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CatalogⅠ IntroductionⅡ The Layout of the Car MarketⅢ The Layout in the Industrial FieldⅣ The Layout on the Internet of ThingsⅤ ConclusionⅠ IntroductionON Semiconductor: In 2021, it will focus on the automotive, industrial and cloud power, and the Internet of Things marketThe end of the year and the beginning of the year is often a time for companies to make summaries and outlook, and the semiconductor industry is no exception. Not long ago, ON Semiconductor also made a year-end review of 2020 and revealed to the media what ON Semiconductor plans to do in 2021. "The year 2020 is a year of surprises for everyone. People around the world are experiencing the worst epidemic in a century. The good news is that the epidemic has eased in some parts of the world. Looking forward to 2021, we hope to get out of the epidemic as soon as possible and have a more favorable business environment." DavidSomo, senior vice president of strategy, marketing and solution engineering at ON Semiconductor, said in his opening remarks at the press conference.Due to the epidemic, the global economic situation in 2020 is not optimistic. According to Bloomberg data, GDP growth in 2020 is expected to drop from 2.8 percent in 2019 to minus 3.7 percent. China will be the only major economy in the world with positive growth by 2020, while all other economies are expected to suffer single-digit declines. Fortunately, in the second half of 2020, the global economy began to recover. As indicated by the PMI (Purchasing Managers' Index), manufacturing activity in all major economies resumed growth in the second half of the year, with the only exception being Japan, which also showed a positive trend. DavidSomo expressed an optimistic outlook for the global economy in 2021. "We expect that the economic outlook for next year will be positive, significantly better than this year, and there is a consensus for overall GDP growth of around 5% in 2021," he said. He also stressed that, for its part, ON Semiconductor wants to be a reliable supplier of power, analog, sensor and connection solutions, enabling innovation in energy-efficient electronics. It will focus on providing comprehensive solutions to global customers in the automotive, industrial and cloud power markets, as well as the Internet of Things market. Ⅱ The Layout of the Car MarketIn the automotive sector, ON Semiconductor implements a comprehensive sensor product and solution layout, including image sensors, radar, lidar, ultrasonic sensors and other products and solutions. In additon to sensors, R&D resources continue to be invested in silicon and silicon carbide power semiconductors, as well as LED lighting and automotive power management products. Those investments have also paid off handsomely, accounting for 33% of ON Semiconductor's $5.5 billion in 2019 revenue. DavidSomo pointed out that in the future, ON Semiconductor will continue to develop new products in the automotive market and increase investment in research and development. "On the automotive side, we will push forward research and development around sensors, autonomous driving-related applications, new energy vehicles, and the electrification of vehicles." He revealed. ON Semiconductor is one of the top 10 semiconductor suppliers in the automotive industry. DavidSomo proudly states, "Since entering the automotive market in 2010, ON Semiconductor has shipped 130 billion chips to automotive customers by 2019. In 2019, there were more than 230 ON Semiconductor devices used in every vehicle produced worldwide."The company has set the industry standard for automotive image sensors, with more than 120 million of them shipped to Advanced Driver Assistance System (ADAS) applications. Over the past 13 years, more than 400 million ON Semiconductor automotive image sensors have been used in vehicles on the road. ON Semiconductor has developed a complete portfolio of product solutions and sensor modes to support L4 and L5 autonomous vehicles, including ultrasonic sensor interfaces, image sensors, solid-state LIDAR and millimeter-wave radar technologies. DavidSomo said that ON Semiconductor's MMW technology, acquired from IBM Research Group in Sea Law (IBM), has been used in communications and fiber optics, and plans to use the technology in the automotive sector. It is currently being tested with customers for prototypes but has not yet been used in commercial automotive production. In the case of LiDAR, the technology came from the acquisition of sensL to acquire technology on solid-state LiDAR. According to DavidSomo, sensL was originally designed for use in the medical market but is now being developed for use in the automotive market. "Multiple customers have incorporated our Silicon Photomultiplier (SiPM) and Single-Photon Avalanche Diode (SPAD) technologies into solid-state lidar systems, enabling commercial lidar applications in the automotive industry for L2+ and L3 level autonomous driving safety applications." He went on to point it out. On the cost side, DavidSomo says that because ON Semiconductor's lidar solution is a solid-state solution, it has been able to bring the cost of lidar down from more than $1,000 for mechanical rotation in the past to the current $500 range for solid-state solutions. In terms of image sensors, over the years, ON Semiconductor has made three acquisitions, including Aptina, Cypress's image sensor technology and TrueSense, to enrich its image sensor portfolio.Ⅲ The Layout in the Industrial FieldDavidSomo said that ON Semiconductor offers a wide range of power and automation solutions in the industrial and cloud power markets that support different application scenarios. In terms of power semiconductors, in 2018, ON Semiconductor ranked second behind Infineon with a market share of about 9 percent, according to IHS. As an example, he pointed out that powering the cloud requires several processes, including generation, power supply and power demand management. "In these processes, we have a complete silicon and silicon carbide technology portfolio that supports power generation, transmission and distribution, as well as power and demand management for data centers and 5G base stations." He points it out. In terms of energy efficiency improvement, the use of ON Semiconductor's cloud power solution increased energy efficiency by about 0.5%. In a typical VL data center, the savings over the life of the system are estimated at approximately $38 million. The energy efficiency improvement is only 0.5%, which may not sound like much, but when measured at the system-wide level of deployment, the savings over the lifetime of the system are significant. The development of energy infrastructure is also unstoppable, as a society and the government further promote the development of new energy sources and shift more from coal-fired power generation to renewable energy sources such as wind and solar power. In order to save energy and reduce emissions, reduce air pollution, from fuel vehicles to new energy vehicles, which has generated the demand for electric vehicle charging pile, and ON Semiconductor silicon and silicon carbide power discrete devices and modules, can support the construction of electric vehicle charging pile. Similarly, its power technologies, such as solar inverters used in solar panels, enable clean energy generation, and "ON Semiconductor is fortunate to partner with customers in China to develop applications in these areas." DavidSomo said. Manufacturing is also one of the biggest users of energy. In the United States, our power solutions are used in plant motor drive systems, resulting in savings of more than $350 million per year. If applied globally, the potential savings could reach approximately $5.8 billion per year, resulting in energy efficiency improvements in manufacturing motor drive systems.