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Exxelia's Smart Magnetic: Breakthrough technology for more compact and powerful converters

The solutions provided by Exxelia's Smart Magnetic project are revolutionizing the field of electrical converters by offering unparalleled performance in terms of power density.

Smart Magnetics Exxelia

This advance makes it possible to design more compact, lighter converters. However, the advantages of this technology are not limited to these fundamental aspects. In this article, we will explore in detail the multiple functional, economic and environmental benefits offered by Exxelia's Smart Magnetic technology.

 

Functional advantages for increased reliability:

The Smart Magnetics project makes it possible in particular to optimize the Dual Active Bridge topology which requires the combination of a transformer and a choke.

The Dual Active Bridge converter is a technology that is becoming widespread because it allows bidirectional power transmission. This meets the challenges of electrical systems (recovery + supply of energy),

Integrating the Dual Active Bridge (DAB) transformer and choke into a single component has significant functional advantages. Unlike assembling two separate components, using an integrated component eliminates interconnections. The repeatability and reproducibility of the processes guarantee perfect control of the electrical characteristics, and ensure optimum performance of the converter. In addition, this consolidation reduces the number of components required, which improves the reliability of the final product.

 

Rationalization of the value chain for optimized production costs:

The Smart Magnetic project also contributes to improving the value chain through effective streamlining. By replacing two distinct components with a single component, the management of the components of the circuit is simplified. From the customer's point of view, there is only one product to supply, one product to integrate/assemble in the system. These simplifications result in high added value and increased competitiveness on the market.

 

Contribution to a more environmentally friendly industry:

By adopting Smart Magnetic solutions, the benefits go beyond simply improving energy efficiency. This innovation also reduces the consumption of raw materials by using less material in the Smart Magnetic component compared to standard formats requiring two separate components. As a result, this technology contributes to the preservation of natural resources. In addition, Smart Magnetic responds to the challenges posed by the electrification of vehicles, whether in air, land or sea transport, by promoting the deployment of solutions that are less dependent on fossil fuels.

 

Various applications:

The versatility of Smart Magnetic solutions makes it suitable for many applications. For example, it can be used as a bi-directional converter between batteries and circuits, for power applications or even in resonant converter topologies. It is also useful in applications requiring high current and in Multi-output flyback converters. This diverse range of applications testifies to the flexibility of the Smart Magnetic project.

 

A project ? Do not hesitate to contact us.

 

 

Published on 24 Jul 2023 by Stephane PERES

New entity, Exxelia Magnetics

This is an internal merger of two innovative, professional and complementary companies both designer and manufacturer of high-end would magnetic components, which have a history of successfully working together for a year. Exxelia Magnetics will have greater scale, breadth and capabilities to compete more effectively in the global marketplace. Exxelia Microspire Microspire was founded in 1978 and became part of Exxelia Group in 2008. Exxelia Microspire has been designing, developing and manufacturing wound components for over 35 years: transformers and inductors, electro-magnets, rotors and stators. Exxelia Microspire has several manufacturing sites, notably newly located low production cost facilities offering competitive solutions. Exxelia Microspire’s know-how includes standard winding technologies: linear (in RM, ETD, EP, EFD, ER, EQ and other formats) and toroid. For harsh environment applications with shock, vibration, and high temperature issues, Microspire offers innovative specific technologies including SESI, TT and CCM. Exxelia Microspire’s qualified technologies, clearly defined design rules and industrial organization provide the platform on which it is able to offer its customers optimal solutions. Exxelia N'Ergy Exxelia N’Ergy (ex N’Ergy) was acquired in 2015 by Exxelia Group.  Exxelia N’Ergy designs and manufactures passive specific electromagnetic components in small and medium range: Transformers, Chokes, Sensors (tachometer, gyros, …), Electromagnets.

WT83 - High Capacitance wet tantalum

Capacitance values have been strongly increased with Exxelia's new range of tantalum capacitors:  WT83 is an extension of the ST79 families (according to CLR93 MIL values) but with double the capacitance. That is a pass for impactful miniaturization of existing designs by playing on both size and weight (for instance, WT83 offers  470µf  100V in a D size, whereas ST79 only gives 220µF in the same other conditions).      
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