Flyback transformer from ZETTLER Magnetics for use in power tools.

According to a recent MarketsandMarkets report, the worldwide market for power tools is estimated to reach USD 41.7 billion in 2024 with a CAGR of 5.5%. Growing adoption of cordless power tools, rising demand for fastening tools in industrial environments, and growing construction industry in emerging economies are the key factors driving the growth of the power tools market.

Currently, drilling, fastening and screwdriving  tools hold the largest market share in the power tools market, and a similar trend is likely to continue during the forecast period. Within that segment residential and “Do-it-yourself” applications are  expanding strongly, driving demand for compact, and easy-to-handle products with robust performance. For manufacturers, this creates challenges in designing ergonomic, lightweight and easy-to-handle power tool products.

A leading power tool manufacturer needed an extremely compact flyback transformer in SMT construction for its next generation cordless charger. To ensure stable load regulation, the transformer required very low leakage inductance. In cooperation with the customer, ZETTLER Magnetics’ engineers were able to develop a transformer solution that meets these specifications in a small size, as well as in compliance with EMC regulations. Customized solutions at competitive prices are at the center of ZETTLER Magnetics’ commercial and engineering philosophy.

Please Contact Us For more information about similar applications and custom solutions, as well as about the comprehensive products from ZETTLER Magnetics.

Join ZETTLER Group on October 15th in Anaheim at the Future Electronics Tech Day!

Location: DoubleTree
Suites by Hilton Anaheim Resort – Convention Center, 2085 S. Harbor Blvd.
Anaheim, CA 92802

Event Date: Tuesday
October 15, 2019

RSVP: Register by Tuesday October 8, 2019

Join Zettler Group for this Free Event

Future Electronics invites you to attend the most advanced hands-on technical learning event in the region. This is a unique opportunity to gain exposure to new technology as you interact with over 50 of the industry’s top suppliers at the Technology Expo event. You can also choose to spend time in the classroom with deep-dive technical training taught by key technologists. Choose your own classes and customize your learning to your training needs.

Event Overview

Future Electronics is bringing together the largest group of leading technologists, from the industry’s top suppliers, to help you connect and learn about the latest technologies, tools, and services. The Technology Expo event will be open all day starting at 8:30am. We are offering 24 classes throughout the day ranging from the latest in edge computing, wireless, sensing, security, artificial intelligence, high performance analog, power, signal chain, connectors, IoT, and much more. We will be providing breakfast, lunch, and snacks throughout the day

Zettler Group

The Zettler Group will be exhibiting our latest product and service offerings for relays, magnetics, and customized LCD solutions. Meet our technical sales team and learn more about our products and latest offerings.

Zettler Magnetics High Frequency Switching Transformers in 3 phase EV Charging Systems.

Application Spotlight September 2019

Zettler Magnetics develops a high-frequency transformer for e-mobility market

The expansion of the electromobility market has provided consumers with choice in EV cars ranging in battery size and range.  Vehicles with larger battery sizes like the Tesla Model S provide users with over 300 miles of range, meaning a single charge can last an entire week for most users.  Other vehicles like the Nissan Leaf or Hyundai Ioniq provide less than half the range and charge times meaning some users could expect more frequent charges. When limited to 7kW single phase charging systems, the longer charge times force users to carefully manage their charging and travel times.The availability of 3 phase EV supply equipment (EVSE) simplifies the user experience by providing faster charge times ranging from roughly half the charge time for a 11kW EVSE to a third of the charge time for a 22kW EVSE.

high-frequency transformerA leading manufacturer in charging infrastructure approached ZETTLER Magnetics in need of a high-frequency transformer for its internal switch mode power supply (SMPS). The challenge for the engineers at ZETTLER was to develop a high-efficiency switching transformer for high input voltages up to 400VAC in a new 3-phase EV charging cable. ZETTLER Magnetics met these challenges with a custom designed high frequency switching transformer, providing for the smallest possible space while also complying with common UL and IEC61558 standards.

ZETTLER Magnetics manufactures more than 40 million switching transformers each year to support a diverse range of applications from washing machines and kitchen appliances to Lighting and IoT. Please contact us with any of your switching transformer needs and/or visit the ZETTLER Magnetics website www.zettlermagnetics.com for further details.

ZETTLER Magnetics Inc. is not affiliated with or endorses any of the electric vehicle brands/models mentioned above, and makes no representations whatsoever to their performance parameters or on-road performance.Their mention in this application spotlight is purely for educational purposes.

ZETTLER’s AHI transformers selected for use in food processing equipment

Zettler AHI transformers selected for use in food processing equipmentWhen designing electrical equipment for international markets, engineers are forced to consider the requirements of a seemingly growing number of countries. If equipment is connected to the electrical grid, this includes additional safety requirements to isolate and protect people and property from dangerous voltage levels.