Ⅳ The Layout on the Internet of ThingsIn the Internet of Things (IoT) area, ON Semiconductor has a complete set of key components and modules that enable devices to be connected, intelligent, aware and actuated in their operating environment."Of course, we recognize that our semiconductor components are not sufficient to build the end-to-end connected Internet of Things (IoT) systems that our customers need, so we are investing more to accelerate development and provide our customers with a number of development tools to enable faster application development and market deployment." DavidSomo admits. While ON Semiconductor can provide many of the key building blocks, DavidSomo believes it is important to work with partners in the Internet of Things (IoT) ecosystem to build IoT solutions for secure end-to-end connectivity. As shown in the figure below, ON Semiconductor works with a number of technology partners to enhance the performance of IoT devices developed by clients, as well as with infrastructure providers such as cloud service providers to enable edge devices to connect securely and stably to the cloud. He also revealed that the company is focusing on three vertical areas in the Internet of Things, namely asset tracking and monitoring, connected lighting, and smart homes and building automation.Ⅴ ConclusionIn conclusion, DavidSomo said that in the process of semiconductor device manufacturing, ON Semiconductor also recognizes the growing need to provide its customers with complete system solutions that add value. As a result, ON Semiconductor offers modular products for power components and built-in controls, as well as reference design kits to speed up customer product development. ON Semiconductor also provides software and design tools to help customers complete designs faster and get their equipment to market faster. He also stressed that ON Semiconductor will focus on research and development, and is committed to developing innovative products and solutions including power, simulation, sensors and connectivity solutions. "Through both endogenous growth and exogenous acquistions, we are further enhancing our capabilities to support the applications our customers are developing, while also building our professional application capabilities to help them develop products better and faster to market."

IntroductionLED lights cannot directly use the conventional mains grid voltage, because of the characteristics of LED lighting. In order to meet the special voltage and current requirements of LEDs, a specially designed voltage conversion device must be used to make LEDs work normally. This device is an LED driver. LED drivers are usually switching mode devices that convert the input voltage (Typically 120-220 VAC or 12 VDC) into a voltage at which the current drawn by the LED's is equal to its drive current. The drive current is regulated for optimum brightness, led service life, and battery life. A drive current lower than the maximum drive current of an LED can greatly prolong service life. As a key part of LED lighting, the quality of LED drivers directly affects the performance of LED lighting.Choose the Correct LED Drivers For LED LightsNo matter how good the quality of the LED driver is, failure and maintenance are inevitable. This article will analyze the 10 failures in LED lighting design and its application based on the relevant technology and practical experience of the LED driver.CatalogIntroductionⅠ LED Driver Failure Analysis1.1 Forward Voltage Drop (Vf) Range1.2 Power Margin and Derating Requirements1.3 LED Working Characteristics1.4 Test Session1.5 Different Load with Different Test Results1.6 LED Driver Circuit Problem1.7 Wrong Phase Wring1.8 Grid Fluctuation1.9 Frequent Line Trips1.10 Drive CoolingⅡ LED Driver Maintenance2.1 Multimeter to Detect LED Driver2.2 Identify LED Power SupplyⅢ LED Driver Circuit Modulation3.1 Pulse Width Modulation (PWM)3.2 Pulse Frequency Modulation (PFM)3.3 Sliding-Mode ModulationⅣ One Question Related to LED DriverⅠ LED Driver Failure AnalysisThe LED driver is measuring current passing through LEDs using sense resistor and then increase or decrease the voltage to maintain constant current continuously. LEDs are kind of diode so they need DC voltage to operate so most of the LED drivers are boost and can vary output supply in wide range (example, 16V to 38V). They also have dimming control by PWM signal from microcontroller OR by having a manual potentiometer to change sense resistor. According to them, LED driver failures are complex, but we can follow the steps below to analyse.1.1 Forward Voltage Drop (Vf) RangeLED lamp load end is generally composed of a number of LEDs connected in series, and its working voltage Vo=Vf×Ns, where Ns represents the number of LEDs. And the Vf of an LED varies with temperature. Generally, at a constant current, Vf becomes lower at high temperatures and becomes higher at low temperatures. The LED lamp load working voltage is VoL at high temperature, and VoH represents a value at low temperature. When selecting an LED driver, consider that the driver output voltage range is greater than VoL～VoH.If the maximum output voltage of the LED driver is lower than VoH, the maximum power of the lamp may not reach the actual power required at low temperature. If the minimum voltage of the selected LED driver is higher than VoL, the output of the driver may exceed the working range at high temperature. And LED driver will work unstable, making the lights flicker.Considering the overall cost and lamp efficiency, don’t blindly pursue the ultra-wide output voltage range of the LED driver. Because the driver voltage is only in a certain range, its efficiency is the highest. When the range is exceeded, the efficiency and power factor (PF) will deteriorate. In addition, if the design of the driver output voltage range is too wide, high costs and unoptimized efficiency will be made. 1.2 Power Margin and Derating RequirementsIn general, the nominal power of the LED driver refers to the data measured under the rated environment and rated voltage. Taking into account different applications, most LED driver suppliers will provide power derating curves in their product specifications (common load vs. ambient temperature derating curves and load vs. input voltage derating curves).As shown in Figure 1, the red curve represents the power derating curve when the input is 120Vac, and its load varies with the ambient temperature. When the ambient temperature is lower than 50℃, the LED driver is allowed to be 100% full load. When the ambient temperature is as high as 70℃, the LED driver can only be derated to 60% of the load. When the ambient temperature changes between 50℃~70℃, the driver load varies with the temperature linearly.Figure 1. Power Derating Curve (Load vs Ambient Temperature)The blue curve represents the power derating curve when the input is 230Vac or 277Vac, and its load varies with the ambient temperature. The principle is similar to the above mentioning.As shown in Figure 2, the blue curve represents the derating curve of the LED driver when the ambient temperature is 55°C, its output power varies with the input voltage. When the input voltage is 140Vac, the load of the driver is allowed to be 100%, and the input voltage will be adjusted downward. If the output power remains the same, the input current will rise, resulting in input terminal loss and lower efficiency. When the device temperature rises, exceeding the rated temperature, which may cause the device to fail.Figure 2. Power Derating Curve (Load vs Input Voltage)Therefore, when the input voltage is less than 140Vac, the output load of the LED driver is required to linearly decrease as the input voltage decreases. According to the above derating curve and corresponding requirements, when choosing a LED driver, actual applying needs are important, as well as the derating margin. 