the potential for interference. The result is a transformer that emits far less electromagnetic noise, making it ideal for use in IIoT systems where precision and reliability are paramount. By reducing EMI at the source, toroidal transformers help ensure stable power delivery, protect sensitive data channels, and support compliance with stringent electromagnetic compatibility standards.
Increased Efficiency in Manufacturing
Sustainability is a key pillar of the future of manufacturing as factories look to increase output in an environmentally friendly manner. Modern-day transformers are now capable of increasing energy efficiency by design, challenging the carbon- intensive narrative of the manufacturing industry.
34 ELECTRICAL ENGINEERING • OCTOBER 2025
For example, the ideal magnetic circuit of the toroid, together with the ability to run at higher flux density than E-I Laminates, reduces the number of turns of wire required and/or the core cross-sectional area, which reduces energy loss. This is particularly relevant in the manufacturing sector as in recent years, as more attention has been given to energy efficiency and sustainability of electrical equipment. Legislation has been introduced dictating minimum efficiency standards for all types of electrical products, which means toroidal transformers help manufacturers achieve compliance and ensure efficiency.
Shaping the Future of
Manufacturing Providing the bridge between advanced IIoT equipment and the electrical infrastructure, toroidal transformers continue to stay relevant as manufacturers look to introduce more advanced technologies to the production line.
There have never been greater demands placed on the manufacturing industry, whether that’s increased yields, greater IIoT adoption, or reduced carbon footprint. Manufacturers need extra support in navigating this challenging landscape, and it’s clear to see why toroidal transformers continue to play a vital role in shaping the future direction of the industry. In short, toroidal transformers aren’t just a component choice – they’re a strategic decision for engineers building the next generation of smart, connected industrial systems.
https://etalgroup.com
electricalengineeringmagazine.co.uk
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