Safety transformers for safe electronic circuits

Safety transformers are special transformers developed to protect electrical devices and systems from electrical faults and accidents. Their main purpose is to transform the voltage in an electrical network while ensuring safe electrical isolation between the input and output of the transformer.

The main function of a safety transformer is to transform the input voltage to a lower or higher output voltage. This is achieved by the principle of electromagnetic induction, in which a primary coil generates magnetic fields through alternating current, which in turn induce a voltage in a secondary coil.

The main advantage of safety transformers is that they provide galvanic isolation between input and output. This means that the primary and secondary windings are electrically isolated and there is no direct electrical contact between the input and the output. As a result, safety transformers can prevent electric shocks and protect people working with the system from electrical hazards.

Safety transformers are used in various applications, including electronics, power supply, industry and household. They are often used in electrical devices such as computers, televisions, chargers and electrical tools to reduce the voltage to a safer level. In addition, they are also used in power supply systems to transform the voltage of high-voltage networks to a lower level for domestic use.

Safety transformers offer a range of safety features and protective functions, including

1. insulation: safety transformers provide electrical insulation between the primary and secondary circuits. This prevents the crossing of current or voltage between the two circuits and reduces the risk of electric shock.

2. earthing: Safety transformers are usually earthed to improve protection against electric shocks. Earthing ensures that excess electrical energy is safely discharged to earth.

3. overload protection: Safety transformers are often equipped with overload protection to protect against excessive current flow. This can be realized by a fuse or a circuit breaker that interrupts the circuit when the current exceeds a certain limit.

4. short-circuit protection: Safety transformers often have short-circuit protection that switches off the circuit in the event of a short circuit. This can be provided by a short-circuit circuit breaker or a fuse.

5. thermal protection: Safety transformers are often equipped with built-in thermal protection that protects the transformer from overheating. This can be realized by a thermal switch or a temperature sensor that switches off the transformer if a certain temperature limit is exceeded.

6. fire protection: Safety transformers are often designed to improve protection against fires. This can be done by using fire-resistant materials or by integrating fire protection devices such as flame arresters or fire-resistant coatings.

These safety features and protective functions are important to minimize the risk of electric shocks, short circuits, overloads and fires and to ensure the safety of people and equipment.

Safety transformers are usually manufactured in several steps. Here is a general description of the manufacturing process:

1. construction and design: first, the safety transformer is designed according to the technical requirements and specifications. Factors such as the desired output power, input voltage, output voltage and safety aspects are taken into account.

2. material selection: The selection of materials depends on various factors such as performance, voltage tolerance, current carrying capacity and operating temperature. Typical materials used in the manufacture of safety transformers are copper wire for the coil winding, silicon steel for the iron cores and insulation materials such as plastics or paper.

3. coil winding: The coils containing the copper wire are wound according to the requirements. Winding can be done either manually or by machine, depending on the size and complexity of the transformer design.

4. core assembly: The iron cores are assembled according to the design of the safety transformer. This may consist of stacked laminations of silicon steel to improve magnetic properties and minimize energy losses.

5. insulation: To ensure safety and electrical insulation, the various windings and components of the safety transformer are coated with insulating materials. This can be done by coating with varnish or by using insulating materials such as plastic or paper.

6 Assembly and wiring: The various components of the safety transformer are assembled and wired to ensure correct operation.

7. testing and quality control: After manufacture, the safety transformers are subjected to a series of tests to verify their performance, safety and reliability. This may include electrical tests, insulation tests and other specific tests.

It is important to note that the exact manufacturing methods and materials used may vary depending on the application and manufacturer.

Various standards and regulations apply to safety transformers, depending on the area of application for which they are used. Here are some common standards and regulations:

1. DIN EN 61558-1: General requirements and tests for safety transformers
2. DIN EN 61558-2-6: Particular requirements for safety transformers for toys
3. din en 61558-2-8: Particular requirements for safety transformers for medical applications
4. din en 61558-2-15: Particular requirements for safety transformers for welding equipment
5 DIN EN 61558-2-16: Particular requirements for safety transformers for lamps
6 DIN EN 61558-2-17: Particular requirements for safety transformers for illuminated signs
7. din en 61558-2-20: Particular requirements for safety transformers for audio, video and similar electronic circuits
8 DIN EN 61558-2-23: Particular requirements for safety transformers for waveguide microwave equipment

These standards and regulations specify requirements for various aspects of safety transformers, such as insulation resistance, protection against electric shock, thermal characteristics and protection against overload. Compliance with these standards and regulations is important to ensure the safety of persons and equipment.

Safety transformers are used in various applications and industries, especially where a reliable and safe power supply is required. Some of the most important areas of application are

1. medical equipment: safety transformers are used in medical facilities such as hospitals and doctors' surgeries to provide a safe power supply for medical equipment such as X-ray machines, ultrasound equipment and patient monitoring systems.

2. industrial applications: In industry, safety transformers are used to provide a safe power supply for various equipment and machinery. This includes, for example, the power supply for motor controls, pumps, fans and lighting systems.

3. telecommunications: Safety transformers are used in the telecommunications industry to ensure a safe power supply for telecommunications equipment such as servers, routers and switches. This is particularly important to avoid interruptions in the communication network.

4. public facilities: Safety transformers are used in public facilities such as schools, government buildings and airports to provide a safe power supply for various applications such as lighting, air conditioning and security systems.

Why are safety transformers particularly important in these areas?

- Reliable power supply: Safety transformers ensure a reliable power supply by transforming electrical voltages and currents and providing the required power. This is important to ensure a continuous power supply and avoid interruptions.

- Protection against power fluctuations: Safety transformers protect electrical equipment from current fluctuations and voltage spikes that can cause damage or malfunction. This is particularly important in sensitive areas such as medicine or telecommunications, where a stable power supply is essential.

- Insulation of electrical circuits: Safety transformers isolate circuits from each other to ensure the safety of people and equipment. This is particularly important in medical applications to prevent electric shocks and ensure the safety of patients and medical staff.

- Compliance with safety standards: Safety transformers must meet strict safety standards to ensure the safety of people and property. For example, they must provide overload protection, short-circuit protection and fire safety precautions. They are therefore particularly important in industries where safety is a top priority.