1.3 LED Working CharacteristicsWhen the required input power is a fixed value, such as a fixed error of 5%, the output current can only be adjusted to the specified power for each lamp. Due to different working ambient temperature and different lighting time, the power of each lamp will vary greatly.Although there are considerations for marketing and business factors. However, the volt-ampere characteristic of the LED lamp determines that the LED driver is a constant current source, and its output voltage varies with the series voltage Vo of the LED load. When the efficiency of the driver is basically unchanged, its input power changes with Vo. And meanwhile, the overall efficiency of the LED driver will increase after thermal equilibrium. Under the same output power, the input power will decrease compared to the boot time.Therefore, when formulating requirements, LED driver users should first understand the operating characteristics of LEDs. Avoid suggesting indicators that do not meet the principles of operating characteristics, and indicators that far exceed actual requirements, resulting in excess quality and cost waste. 1.4 Test SessionSample test problems, for example, multi-brand LED driver samples all failed during the test. The reason is that a self-dual voltage regulator is used to directly power the LED driver for testing. After power on, the voltage regulator is gradually adjusted from 0Vac to the rated operating voltage of the LED driver. This kind of test operation can easily make the LED driver start and work with the load when the input voltage is very small, but this situation will cause the input current to be far greater than the rated value. And the internal input terminal related components, such as fuses, rectifier bridges, thermistors, etc. will fail due to excessive current or overheating, damaging the LED driver.The correct test method is to adjust the voltage regulator to the rated operating voltage range of the LED driver, and then connect the driver to power-on test. Of course, technically improving the design can also avoid the failure caused by this kind of test misoperation. That is, a starting voltage limit circuit and an input undervoltage protection circuit are set at the input of the driver. When the input does not reach the start-up voltage set by the driver, the driver does not work. When the input voltage drops to the input undervoltage protection point, the driver enters the protection state. Although the driver has a self-protection function and will not fail, you must carefully understand whether the purchased LED driver product has this protection before testing (considering the actual application environment of the LED driver, most LED drivers currently do not have this set). 1.5 Different Load with Different Test ResultsOn the one hand, when the LED driver is tested with LED lights, the result is normal; on the other hand, when driver tested with an electronic load, the result may be abnormal. Usually this phenomenon has the following reasons:1) The output instantaneous voltage or power of the driver exceeds the working range of the electronic load instrument. (Especially in CV mode, the maximum test power should not exceed 70% of the maximum power of the load. Otherwise, the load may instantaneously have overpower protection when loading, causing the driver to fail to work.)2) The characteristics of the electronic load instrument used are not suitable for measuring constant-current device. And the load voltage gear jumping, result in the drive to fail to work.3) Because there is a large capacitor inside the input of the electronic load meter. The test is equivalent to connecting a large capacitor in parallel with the driver output, which may cause the driver's current sampling work to be unstable. As we all known, the LED driver is designed to meet the working characteristics of LED lamps. The most practical test method is to use the LED lamp as a load, and connects an ammeter and a voltmeter in series to test. 1.6 LED Driver Circuit ProblemThe following conditions often cause damage to the LED driver:Connect AC to the DC output terminal of the driver, causing the driver to fail.Connect AC to the DC/DC output or input of the driver, causing the driver to fail.Connect the output terminal of the constant current to the dimming light, causing the driver to fail.Connect the phase wire to the ground wire causing the driver has no output and the housing is charged. 1.7 Wrong Phase WringTake an international example: the rated working voltage between each phase line and the neutral line is 220V, and the voltage between the phase line and the phase line is 380V. If the driver is connected to two phase wires, after power on, the LED driver input voltage exceeds the rated range, which cause the product to fail.As shown in Figure 3, V1 represents the first phase voltage, V2 represents the second phase voltage, and R1 and R2 respectively represent the drivers normally installed on the line. When the neutral line (N) on the circuit is disconnected, the drivers R1 and R2 on the two branches are connected to the 380V voltage after being connected in series. Because of the difference in input internal resistance, when one of the drivers is charged to start, the internal resistance becomes smaller. Most of the voltage may be applied to another driver, causing the overvoltage damage. Therefore, it is recommended that switches or short-circuiters on the same distribution branch should be disconnected together, not just cut off the neutral line. What’s more, do not put the power distribution fuse on the neutral line to avoid bad effect of the neutral line on the circuit.Figure 3. Neutral Line Open Circuit Diagram 1.8 Grid FluctuationWhen wires of a transformer grid branch is too long and there is large power equipment on the branch, the grid voltage will fluctuate sharply when the large equipment starts and stops. It even causes the grid to be unstable. When the grid voltage exceeds 310V, the drive may be damaged (even if there is an LED lightning protection device, it is useless. Because the lightning protection device is to deal with pulse spikes of tens of uS level, and the fluctuation of the grid may reach tens of mS, or even hundreds of mS) . Therefore, special attention should be paid when there is large electric machinery on the street lighting branch power grid. It is best to monitor the fluctuation range of the power grid or to supply power to the grid transformer separately. 1.9 Frequent Line TripsToo many lights are connected on the same branch, which leads to overload on a certain phase and uneven power distribution among the phases, resulting in frequent line trips. 1.10 Drive CoolingAlthough the LED has high luminous efficiency, only a small part of the energy flowing through the LED is radiated in the form of visible light. And most of the remaining energy is consumed in the LED in the form of heat, so the LED generates more serious heat. When the driver is installed in a non-ventilated environment, the driver housing should be in contact with the lamp housing as much as possible. If possible, apply thermal glue or a thermal pad on the contact surface between the housing and the lamp housing to improve the heat dissipation of the LED driver and ensure the reliability of the driver.