Custom 50A 100A 150A High Current Inductor For Industrial UPS And Inverter

The AS777026 is a toroidal PFC inductor designed as the boost inductor in an active power factor correction stage. In a PFC converter the inductor is the element that stores energy during the switch on period and releases it to the output during the off period, which is what allows the converter to shape the input current so that it follows the input voltage waveform. The quality of this inductor therefore decides the power factor the finished supply can reach, the level of input current distortion, and how much of the input power is lost as heat before it ever reaches the load.

The AS777026 is built on a toroidal powder core wound with heavy gauge enamelled copper wire in a single layer. A toroidal geometry keeps the magnetic path closed inside the core, so leakage flux and radiated emission are much lower than an equivalent gapped bobbin design. A distributed air gap powder core gives a soft saturation curve, which means the inductance falls gradually as DC bias rises instead of collapsing at a defined knee. For a PFC stage this behaviour is important, because it allows the converter to survive load transients and inrush events without the inductor going hard into saturation and the current loop losing control.

The assembly is finished on a small PCB base with two heavy through hole pins. This gives the coil a defined footprint, keeps the winding mechanically stable during transport and vibration, and lets the customer wave solder the part as a standard through hole component instead of hand fixing a loose toroid.

The AS777026 is manufactured to order. Inductance, current rating, core material, wire gauge, turn count, pin spacing and base dimensions are all defined against the customer drawing or the electrical requirement of the customer converter.

Note: inductance, rated current, core material, outer diameter and turn count are defined per application. Approval samples and drawings are issued for your confirmation before mass production.

• Toroidal closed magnetic path. Because the flux stays inside the ring, stray field is low and the inductor couples very little noise into nearby traces, sensors and control circuitry. In a PFC stage that sits directly behind the input rectifier, this makes conducted and radiated EMI significantly easier to pass, and often reduces the amount of input filtering the customer has to add.
• Soft saturation powder core. The distributed gap inside a powder core gives a gentle inductance roll off with DC bias instead of a sharp saturation knee. The converter keeps control of the current loop during load steps and startup inrush, which protects the switching device and improves real world reliability rather than only bench performance.
• Single layer heavy gauge winding. Spacing the turns in one layer reduces interwinding capacitance and proximity effect losses, so the AC resistance stays low at switching frequency and the coil runs cooler at full load.
• Low core loss under high frequency ripple. The core material is selected against the customer switching frequency and ripple current, so loss is optimised for the actual operating point instead of being a catalogue compromise.
• Mechanically stable assembly. The coil is varnish impregnated and fixed onto a rigid PCB base, so the turns do not shift under vibration or thermal cycling. Stable geometry means stable inductance over life, which means the control loop of the converter stays in tune.
• Through hole pin termination. Two heavy pins on a defined footprint allow standard wave soldering and give a mechanically strong joint that can carry high continuous current without relying on the solder fillet alone.
• Built around your converter. Inductance and current rating are engineered from your topology, switching frequency, ripple target and thermal budget, not picked from a fixed list.

• Industrial switching power supplies with active PFC front end
• Solar inverters and energy storage power conversion systems
• Uninterruptible power supplies and industrial backup power
• Motor drives, servo drives and variable frequency drive input stages
• LED industrial lighting power modules requiring high power factor
• Welding equipment and industrial heating power supplies
• Telecom and server rectifier modules
• Industrial battery charging systems and DC power modules
• Test and measurement power sources

Typical circuit positions include the boost inductor in a continuous conduction mode PFC stage, the choke in a bridgeless PFC topology, the output inductor in a buck stage, and the energy storage inductor in an interleaved converter where two matched parts are used in parallel phases.

• Established in 2000, with 26 years of continuous experience in magnetic components and power solutions for industrial control and power electronics.
• A 10,000 square metre self owned factory with 8 complete production lines, so capacity, process control and delivery are managed in house rather than subcontracted.
• Toroidal winding is a core in house process, supported by a 20 person R&D team and a 20 person quality control team covering incoming material and outgoing product inspection.
• Certified management system: ISO 9001 for quality and ISO 14001 for environment. Products comply with RoHS and REACH, with CE, CB, UL and cUL coverage across the product range.
• Annual export value of 42 million USD, serving North America, Northern Europe, South America and Southeast Asia, including established industrial equipment brands.
• An 11 person export team providing direct technical communication in English, so engineering questions are answered without a trading company in between.

• Higher measured power factor and lower input current distortion, because the inductor is designed against your actual ripple and frequency rather than selected from a standard catalogue.
• Lower system EMI. The closed toroidal path reduces stray field at the source, which is cheaper and more effective than filtering it out later.
• Better thermal behaviour at full load. Single layer heavy gauge winding and a matched core material keep both copper loss and core loss under control.
• Predictable behaviour during transients. Soft saturation gives the control loop margin that a hard saturating gapped core does not.
• Consistent inductance batch to batch. Controlled winding tooling and 100 percent electrical testing keep the part inside the tolerance window your converter needs.
• Free electrical design service. Send the specification and we will propose core material, turn count and wire gauge, then confirm it with samples.