For designers in need of linear Class 2 transformers, Zettler offers a robust line of international power transformers with an industry leading 4200Vrms isolation rating.  A leading US appliance manufacturer recently chose Zettler Magnetics’ AHI01024 transformer for one of their products supplied globally. The appliance was designed for a commercial kitchen environment, meeting the high standards and daily routine of a busy restaurant.

Zettler Magnetics AHI01024 50/60Hz isolation transformerThe Zettler AHI series of laminated PCB transformers offer 115V or 230V input capability in 2.5VA, 5VA and 10VA configurations with outputs ranging from 5VAC to 36VAC.  They are UL Class 2 recognized, constructed with a UL Class B (130°C) insulation system, and conform to IEC/EN61558-1.  Custom options are also available.

Please contact us with any of your transformers needs and/or visit the Zettler Magnetics website for further details.

Customized Transformer Solutions by Zettler Magnetics for Household Appliances.

High Frequency Ferrite Transformers are a major component of switching power supplies, and choosing the right product configuration is a key element in any power supply design.
ZETTLER Magnetics’ proven formula of close customer engagements focused on individual design requirements, combined with highly cost-effective manufacturing automation is perfectly suited for many industry applications.

Customized Transformer Solutions by Zettler Magnetics in Household AppliancesApplication example: Household Appliances

Recently, an industry-leading home appliance manufacturer asked Zettler Magnetics to design a 2.6W switching power supply transformer with a wide input voltage range that meets several critical requirements including: electromagnetic interference performance to achieve EN55022, pass 85/85 temperature and humidity testing to meet IEC61558, and meet IEC60335 electrical performance and structural insulation requirements.

Zettler Magnetics XM-E16187 power supply transformer.A team of Zettler Magnetics engineers custom-designed a transformer by performing double-layer shielding of the inner and outer layers, while using minimalist skeleton design.
The tailor-made transformer met the customer required design parameters, simplified materials during the design process, while also optimizing the electrical performance of the product, and enabling fully automated high-volume production.

 
Zettler Magnetics produces more than 40 million transformers per year and has power supplies ranging from more than 50 different form factors to 1W to 1KW. To support a wide range of applications from washing machines and kitchen appliances to lighting and the Internet of Things.

ZETTLER Magnetics 1-Watt Switch Mode Power Supply in High Volume Smart Lighting application.

Application Spotlight, January 2019.

Zettler Magnetics continues to support the burgeoning Smart Lighting control market with its expanding range of Switch Mode Power Supplies.

Zettler Megnetics HP01SXX00WI-X module

ZETTLER’s 1 Watt Encapsulated SMPS was recently selected by a global leader in the Lighting industry. The application required a compact, cost effective plug & play solution with regulatory agency approvals. With an additional requirement for a zero-cross detection feature, ZETTLERS’s HP01SXX00WI-X module offered the ideal solution.

Zettler Solutions for Indoor Lightening

Lighting control is just one of the many Smart Home and IoT applications where Zettler’s SMPS modules are the ideal choice. These fully integrated, competitively priced plug & play modules offer excellent efficiency and EMI performance in a small form factor.

ZETTLER produces the entire range of SMPS modules, from 1W to 20W, in high volume at its wholly owned manufacturing facility in Xiamen, China.

Please contact us with any of your Switch Mode Power Supply needs and/or visit the
Zettler Magnetics website for further details.

About ZETTLER Magnetics, Inc.
Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.
Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Zettler Magnetics range of Ferrite Switching Transformers supports large spectrum of Custom Power Supply solutions.

Product Spotlight October 2018

High Frequency Ferrite Switching TransformerOver recent years, Zettler Magnetics has expanded its range of High Frequency Ferrite Switching Transformers to now cover more than 50 different form factors, supporting power supply designs ranging from 1W to 1KW.

Selection of the appropriate structure is a critical element in any power supply design, which needs to consider a variety of electrical, safety and mechanical parameters.
Appropriate solutions therefore typically involve custom designs. At the same time, customers expect competitively priced solutions.




Zettler Magnetics’ response to this challenge is based on a two-pronged approach. An experienced team of transformer design-engineers closely engages with the customer in regard to individual design requirements, while highly automated production lines support a broad range of possible form factors, hence allowing us to manufacture high-volume custom designs at very competitive prices.

Example Application: Outdoor Lighting Control

Zettler custom switching transformer applicationRecently, an industry leader in Street Lighting Control requested Zettler Magnetics to design a 2.6 Watt wide input-range, custom switching transformer. The customer had unique requirements for operating temperature, UL Class B insulation, and physical size constraints within the Controller. Zettler was able to design a custom transformer meeting all of these design parameters. The bespoke design was tailored to suit Zettler’s high volume automated production line capabilities, resulting in a highly cost-effective solution for this transformer application.