Ⅱ LED Driver Maintenance2.1 Multimeter to Detect LED DriverMeasuring the output voltage of the no-load LED driver with a multimeter, if the output voltage is not detected, does it mean that the driver is broken? Look at the following steps:1) The voltage of the non-isolated LED power supply in the no-load state is about 300V tested with a multimeter, and it is about 220V with a PFC.2) Isolating the LED power supply, the voltage in the no-load state, tested with a multimeter, is about 3-5V more than the total voltage of the rated LED series. However, although the output voltage can be tested under no load, it does not mean that it can be normal under load. At this time, it is necessary to connect the corresponding LED light board to see the performance of the LED lighting. If there is no flicker, the output voltage is also equal to the total voltage of LED lights in series connection. This situation can be considered normal, otherwise it fails. If there is no output voltage at no load, the power supply must be broken. 2.2 Identify LED Power SupplyThe LED power supply is widely used in many applications. So how to distinguish the quality of LED power supply is particularly important. A few methods are briefly introduced below. LED Driver ICThe power of IC drive, the quality of IC directly affects the whole power supply. The lighting manufacturer should understand the IC design solution and calculate the cost of the driver, so as to purchase power products at a reasonable price. TransformersThe control chip can be regarded as the brain center of the power supply, while the transformers determine the power and temperature resistance. The transformer is responsible for the transfer of "AC to DC". However, the energy overload will damage the device. The core of the transformer is the magnetic core and the wire package. Electrolytic Capacitors and Ceramic CapacitorsThe quality and life requirements of input electrolytic capacitors are important. However, people tend to ignore the quality requirements of the output capacitor. In fact, the life of the output capacitor also has a great impact on the life of the power supply. The output end has a switching frequency of up to 60,000 times per second, which causes the parasitic resistance of the capacitor to heat up and produce substances similar to scale. Finally, the electrolyte heats up and bursts. Ceramic capacitors: The materials are divided into X7R, X5R and Y5V, and the actual capacitance value of Y5V can only reach 1/10 of the actual value. In addition, the nominal capacitance value only refers to when a capacitor works at 0V. Therefore, this tiny chip with poor options will also lead to a price difference in cost and greatly shorten the life of the power supply. Circuit Design and Welding ProcessJudgment of the pros and cons of the design: Aside from the professional point of view, it can be distinguished by some intuitive methods, such as the neat layout of the components, and soldering points. As for flying leads and manually adding components, it is a serious lack of techniques and efficiency. As we all know, the quality of mechanized production of wave soldering process is definitely better than manual welding. Because the machining process is more neat and uniform. Identification method: whether there is red glue on the back board.The flashing phenomenon of the lamp after a period of use is basically caused by the power supply or the weak welding of the lamp beads. However, it is extremely difficult to detect the virtual welding of products through aging, so AOI must be used to detect the quality of the power supply. Batch Inspection of Aging Racks and High Temperature Aging RoomsNo matter how good the power products are controlled by materials and production processes, they still need to be tested for aging. Because the incoming inspection of electronic components and transformers is difficult to control. Only through the aging of the entire batch of power supplies and the high temperature sampling inspection of the high temperature room. This is a wide-ranging screening to determine whether the materials have safety hazards. Ⅲ LED Driver Circuit ModulationThe LED driver circuit is divided into constant-voltage type and constant-current type according to the power supply to the LED. Constant-current switch type LED driver circuit samples the current flowing through the LED lamp, and gives the output control signal to control the on and off of the switching power tube, which aims to adjust the output current as the set value. The dimming control circuit mainly includes SCR dimming circuit, pulse width modulation (PWM), pulse frequency modulation (PFM), sliding mode control, PWM_PFM, PSM, etc. Let's take pulse width modulation (PWM), pulse frequency modulation (PFM), and sliding mode modulation to introduce in detail below. 3.1 Pulse Width Modulation (PWM)Pulse width modulation, shown in the figure below, refers to the stability of the output voltage by changing the on-time of the switching power tube in each cycle at a specific frequency. That is adjusting the duty cycle to obtain stable output voltage. When the output voltage changes due to the working environment, noise and other factors, the error amplifier samples the voltage change and sends the signal to the control circuit. The control circuit adjusts the duty cycle of the switching power tube signal to maintain the stability of the output voltage.Figure 4. PWM Modulation Based on BUCK StructureFigure 4 (a). Voltage ModeFigure 4 (b). Peak Current ModeFigure 4 (c). Average Current Mode3.1.1 Advantages of PWM(1) The PWM modulation method has high efficiency under heavy load, and has a good dynamic response to load changes.(2) The output ripple voltage is small and the linearity is high.(3) The frequency is stable, the duty cycle adjustment is not restricted, the control is simple, and both the current control mode and the voltage control mode are applicable.3.1.2 Disadvantages of PWM(1) The efficiency of PWM modulation method decreases at light load.(2) The transient response is slow during constant-voltage driving, and a more complicated compensation circuit is required.(3) Accurate current detection circuit is required for constant-current driving. 3.2 Pulse Frequency Modulation (PFM)The pulse frequency modulation is shown in the figure below. Under the condition of a certain on-time of the switching power tube, the output voltage can be controlled by adjusting the off time. When the output voltage changes, the error amplifier samples the feedback signal and sends the output signal compared with the reference signal to the control circuit. The control circuit analyzes the error signal and generates a square wave signal with constant pulse width and varying frequency to control the switch power tube to maintain the stability of the output voltage.Figure 5. Pulse Frequency Modulation Based on BUCK Structure3.2.1 Advantages of PFM(1) The PFM modulation has very high efficiency, better frequency characteristics and higher voltage regulation rate at light load.(2) The PFM modulation has a relatively high transmission signal-to-noise ratio and a good anti-interference ability.(3) The output voltage has a large adjustable range and low power consumption.3.2.2 Disadvantages of PFM(1) The efficiency of the PFM modulation will decrease under heavy load.(2) The frequency spectrum of the output ripple is scattered and irregular.(3) The load adjustment range is very small, resulting in high filtering costs. 