Elmas Magnetics

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.

 
 
 

Success Stories

Elmas ‘centres’ its focus for ‘powering’ computers with 99% efficiency

 

 

DEAR CUSTOMER

  • Computing today has become all pervasive. With advances in Information Technology and innovative business models like Cloud computing, Software as a Service (SaaS), Data centres have become the norm today. The life-line of businesses is data and given its criticality the uptime and efficiency of computers in such centres assumes added significance. So thus the need for reliable quality power is a given. This naturally devolves on the power backup equipment like transformers which are an integral part of the PDUs (Power Distribution Units).

CHALLENGE

  • A reputed supplier of PDUs to the Data Centre segment had a critical need which otherwise was not being met. Given the nature of power conditions in India, even at different load levels the efficiency of the transformer had to be high.
  • A 250 KVA K-rated transformer with 99% efficiency at 50% load
  • The form factor was quite compact to blend with the ambience in the Data centre.
  • The above had to be done without increase any increase in cost compared to their normal procurement at lower efficiency levels.

The limited space with the requirement for high efficiency output brought the challenge of temperature rise. Even with the cabinet and cooling fans this limitation could not be overcome.

SOLUTION

  • Other than extraneous factors like cabinet design, fan layout the team at Elmas decided to focus on the actual build of the transformer. The study extended to analyze the impact of reducing stray losses and skin effect related eddy current losses. An efficient coil and winding design helped improve the efficiency. Apart from this the choice of materials and a different process of varnishing helped reach all desired parameters. All this was done without a run-away cost escalation.

RESULTS

  • The final sample in its complete form with the cabinet was supplied to the customer for real-life testing. The unit passed the arduous conditions with flying colours. The annual business potential at US $ 800K matured with an initial order for over US $ 200K which was satisfactorily installed. This new category of transformers (99% efficiency) was a relative first and has helped open up opportunities for the client to explore many more such high-performance Data centres
  • The young team at Elmas found the congratulatory message from the senior management at the client a big morale booster. This pattern of fresh thinking to tackle any problem or challenge as an opportunity distinguishes the fighting spirit at Elmas.
  • Do count on us to help you resolve any challenges that you may have. Our successful track record is testimony to our claim of declaring that there is a fair chance we would have an acceptable solution for you.
 
 
 

With advances in Information Technology and innovative business models like Cloud computing, Software as a Service (SaaS), Data centres have become the norm today.

 
 
 

Success Stories

Elmas faces heat to register a 'cool win'

 

 

DEAR CUSTOMER

  • The galloping digitization in business processes is a reality not only globally but also in India. Companies have seen their IT infrastructure becoming more sophisticated by the day where not only processes but critical data bases too reside on premises. In this context the growth of in-house data centres by many business houses has been rapid given its potency as a huge business differentiator and enabler. Naturally it has assumed proportions of a ‘mission critical’ asset which can brook no downtime.

CHALLENGE

  • A large entity, that had set up a data centre with power management solutions in the form of 250 KVA Isolation transformers, from another brand, had been facing problems with uncontrolled temperature rise. No amount of analysis could lead to a proper diagnosis of this phenomenon. Its resolution was critical as the ramifications of temperature rise and imminent failure of the transformer would lead to catastrophic damage to the high-sensitive computing and storage devices in the data centre.

SOLUTION

  • The Elmas team was sought to step in for a proper diagnosis of the situation so a solution could be found. A thorough study of the build and the performance of the installed transformers helped narrow the focus to critical design parameters of the transformer. It was a design challenge which was taken up in full earnest by the Elmas team. A de novo design approach aided in drawing up specifications and layout that were completely different from that of the installed transformer. The core design contributed to addressing the functional needs; an innovative layout with channels to both increase the surface area and also bring in better air flow enhanced the cooling for the windings.

RESULTS

  • Approaching the challenge right from the basics brought about benefits across a diversity of parameters: The Mitre core design reduced losses; improved efficiencies; significantly reduced the core by over 50 Kgs; Temperature rise throttled by 18%; and the entire form factor more elegantly packed in a tighter foot print. Naturally – as is to be expected from Elmas - there was also a decent cost savings which was passed on to the customer. From the initial US $ 120 K business volume it opened the doors for a 3X scaling up in revenues.
  • It was a matter of professional pride and satisfaction to the entire team members at Elmas that they could rise to the challenge so effectively. From a seemingly narrow problem of one that was to arrest the temperature rise, the analysis and the approach of fresh design thinking brought about a comprehensive solution that was multifaceted. This confidence in Elmas’s capability and competence to tide over tough challenges not only brought in a reputed customer into Elmas’s fold, but it also helped strengthen the relationship for repeat business.
  • We encourage you to write to us about your needs however intractable they may seem. The team at Elmas will go all out to hammer out a solution: on that spirit you can count!
 
 
 

Its resolution was critical as the ramifications of temperature rise and imminent failure of the transformer would lead to catastrophic damage to the high-sensitive computing and storage devices in the data centre.

 
 
 

Success Stories

‘Smart’ approach by Elmas to meet needs of ‘Smart’ devices.

 

 

DEAR CUSTOMER

  • With the advent of connected devices, the pursuit of embedding them with ‘smartness’ has been a growing trend in many industry verticals. Beyond the unmatched convenience afforded to customers, it also helps in optimizing energy utilization: necessary functionality is invoked only on a ‘need-to’ basis – essentially this is the manifestation of the ‘smartness’ of the device. In making this a reality, the attendant demand also devolves on the various components that go to power the device, such as transformers. One such potential device is that of Inverters, so vital for rendering reliable power in the households in a country like India, which is often faced with the issue of non-availability of consistent round-the-clock power.

CHALLENGE

  • A leading Inverter manufacturer had embarked on a product refresh to develop Smart Inverters that would be controlled through a Smart phone. Some of the key new functionality included switching On/Off; control of performance levels; battery usage/life monitoring and a unique ‘Holiday’ mode for an extended dormant period. The need was for a cost-effective solution from the transformer used in the Smart Inverter device. From among the existing vendor base, the customer could not get the desired solution. Elmas was approached with this challenge.

SOLUTION

  • The conventional transformer design for Inverters could not meet the performance-cost requirements. A detailed study delved into the basics of the construct and potential areas for innovation spanned type of Insulation used as well as that of the Wire termination. Through prototypes and extensive testing the ideal combination was arrived at – all within the target parameters specified.

RESULTS

  • The first lot of bulk Inverters, numbering above 1000+ nos., was supplied for field deployment. The market feedback has been quite encouraging setting the base for a rapid scale up. This new product line with an annual business value of about US $ 200K, has become a significant vertical for both the customer and for Elmas.
  • A challenge, which otherwise seemed difficult – better build material, better functionality and at a lower cost – was overcome through diligent application of engineering principles by the design and manufacturing team at Elmas.
  • It has been our constant endeavor to take up newer challenges, and single-mindedly pursue a feasible solution for our customers, which has set us apart from the others in the industry. Kindly feel free to involve us for solutions that you may be seeking in the area of Electro-magnetics. Elmas will not let you down.
 
 
 

A leading Inverter manufacturer had embarked on a product refresh to develop Smart Inverters that would be controlled through a Smart phone.