SUCCESS

STORIES

Success Stories

Telecom

Infrastructure

 

NEED

  • Telco towers (the backbone infrastructure for supporting the telco network) need high performance, compact transformers in the Servers used for managing them.

CHALLENGE

  • Requirements are very demanding on efficiency and temperature limits for the transformers used in these Servers.
  • Requirements are very demanding on efficiency and temperature limits for the transformers used in these Servers.

SOLUTION

  • Elmas did a complete grounds-up design after understanding their needs.
  • It resulted in lesser usage of Copper and also contained the temperature rise to requisite limits.
  • A combination of materials used and the circuit layout helped reduce costs as well.
 
 
 

While this exercise got us good recognition from the customer, what gave us added satisfaction was that it resulted in a win-win situation.

 
 
 

Success Stories

Solar inverters

for use in households

 

'Flexes' its Design Strength

NEED

  • Redesigned Original equipment (Inverter) for improvement in functionality resulted in
  • Smaller footprint and tighter dimensions.
  • Transformers and Chokes from Elmas had to be fitted in
  • Without compromising functionality and reliability.

CHALLENGE

  • Existing sizes for transformers and chokes were optimized for best performance
  • Changes in dimensions would impact performance and reliability
  • New original equipment with smaller dimensions required proper fitment of the power devices (transformer and choke).
  • Solution from Elmas was critical to retain customer.

SOLUTION

  • Thorough study of the layout of the inverter offered clues.
  • Change in dimensions was in the horizontal plane; in the vertical plane there was relatively lesser constraint.
  • Elmas did a complete overhaul of the topology so that the Choke could piggyback on top of the transformer.
  • Layout and mounting was modified to fit the dimensional needs of the final product.
 
 
 

For Elmas it was not just about retaining the customer – the outcome was so satisfying professionally since the end result was accomplished without any compromise, yet delivering an increased value to the customer.

 
 
 

Success Stories

Stepdown

& K Rated

 

K-13 Isolation transformer

CHALLENGE

  • Imported machinery & equipment from Japan operate at voltage levels that are distinctly different from those in India. Typically they work on 200 V, 3 Phase modes. In India however the standard is 415V/400 V , 3 phase modes. The customer's requirement was for a step-down of the incoming 400 V to 200V to enable the equipment operate as per its design norms. In addition, in this specific instance, the equipment in use was of a very sensitive nature and it was a non-linear load. The expectation from the customer was to address the twin needs of step down as well as suppression of the harmonics.

SOLUTION

  • The design team at Elmas understood the critical nature of the client’s requirements. A detailed study of the load conditions was done. Involved calculations resulted in a design output that suggested the best solution was a K-13 Isolation transformer with a step down capability. This comfortably met the voltage step down needs and also helped attenuate the harmonics generated by the non-linear loads.

RESULT

  • The integrated solution of the K-13 Isolation transformer was an effective solution. Instead of two transformers with its attendant costs and foot print implications a single device met the needs of the customer. It resulted in savings of 50% for the customer and reduced the footprint for the solution by 60%.

Success Stories

Capital Equipment with high sensitivity to power conditions

 

Steps' for a 'Capital' Win

NEED

  • Step down from 400V 3 Phase modes to 200 V 3 Phase modes.
  • Capital equipment was highly sensitive to non-linear loads
  • Necessitating dampening the harmful harmonics

CHALLENGE

  • High cost imported Capital equipment could not change their electrical system.
  • A local solution was mandatory
  • Step down the input voltage
  • Counter the harmonics generated due to non-linear loads

SOLUTION

  • Grounds up design resulted in a K-13 isolation transformer as the most practical solution.
  • A single transformer met the twin needs of
  • Step down voltage
  • Attenuate the harmonics
  • More than 50% cost savings and more than 60% reduction in footprint.
 
 
 

Such experiences have emboldened the team at Elmas to invite our customers share challenges in the field of transformers and magnetics, both for current products or for new projects under development. We are certain that with both teams working closely, there would be workable.

 
 
 

Success Stories

Telecom towers infrastructure

 

'breathes Life' to revive Telco operations

NEED

  • Diagnose the root cause for the high failure rate of 3rd party transformers deployed in thousands in the field.
  • Have a work-around that avoids if not minimizes large scale recall and replacement.

CHALLENGE

  • Recall and rework would have entailed an enormous financial burden not to mention the end-customer's loss of trust and faith with the supplier.
  • A rapid, workable, field-deployable resolution was critical.

SOLUTION

  • A thorough dissection of the 3rd party transformers was done. Quickly the problems were isolated to the tapping design as also use of inappropriate components in the circuitry.
  • The solution provided was elegant in that a small workaround in the existing circuitry and design overcame the problems.
  • An otherwise costly and time-consuming recall and replacement was thus avoided.
 