3.3 Sliding-Mode ModulationSliding-mode modulation mode, the full name is sliding mode variable structure control,  is a discontinuous control. As shown in Figure 6, the sliding mode makes the system structure change purposefully according to its current state, which force the system to make small amplitude and high frequency up and down movements along the designed trajectory under response conditions. That is, sliding mode movement. Reduce the system's sensitivity to disturbances and load jumps.Figure 6. Sliding Mode Control Based on BUCK Structure3.3.1 Advantages and Disadvantage of Sliding ModeIt has the advantages of fast dynamic response, strong robustness and wide stability range, but it also has a problem that the operating frequency is not fixed. Ⅳ One Question Related to LED Driver4.1 QuestionHow long do LED drivers last?4.2 AnswerWhile the light function of an LED may last for years, drivers can give out much sooner. This is why we recommend name brand LED bulbs for the home, especially those with 25,000 hour rated lives. In general, high power white LEDs use much more current, and need of more complicated drivers. Frequently Asked Questions about LED Drivers Failure Analysis and Maintenance1. What is a LED driver IC?They are configured as either inductorless (charge pump) or switching regulator-based LED drivers that support driving white LEDs in series, parallel or combination. ... Topologies include boost regulator, buck regulator, buck/boost, SEPIC topology LED drivers, and more. 2. What is a LED driver used for?LED drivers are electrical devices that prevent damage to LEDs by regulating the forward voltage (VF) of the LED that changes with temperature, avoiding thermal runaway while delivering a constant current to the LED. LED drivers also aid efforts to meet new energy requirements (e.g., Energy Star). 3. How do I choose an LED driver?Use an LED driver with at least the same value as your LED(s). The driver must have a higher output power than your LEDs require for extra safety. If the output is equivalent to the LED power requirements, it is running at full power. Running at full power may cause the driver to have a shorter life span. 4. Why do LED drivers fail?LED FailureThe LEDs usually fail, because they have been connected to a constant LED driver in parallel. If the LEDs have failed you may want to also replace the LED driver. We usually recommend using a model with an adjustable output, and trimming down the output voltage slightly, to avoid over powering the LEDs. 5. How long do LED drivers last?Namely, the life of the driving circuit expires prior to when the LED stops emitting light or has its brightness dropped. The typical nominal lifetime of these elements is often times less than 25,000 hours, while the lifetime of LED itself could be as long as 50,000-100,000 hours. 6. Why do my LED drivers get hot?If the LED driver is trying to draw DC (not a balanced load circuit) then that can also cause the transformer to overheat.7. What is the difference between a transformer and an LED driver?LED drivers and electronic transformers for retrofit LED lighting are not interchangeable. They differ in output and load compatibility i.e. which LED lights they will work with. The fundamental difference between the two is that LED drivers output DC while electronic halogen transformers output 12VAC.

I IntroductionThis article introduces the basics of low voltage transformer, including the definition of low voltage transformer, the principle of low voltage transformer, its installation method, malfunction, and how to repair a household low voltage transformer. A transformer is an electronic instrument that we can use everywhere in our lives. For example, we are inseparable from the mobile phone chargers. The internal components also have transformers. For example, the power supply in our computers is also composed of transformers. Therefore, all electronic products are indispensable for transformers. The transformers used in electronic components are all power transformers (included low voltage transformers). The power transformer is mainly used in electronic products to convert the power supply to the voltage required by the electronic circuit.CatalogⅠIntroductionⅡ Basics of low voltage transformer2.1 Definition of low voltage transformer2.2 Types of low voltage transformers2.3 How does low voltage transformer work?2.4 Design requirements of low voltage transformer2.5 Application environmentⅢ Differences between low&high voltage transformerⅣ How to Estimate the Loss of Low Voltage TransformerV Guide to What You May be Interested in5.1 How to Install Low Voltage Transformer for Household?5.2 How to Troubleshoot a Low-Voltage Transformer5.3 Repairing a household transformer5.4 Malfunction of factory low voltage transformerVI One Question Related to Low Voltage Transformer6.1 Question (Multiple choice questions)6.2 AnswerVII FAQII Basics of Low Voltage Transformer2.1 Definition of Low Voltage Transformer Transformers are important power equipment in our life, especially low-voltage transformer. Whether it is for large-scale power plants or home circuits, it is inseparable from the transformer. There are two kinds of transformers used in our life, one is the high-voltage transformer which used in the high-voltage or ultra-high-voltage circuit, the other is the low-voltage transformer which used in the family lighting circuit or small power circuit.The so-called low-voltage transformer refers to the transformer with low load voltage. As long as the load is lower than 600V, it can be called a low-voltage transformer. The low-voltage transformer is mainly composed of primary coil, secondary coil, and a magnet iron circuit. Low voltage transformers are commonly used for low voltage lighting, which typically only uses 12 or 24 volts. 2.2 Types of Low Voltage TransformersThere are two main types of low voltage transformers: electronic and magnetic.（1）Electronic Low Voltage TransformersElectronic transformers are much smaller, lighter, and less expensive than magnetic counterparts. But they only have about a 5-6 year lifespan. Also, electronic low voltage transformers are known for being noisy.Electronic Low Voltage TransformersAdvantagesDisadvantages▪ Smaller and lighter, easier to hide▪ Less expensive▪ Shorter life span▪ Noisy▪ Heat-sensitive（2）Magnetic Low Voltage TransformersThere are two types of magnetic transformers: stack laminated and toroidal.  Stack laminated transformers have a longer lifespan, about 15 to 20 years. But they only operate at about 80 to 85 percent efficiency, also are known for being noisy.Toroidal transformers are very quiet and more energy efficient. They can operate at about 90 to 95 percent efficiency. And they are long-lived, lasting 20 to 25 years.Magnetic Low Voltage TransformersAdvantagesDisadvantages▪ Long life span of over 15 years▪ Energy efficient▪ Quiet▪ Heavy, big, and difficult to hide▪ Expensive2.3 How Does Low Voltage Transformer Work?Electricity and magnetism are two kinds of energy that can mutually transform. Electricity can generate magnetism, and magnetism can also generate electricity. The low-voltage transformer uses this principle to adjust the voltage through the mutual conversion of electricity and magnetism.A low voltage transformer consists of two electrical coils of wire, one of which is called primary winding and the other is called secondary winding. The primary side of the transformer collects power and the secondary side provides power.Figure 1. Low Voltage Transformer StructureThe two coils intertwine together on a magnet iron circuit core, but without electrically in contact with each other. The magnetic core is made of soft magnetic material, which consists of laminations connected together to help reduce core loss. The core allows power to be transferred from one coil to another. When the primary winding is connected to the power supply, the generated magnetic field transfers the voltage to the secondary winding.Figure 2.  