CUSTOM MAGNETICS & ASSEMBLIES
Custom products are the special focus of BH Electronics. For each application, be it small or large, our engineers draw on extensive resources and experience to create exactly the right product for each application. Once designed each product is constructed as a prototype to verify the design and provide our customer with an example of the finished item for testing in their facility. These prototypes are prepared in our complete prototype facilities which include special machining, molding and assembly processes as well as extensive testing equipment. Examples of typical product developed in this way are shown below.
The laws of physics require that a transformer be of a certain minimum size to properly function. This size is often in conflict with the space available on a PC board. Our design team worked together with our customer’s engineers to create a low profile transformer. The particular application that led to its creation required a transformer design that was too tall for the assembly into which it was to be placed. Board space was not available to permit a larger footprint. The solution was a part that can be mounted upside down with the magnetic core protruding through a hole in the PC board, thus meeting the overall assembly height requirements.
In order to provide power conversion, power control and communications to the sophisticated, high operating temperature bits used in oil well drills, we have developed inductors and transformers that are designed to operate continuously at temperatures up to 250°C. The pictured components fit inside the drill casing and perform reliably at temperatures of 220°C, providing necessary small diameter packaging and support of power levels up to 100 Watts.
The pictured high reliability planar device replaced a low profile wire wound transformer in a high vibration environment. This Planar Transformer was built using multilayer printed circuit board technology. At its heart, this transformer is comprised of an 18 layer printed circuit board with windings etched onto the layers and plated through holes to provide interconnection between layers. This efficient construction technology maximizes space utilization while providing the highest levels of performance and repeatability from part to part, all while withstanding shock, vibration and temperature extremes.
We developed this precision bandpass filter in three versions to pass frequencies of 250KHz, 500KHz and 2MHz. In each case the tolerance on the passband frequency was only ±0.4%. This tight tolerance required that each part be individually tuned to meet the demanding specification.
Our customers often provide us with difficult specifications for their custom orders. The Ultralow Capacitance Transformer was one of our most challenging designs, requiring a low level of interwinding capacitance, an extremely low level of noise coupling, high voltage isolation, low physical profile and operation from 200Hz to 6.5KHz. Our designers opted for a dual bobbin transformer, creating an efficient and dependable transformer in the smallest possible size.
To create this intrinsically safe transformer with a 6 mm minimum distance between its primary and secondary metallic elements, we folded the spacing to maximize the creepage and clearance mandated by safety agencies while keeping the package size as small as possible. The transformer in the image is only 12 x 14 x 12mm. BH Electronics has created several designs that use this technology, mostly for medical applications that require transformer isolation of small electronic devices that are directly connected to patients.
Engineering Expertise
BH Electronics’ strength in engineering design are coupled with deep manufacturing expertise that provides unique capabilities for product development and re-engineering. Our team of experienced design engineers specialize in collaborating with our customers to develop exceptional products that meet or exceed their requirements and needs.
Our list of services include:
- New Product Design: All aspects of the product development process from concept development through manufacturing and testing to meet our customer’s specifications and requirements
- Re-engineering: Improving existing designs for performance
- Reverse Engineering: Utilizing extensive history and knowledge based to recreate legacy components no longer supported by their original equipment manufacturer (OEM)
- Prototype Manufacturing: A fully equipped engineering lab capable of assembly and testing
- Program Management: Planning and management of engineering design, prototyping, production, testing, as well as implementation of factory resources and raw material to ensure products are high quality and delivered on time
QUALITY ASSURANCE
Our commitment to quality is proven with our ISO 9001 Quality System, and our decades of experience as a cost effective, high quality magnetics engineering and manufacturing company. From initial customer consultation to design review to high volume manufacture, we follow a rigorous quality process that includes:
- Prototype construction and product approval.
- Process development and approval in the U.S.
- Process approval at the manufacturing location.
Our test equipment is calibrated to NIST standards to ensure consistent results.
