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how to specify a transformer for manufacture
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jaunty:
So i have occasion to need to get some toroids built ... I described what i needed in terms of windings and taps on primary and secondary sides - expected voltage and current load on each winding etc and am being told by the manufacturer's sales department that it's simply not enough to base an estimate on ... i think i was rather thorough ... but they are insisting i send in a sample unit before giving an estimated price. What gives?? Is there something i am missing here? I believe i answered all their questions to their satisfaction... anyone here had transformers built for manufacture? One aspect that occurred to me is that there's always a kind of cultural or sociological boundary involved when trying to do business with new people ... a trust has to be built up first (?) (not very professional of them i would say though)
jaunty:
well technically i AM trying to 'clone' a product - though in this case the product is just a normal toroidal tansformer - but the manufacturer has been out of business since the late 80s ... i mean LOTS of people make these things right? you can't really patent, say, a toroid with a 110/240v primary and three secondaries at 15/15/5v .. plust a tap ...? i'm also wondering if maybe the quantitiy was too low to be of interest that they were just trying to make it hard for me ...
james_s:
The transformer place I've dealt with has their own magnetics engineer and can perform these services. When I designed a transformer I provided them with complete specs, core type, wire gauge, turn count, etc. They modified a few mechanical details to suit their manufacturing process but otherwise built it as designed and it worked out.
soldar:

--- Quote from: jaunty on December 21, 2018, 04:17:25 am ---So i have occasion to need to get some toroids built ... I described what i needed in terms of windings and taps on primary and secondary sides - expected voltage and current load on each winding etc and am being told by the manufacturer's sales department that it's simply not enough to base an estimate on ... i think i was rather thorough ... but they are insisting i send in a sample unit before giving an estimated price. What gives?? Is there something i am missing here? I believe i answered all their questions to their satisfaction... anyone here had transformers built for manufacture? One aspect that occurred to me is that there's always a kind of cultural or sociological boundary involved when trying to do business with new people ... a trust has to be built up first (?) (not very professional of them i would say though)

--- End quote ---
How many units do you need? Because I can understand their reluctance if the quantity is small. It is just not worth their time. Or they would have to quote a price you would surely not want to pay.

You might need to approach someone who does prototypes and small series.

Having said that, there are other red flags in your post. Do you have for them a complete detailed specs of what you want built? Core material and properties, wire specs and properties, insulation, etc. Is it all materials they work with and have in stock?

Either you design it completely and take responsibility for the result or you can give them some specs and ask them for a design. What you are asking, it seems, is to give them sort of a rough design (x turns) and then talk about voltage which is your problem, not theirs. So you are kind of asking for them to review your design and I can understand their reluctance to get involved in a project for a small quantity with someone who is not sure of what they want. To them this is a sign of a customer who will take much of their time and give them much trouble and little profit. 

If the quantity is small you might want to wind them yourself.  If you want to order them I would advise you to go to some place where they do small orders and can help you with the design.

If you post your requirements in detail maybe we can help further.
Benta:
This is complete BS. Mains transformer companies do this every day.
You specify primary voltage(s), secondary voltage(s) VA, operating temperature, isolation class, form factor/shape and that's it.
My feeling is that you're trying to get some Chinese super low cost offer, which explains the reaction from the manufacturer.

One-offs cost a bit.

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