How Does Low Voltage Transformer Work?In summary, the primary winding transforms the electrical power into magnet field when connected to the input voltage supply while secondary winding transforms alternating magnetic field into electrical power of required output.2.4 Design Requirements of Low Voltage TransformerThe low-voltage transformer should be vacuum cast, molded resin encapsulated, 60Hz, Class F insulation, comply with the requirements of IEC726, and meet the requirements of capacity, voltage, phase number, and wiring shown. Each low-voltage transformer has separate primary and secondary windings, and there are two 2.5% normal voltage full-capacity taps above and below the rated voltage on the primary side. The low-voltage transformer should be installed on a base that can isolate, reduce vibration and noise, and the iron core and coil should be properly fixed to withstand the mechanical stress generated in the event of line failure and can withstand 16460 Lite 16460-6 V2. 0 2002/ 11/ 25 Vibration and impact during shipment. Unless otherwise specified, the impedance of low-voltage transformers shall be in accordance with IEC 726. The average noise level of the low-voltage transformer should not exceed the value specified in IEC 726. Each dry-type low-voltage transformer should have appropriate terminals to accommodate the required primary and secondary wiring connections. Low-voltage transformers can be reserved for cable entry from either side or bottom.2.5 Application Environment(1) Ambient air temperature - 5 ℃ to + 40 ℃, 24-houraverage value not more than + 35 ℃(2) The altitude of the installation site shall not exceed 2000m(3) The relative humidity of the atmosphere shall not exceed50% when the ambient air temperature is + 40 ℃(4) A place without violent shaking and impact vibrationIII Differences Between Low&High Voltage Transformer Low Voltage TransformerHigh Voltage Transformerwindingcontinuous windingInterleaved WindingscoolingOil-immersed cooling or air coolingOil-immersed coolingstructureoil tank structurebell jar type oil tankⅣ How to Estimate the Loss of Low Voltage TransformerTransformer loss include copper loss and iron loss. The loss of iron loss is also called no-load loss, and the loss of copper loss is also called load loss. The open circuit of the secondary winding of the transformer applies the no-load current of rated frequency and rated voltage to the primary side, and the active loss caused by the transformer core is called the no-load loss of the transformer. The loss figure can be obtained by the unit loss of the iron core silicon steel sheet multiply the quality of the silicon steel sheet. In general, its loss is very small. For example, the S9-100/10 distribution transformer has a no-load loss of 290W. The larger the transformer capacity, the smaller the no-load loss, generally between 0.3-0.15% of the rated capacity. However, the transformer works continuously for 24 hours, and this loss cannot be ignored. The load loss: The short-circuit of the coil on the secondary side apply the rated current at the rated frequency on the primary side. The transformer loss at this time is the loss of the transformer coil and the iron core. Let's take the S9 series transformer as an example and see its load loss value:The load loss of S9-100/10000 transformer is 1500W.The load loss of S9-1000/10000 transformer is 10300W.The load loss of a transformer is generally between 0.9-1.8%. The larger the transformer, the smaller the load loss.V Guide to What You Maybe Interested in 5.1 How to Install Low Voltage Transformer for Household? First, make sure you have an outlet available. Most family homes will have several outdoor power outlets installed. Second, think about the layout of the lighting. It is important to plan ahead when installing low voltage lighting so that you can avoid any potential problems, especially with the setup.Third, choose a transformer.①Magnetic or Electronic.②Make sure to buy a transformer that can handle the lighting load you need it to.Fourth, install the transformer. Transformers are installed simply by plugging them into your outdoor outlet.5.2 How to Troubleshoot a Low-Voltage Transformer(1) First, check whether there are obvious abnormalities by observing the appearance of the transformer: such as whether the coil lead is broken, whether the insulating material has scorch marks, whether the fastening screw of the iron core is loose, whether the silicon steel sheet is rusted, and whether the winding coil is exposed Wait. (2) Test a transformer with a digital multimeter, open all secondary windings, put the multimeter in the AC block (500mA, in series into the primary winding). When the plug of the primary winding is inserted into the 220V AC mains supply, the multimeter indicates the no-load current value. This value shall not be greater than 10% - 20% of the full load current of the transformer. Generally, the normal no-load current of the power transformer of common electronic equipment should be about 100mA. If too much is exceeded, the transformer has a short-circuit fault. Low Voltage Electronic Transformer Troubleshooting Guide5.3 Repairing a Transformer(1) Understand the reasons for the problem. Generally, a transformer has failed due to some fault in the electrical circuit.(2) Check the replacement transformer. If the short circuit is caused by component failure, the new transformer may still burn out. If you replace the transformer, examine it to make sure that the incident will not occur again.(3) Check the condition of the external fuse. If the transformer has an internal fuse, there may not be a fuse on the power line. On the contrary, the device must be protected by a fuse mounted on the power circuit. Check whether the fuse is intact and replace the faulty fuse.(4) Check the secondary power consumption. Sometimes, this kind of consumption is very high, which leads to equipment failure. If the transformer has multiple ratings and the multimeter shows the value "OL" during the measurement, it may be a short circuit in the secondary winding.5.4 Malfunction of Factory Low Voltage Transformer(1) Abnormal sound in transformerThe abnormal sound inside the transformer may be caused by the following reasons:①Heavy overload causes buzzing sound inside the transformer; ② Due to poor internal contact or breakdown point, the transformer occurs crackle sound③ Some parts of the connection shaft and the core of the transformer are loose, which causes the silicon steel sheet to vibrate④ When there is a grounding or short-circuit fault in the power grid, a large current flows through the winding, which will produce strong noise⑤ The iron core, the winding discharges to the shell, or the core ground wire is disconnected. All these can make the transformer discharge sound. (2) The oil level of the transformer is too high or too lowUnder normal circumstances, the changes in oil temperature can cause a change in oil level. As the oil temperature changes, the oil level also changes accordingly. However, under abnormal conditions, abnormal oil levels can also be caused by faults such as oil seepage and water seepage and other accidents. Second, the change in oil temperature is related to load conditions, ambient temperature and other conditions. When the change of oil level is inconsistent with these elements, it may be a false oil level. (3) Transformer oil quality has deteriorated or oil temperature has suddenly increasedIn working condition, the main function of transformer oil is cooling and insulation. When running overheated for a long time or if water enters the casing and absorbs moisture, the oil quality will deteriorate. Through the oil mark, we can found  that the oil color is abnormally deepened or blackened. Through sampling and analysis, it can be detected that the oil contains carbon particles and moisture, the acid value increases, the flashpoint decreases, and the insulation strength decreases. This situation can easily lead to serious accidents. A sudden rise in oil temperature when the