Zettler Magnetics manufactures more than 40 million Switching Transformers each year to support a diverse range of applications from washing machines and kitchen appliances to Lighting and IoT. Many of these high-volume designs are manufactured on fully automated production lines in Zettler’s wholly owned manufacturing facility in Xiamen, China.

Please contact us with any of your Switching Transformer needs and/or visit the Zettler Magnetics website www.zettlermagnetics.com for further details.

About ZETTLER Magnetics, Inc.
ZETTLER Magnetics, Inc., a ZETTLER Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

ZETTLER Magnetics 1W Switch Mode Power Supply selected for residential smart home system

Application Spotlight May 2018

The Design
ZETTERs customer, a global leader in wireless communication protocols, selected a 1 watt SMPS from Zettler’s new HP01 series to power the control unit of their new wireless sensor solution for building automation and smart homes. The application wirelessly controls light switches, thermostats and almost any IoT device. The customer required a compact package, energy efficiency and competitive pricing to compete in the competitive market of wireless connectivity.

About the Power Supply
ZETTLER’S encapsulated SMPS series are a compact, energy efficient, plug & play solutions for the IoT market. Zettler’s versatile range of encapsulated switching power supplies offer a wide input range up to 90-305VAC for universal coverage, a high ambient temperature rating up to 85C at full rated load and an energy efficient low stand by power of custom solutions and zero cross detection are also available.

About ZETTLER Magnetics, Inc.
ZETTLER Magnetics, Inc., a ZETTLER Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

ZETTLER Magnetics provides an Encapsulated Power Transformer for a residential security application

Application Spotlight February 2018

The Design
Application solutions for residential security systems require highly reliable,
low-frequency power transformers with UL recognition. At the same time, the price
competitive nature of the residential security business also dictates the need for
low cost solutions. A leading manufacturer of home security systems recently put
these requirements to the ZETTLER Magnetics engineering team. In addition, the customer
also demanded a transformer in a compact size and with excellent heat dissipation
to accommodate the sleek and modern design of the control panel of the application.
ZETTLER’S 1.5VA BV series encapsulated transformer seamlessly met all these requirements while costing less than an electrically equivalent
laminated transformer.

About the transformer
ZETTLER’S versatile BV series of encapsulated transformers are less expensive than traditional laminated transformers while providing better
performance… the best of both worlds! Encapsulating the transformer in epoxy
improves isolation and heat dissipation, which allows for a smaller package size
that still meets UL’s stringent class II standards. Suitable for a wide range
of industrial control applications ZETTLER’s BV series [/encapsulated-power/]
is available in 115V or 230V inputs and from 0.35VA to 10VA. ZETTLER builds the
BV series, at our factory
in Southern China, on automated production lines which ensure consistent quality
at a very competitive price.

About ZETTLER Magnetics, Inc.
Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.
Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Switch mode power supply modules from ZETTLER Magnetics in intelligent street lighting concepts

Application Spotlight June 2018

Munich, Germany 20. of June 2018 –Future street lighting concepts and their intelligent control include far more functions than simply illuminating the surroundings. These include e.g. automatic regulation of the lighting level via sensors, charging functions for electro mobility or the integration of traffic control systems or the detection of parking space utilization.

For a leader in intelligent lighting control systems, ZETTLER Magnetics recently customized its standard ZP05 5 Watt power supply module series to meet all specific customer requirements. In particular, outstanding EMC values in the use of the controller for the power line communication convinced the customer to choose the Zettler power module in this application .

The components have a universal wide-range input of 85 to 265 VAC or 100 to 370 VDC and are available with common output voltages.

ZETTLER Magnetics SMPS are deployed in a wide range of applications such as smart home controls, wireless switching, lighting controls (incl. LED boards), test and measurement devices such as smart meters, as well as a variety of white goods and appliances.

For more information about similar applications, as well as about the comprehensive switch mode power supply solutions from ZETTLER Magnetics please contact us.

About ZETTLER Magnetics Europe – ZETTLER Magnetics Europe, a ZETTLER Group division, provides application-engineering, sales, distribution and customer service in the EMEA region for a wide variety of top quality transformers and magnetics components. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. Our sales, marketing, technical support, quality control and customer service departments work closely with our team of experienced design engineers at our manufacturing plant to help define the needs of our customers, and to provide optimal technical solutions for the most demanding application requirements. ZETTLER Magnetics engineering departments and manufacturing facilities, located in Xiamen, China, are fully vertically integrated and wholly owned. Read more at www.ZETTLERmagnetics.eu.