 
 

Should you have challenges in the field of transformers, magnetics and Power Electronics both for current products or for new projects in development, do involve us. We are confident that in partnership with your team we would be able to evolve good feasible solutions.

 
 
 

Success Stories

'Star' rating for 'K-Rated' transformers

 

'Flexes' its Design strength

NEED

  • Diagnosis the problem of burning and failure of 400KVA transformers deployed in Data centres.

CHALLENGE

  • Relatively new domain.
  • Rapid diagnosis as well as evolution of a practical solution.
  • Address field installations.
  • Institute changes in all future shipments.

SOLUTION

  • Investigation led to quick identification of problem
  • Faulty insulation was unable to withstand temperature rise.
  • Workmanship too of the inner transformer construct was a contributor.
  • Both the areas - proper insulation on winding; as well as an improved manufacturing process - were recast for effectiveness.
  • Modified transformers withstood stringent quality testing.
 
 
 

This spirit of 'can-do' at Elmas is quite infectious making each of its team members to rise up to newer challenges in the field of power management. Do continue to involve us for all your requirements.

 
 
 

Success Stories

Nuclear power plants – Transformers in Atomic power installations

 

NEED

  • Robust transformers for use in Nuclear power plant installations
  • Apsara nuclear research project by NPCL through ECIL needed special design
  • Had to withstand seismic shocks and adverse climatic conditions (being located primarily on coastal areas).

CHALLENGE

  • Standard design for transformers used in industries had to be redone.
  • Changes in design and build had to still deliver performance and reliability.
  • Despite building robustness cost of ownership could not be compromised.

SOLUTION

  • Grounds up design philosophy was adopted
  • Rethink the complete construction and layout.
  • Numerous iterations to get the mix right.
  • Rigorous testing at CPRI, Bangalore proved the mettle of the transformer.
  • Elmas gained quick acceptance in this specialized domain to supply to other atomic power plants.
 
 
 

Elmas has been fortunate to have had customers rely on its 'never say die' spirit. This has helped the young team at Elmas gain good working knowledge and experience across diverse end user applications.

 
 
 

Success Stories

High rating transformers in sensitive applications

 

NEED

  • Overcome high in-rush currents in transformers to reduce damage to the costly equipment and also minimize if not avoid outages due to tripping of the circuit-breaker.

CHALLENGE

  • Matching Transformer design is impractical and too costly.
  • The time-tested solution of a Soft-starter had only transient success.

SOLUTION

  • Innovative design that increases Transformer’s impedance on high in-rush current.
  • The ‘In-rush current limiter’ designed scored on many counts
    • Less complicated design.
    • Lesser component count in the build.
    • Higher reliability.
    • Easy field diagnostics and resolution.
  • The new solution successfully withstood highly adverse ambient conditions.
 
 
 

This was one instance where it was not a case of ‘Fools rush where Angels fear to tread’!

 
 
 

Success Stories

Inverters for the Consumer segment

 

NEED

  • Seasonal peaking of demand for transformers used in Home Inverters.
    • This happens in the March-July period due to severe summer with attendant power cuts.

CHALLENGE

  • Unpredictable forecasts resulting in need for fast turnarounds to deliver transformers.
    • The scale up in volumes had to go up by over 100%!
  • It was not feasible to add equipment or additional hands for such variations just for the season!
    • Yet the need was real. And the business opportunity BIG!

SOLUTION

  • Complete re-examination of manufacturing process undertaken.
    • One potential area identified to improve cycle time was in Heat Shrink Termination of the sleeve using a manual Heat gun.
    • This required 3 operators, synchronization, and due to higher volumes it did have an adverse effect on the quality of output.
  • Re-engineering was done to automate the heating process.
    • Automated temperature controlled heating system was designed to address the operation.
  • Resulted in triple benefits
    • Quality, Costs and Output.
 
 
 

Elmas with its rich experience and successful track record – across different domains -  is well equipped to meet your needs. Give us a problem and let us in on the challenges you are facing. There is a good chance we will come back to you with an attractive solution.

 
 
 

Success Stories

Airport Infrastructure

 

NEED

  • Constant Current Regulator Transformers with stringent international norms for the highly sensitive application of airport Runway lighting.
  • The prevalent sourcing was from Western Europe with the twin challenges of higher imported landed costs and large lead times.

CHALLENGE

  • Local sourcing was not reliable.
  • The associated design and manufacturing techniques were completely new.

SOLUTION

  • A ‘back to basics’ helped the team at Elmas to completely take control of all aspects (key being winding and assembly of the unit).
  • The final product proved its mettle even in an international testing lab.
  • The final offering too was commercially attractive.
  • It helped the customer overcome the twin problems of reliance on a high priced overseas supply source as well as long delivery periods.
 
 
 

Elmas took more than a couple of quarters of intense and continuous working to complete the assignment. However, the final successful outcome helped boost the confidence of the design & operations team that no challenge is beyond them.