transformer is operating normally is often related to the overheating inside the transformer. The iron core catches fire, the internal screws are loose, the cooling device is faulty, the transformer is heavily overloaded, all may cause the oil temperature to rise suddenly. (4) Transformer on fireWhen the transformer is out of order and it is not handled in time, it may catch fire. When the transformer is on fire, the insulating oil burns and turns into gas, which makes the oil tank burst. The burning insulating oil sprays out of the transformer, which will cause equipment damage and property loss. The short circuit inside or outside the transformer wire, severe overload, a lightning strike may cause the transformer to catch fire.VI One Question Related to Low Voltage Transformer6.1 Question (Multiple choice questions)The winding of wire around a core which is connected to a source of energy is called the ______ coil.primarysecondarytertiary6.2 AnswerA、B  VII FAQ1. What are low voltage transformers?A low voltage transformer is at the heart of every landscape lighting system. It converts 120-volt current to a low voltage current (between 12-15 VAC). ... Magnetic transformers use two coils to reduce the voltage from 120 volts down to 12 volts. 2. What low voltage transformer do I need?Transformers generally range from 150- to 900-watt capacity. Matching the size of the transformer to the lighting design is important for the efficient operation and function of the system. House current, 120 volts, is reduced by a transformer to 12 to 20 volts, the current needed to operate low-voltage landscaping lights. 3. What are low voltage transformers used for?Low Voltage Transformers Low voltage transformers are power transformers that are used to change the voltage capacity of a low-voltage electrical transmission line. Typically, electronic low voltage transformers convert 120 volts into 12 volts or 24 volts. 4. How do you test a low voltage transformer?• Identify the transformer's terminals, using its label as a guide. • Turn a multimeter to its VAC function. • Test the transformer's input voltage with the multimeter, using the transformer's label as a terminal guide. • Test the transformer's output voltage with the multimeter. 5. How long do low voltage transformers last?20 to 25 years.They operate at about 90 to 95 percent efficiency and can run for a very long time, anywhere from 20 to 25 years. They also are much quieter, so you can place them close to the fixtures, rather than having to run wires a long way from the transformer to the fixture itself. 6. Can I plug a low voltage transformer into an extension cord?One warning though to be observed is to never use an extension cord between the transformer and the electrical outlet. Always plug the transformer directly into the power outlet. As you can see, low voltage outdoor lighting is not all that hard to install or maintain. 7. Can you hardwire a low voltage transformer?To hardwire a low voltage transformer, the main power should be turned off at the breaker panel before making any electrical connections. ... The polarity of these wires is not important; either wire on the output side of the transformer may be connected to either wire of the low voltage circuit. 8. Do you need a transformer for low voltage lighting?When operating low voltage lights, you need a transformer to convert your standard line voltage (120V or 277V) into low voltage (12V or 24V). This allows your lights to function properly. If you connect low voltage lights directly to line power, the higher voltage would cause them to burn out immediately. 9. How do you tell if a transformer is going bad?Symptoms of power quality issues include vibration, excessive buzzing or humming and overheating. Technicians should occasionally check the power of transformers that supply nonlinear loads, such as variable frequency drives (VFDs) or switching power supplies. 10. Can you replace a transformer with a light fitting?They will have a transformer either in the ceiling or light fitting. Some LED bulbs, like the Philips Master LED range, have in-built circuitry that can deal with most (but not all) transformers, so you don't have to change them. In other cases, you need to replace the transformer with an LED driver. 

2026 Executive Summary: Resistors remain the fundamental components of modern circuitry, from consumer electronics to electric vehicle (EV) power management. This guide classifies resistors by material (Film, Composition, Alloy) and application (Precision, High-Power, Sensitive), providing engineers and hobbyists with critical selection criteria for voltage, power rating, and tolerance in 2026.I. Introduction: The Role of Resistors in 2026Resistors are passive electrical components that restrict current flow to adjust signal levels and voltage. In the 2026 electronics landscape, the variety of resistors continues to expand with the rise of IoT devices and high-voltage EV architectures. Resistors are generally divided into two primary categories: fixed resistors and variable resistors. Fixed resistors are categorized by material into wire-wound and non-wire-wound types. Non-wire-wound resistors split further into film and composite types. Structurally, they appear as tubular, disc, or planar (SMD) components. Depending on protection needs, they can be painted, plastic-pressed, or vacuum-sealed. This guide details the classification, characteristics, and pros/cons of resistor types, updated for 2026 standards. It serves as an essential resource for selecting the right component for modern circuit design.Video: Understanding Types of ResistorsII. How are Resistors Classified by Material?Material composition determines a resistor's noise, tolerance, and stability. In 2026, film-based resistors dominate consumer electronics, while wire-wound types are preferred for high-power applications.2.1 Film Resistors(1) Carbon Film ResistorsCarbon film resistors consist of a ceramic core coated with a crystalline carbon layer, thermally decomposed in a high-temperature vacuum. The resistance is precisely calibrated by cutting a helical groove into the carbon film. These resistors offer a balance of cost and performance. They feature good stability, a low negative temperature coefficient, and stable pulse load handling. Due to their low production cost, they remain widely used in general-purpose consumer electronics where ultra-high precision is not critical.Figure 1. The Appearance and Structure of Carbon Film Resistor(2) Metal Film ResistorsMetal film resistors are manufactured by vacuum-depositing a nickel-chromium (NiCr) or similar alloy onto a ceramic substrate. This technology allows for tighter tolerances than carbon types.Known for superior stability, heat resistance, and low noise electromotive force, metal film resistors are the standard for 2026 precision circuits, including audio equipment and measuring instruments.Figure 2. Metal Film Resistor(3) Metal Oxide Film ResistorsThese are created by spraying metal salt solutions (like tin tetrachloride) onto a heated ceramic skeleton at approximately 550°C. The resulting conductive film is fused firmly to the substrate. Metal oxide variants excel in harsh environments, offering stronger oxidation, acid, and salt resistance than standard metal films. While their resistance range is narrower (typically 1Ω ~ 200 kΩ), they handle power ratings from 1/8 W up to 50 kW in industrial applications.Figure 3. Metal Oxide Film Resistor2.2 Composition ResistorsComposition resistors mix conductive granules with a binder. While less common in modern high-precision tech, they are prized for their high surge energy handling. The distinct advantage of solid core resistors is reliability—often 5 to 10 times higher than film types in pulse-heavy applications. Despite drawbacks like higher noise and poor linearity, they are utilized in aerospace and submarine cabling where component failure is not an option. Solid Core Resistor (Model S): Common model RS11. Range: 4.7Ω – 22MΩ. Accuracy: ±5% to ±20%.High Voltage Composite Film: Models like RHY-10 (10kV) and RHY-35 (35kV) handle extreme voltages with resistance up to 1000MΩ.Carbon Film Composition: High resistance range (up to 106 MΩ) and 35kV working voltage. Used in vacuum megohm resistors for micro-current testing, despite poor moisture resistance.Organic Solid Composition: Pressed mixtures of graphite and organic binder. Compact and robust against overload, but with poor temperature stability. Common in older automotive instrument clusters.Glass Glaze Resistor: A sintered mix of metal oxides (ruthenium) and glass glaze. Features high-temperature resistance and high voltage handling (up to 15kV). Power ratings can reach 500W in specialized units.Figure 4. Different Types of Resistors2.3 Alloy Resistors(1) Precision Wire Wound Resistors (Model RX)Used in measurement instruments requiring stability. Tolerances can be as fine as ±0.005%. However, due to the coil structure, they act as inductors, making them unsuitable for high-frequency circuits.Figure 5. Precision Wire Wound Resistor(2) Power Type Wire Wound ResistorsDesigned for dissipation, these handle 2W to 200W+. They are often ceramic-encased and used in power supplies. Adjustable versions allow for manual resistance tuning during machine calibration. (3) Precision Alloy Foil ResistorsThe gold standard for stability in 2026. These resistors automatically compensate for temperature coefficients, maintaining accuracy across wide temperature ranges. Accuracy reaches ±0.001%, with stability around ±5 × 10-5%/year, making them vital for high-speed response circuits.III. What are the Main Classifications Based on Purpose?Beyond material, resistors are categorized by their specific function in a circuit topology.General Type: Standard components for consumer tech. Power: 1/20W ~ 2W. Tolerance: ±5% ~ ±20%.Precision Type: High stability for medical and audio devices. Tolerance: 2% down to 0.001%.High Frequency Type: Non-inductive designs (often film or solid) essential for RF and 5G communication circuits. Can handle up to 100W.High Voltage Type: Engineered for 1kV ~ 100kV applications, such as X-ray power supplies.High Resistance Type: Specialized for detecting weak currents, with values exceeding 10 MΩ (up to 1014Ω).Integrated Resistance (Resistor Networks): Multiple matched resistors on a single substrate (SIP/DIP packages). Critical for saving space in computer interfaces.Insurance (Fusible) Type: A dual-function safety component. Acts as a resistor under normal load but fuses open like a circuit breaker within seconds (7s to 120s) during overloads (12x-30x rated power).Figure 6. Different ResistorsIV. What are Sensitive Resistors (Sensors)?Sensitive resistors change their resistance in response to environmental stimuli, acting as the "senses" of modern IoT devices.(1) ThermistorTemperature-dependent resistors used for measurement and protection.NTC (Negative Temperature Coefficient): Resistance drops as heat rises. Used in temperature sensors.PTC (Positive Temperature Coefficient): Resistance spikes with heat. Used as self-resetting fuses.Figure 7. Thermistor(2) Photoresistor (LDR)Made from semiconductors like Cadmium Sulfide (CdS). High resistance in dark (>1.5MΩ) drops drastically (<1kΩ) when illuminated. Used in automatic streetlights and photoelectric controls.Figure 8. Photoresistor(3) Varistor (MOV)Voltage-dependent resistors, typically Zinc Oxide. They act as open circuits normally but short-circuit dangerous voltage spikes to ground. Essential for surge protection in power strips and automotive electronics.Figure 9. Metal Oxide Varistor(4) Magneto-resistorUtilizes the magnetoresistive effect (e.g., Indium Antimonide). Resistance rises with magnetic flux. Used in speed sensors, magnetic card readers, and brushless motor control.Figure 10. Magneto Resistor(5) Force Sensitive Resistor (FSR)Converts physical pressure/stress into electrical signals. Found in electronic drums, robotics touch sensors, and industrial scales.Figure 11. Force Sensitive Resistor(6) Gas-sensitive ResistorUtilizes metal oxides (like Tin Dioxide) that change resistance when gas molecules adsorb onto the surface. Standard in 2026 smart home air quality monitors and breathalyzers.Figure 12. Gas-sensitive Resistor(7) Humidity ResistorDetects relative humidity changes. Critical for HVAC systems and weather stations.Figure 13. Humidity ResistorV. Types of Potentiometers (Variable Resistors)5.1 What is a Potentiometer?A potentiometer is a three-terminal resistor with a sliding or rotating contact that forms an adjustable voltage divider. It is the manual interface for many electronic devices (volume knobs, dimmer switches) and a calibration tool for circuits (trimpots).5.2 How are Potentiometers Classified?By Material: Carbon Film (standard), Cermet (Ceramic/Metal mix for long life), Wirewound (high power).By Structure: Single-turn (general use), Multi-turn (high precision), Slide/Linear faders (audio mixers).By Resistance Scale:Linear (Type B): Resistance changes evenly. Used in brightness controls.Logarithmic (Type A): Resistance changes exponentially. Used in audio volume controls to match human hearing.Figure 14. PotentiometerVI. Comparison: Advantages and DisadvantagesChoosing the right resistor in 2026 requires balancing precision, power, and cost.6.1 Mind Map of Resistor ClassificationFigure 15. Mind Map of Types of Resistor6.2 Resistor Comparison TableResistor TypeKey CharacteristicsPrimary ApplicationsAdvantagesDisadvantagesCarbon Film (RT)Hydrocarbon deposit on ceramic. Tolerance ±5% to ±20%.General consumer electronics, toys, basic logic.Low cost, widely available.Poor thermal stability, higher noise.Metal Film (RJ)Vacuum evaporated alloy. Tolerance ±0.1% to ±1%.Audio equipment, precision instruments.Low noise, excellent stability, compact.Higher cost than carbon.Metal Oxide (RY)Tin/Antimony salt spray.Industrial power supplies, high temp zones.Resists oxidation, acids, and heat.Limited resistance range.Wire Wound (RX)Resistive wire wrapped around core.Power supplies, load testing, shunts.High power handling, thermal stability.Inductive (unsuitable for HF), bulky.Organic Solid (RS)Granular conductive mix, hot pressed.High-surge audio outputs.Robust overload capacity, reliable.Low precision, unstable with temp.Cement ResistorWire-wound encased in ceramic fireproof shell.Power adapters, current limiting.Explosion-proof, heat resistant.Large physical size, runs hot.0-ohm Resistor"Jumper" resistor (~0Ω).PCB bridges, configuration toggles.Simplifies PCB routing.N/A6.3 Comparison MatrixA quick reference guide for selecting resistors based on application (vertical) and material (horizontal).Classify by Use Classify by MaterialWire WoundFilm TypeCompositeCarbon FilmMetal FilmMetal OxideGlass GlazeComp. CarbonMetal FoilOrganic SolidInorganic SolidGeneral●●●●●  ●●Precision●●●   ●  High-Resistance  ● ●●   Power●●●      High-Voltage    ●●   High-Frequency   ●     VII. Quick Quiz: Resistor ClassificationQuestionWhat are the two primary macro-classifications of resistors?Answer1. Fixed Resistors (Value remains constant)2. Variable Resistors (Value is adjustable, e.g., potentiometers)VIII. Common Resistor Questions1. What is the main function of a resistor?A resistor opposes current flow to prevent short circuits and manage signal levels. It acts as a gatekeeper, ensuring downstream components receive the correct voltage and current.2. How does a resistor work?Resistors work by restricting the flow of electrons, similar to kinking a garden hose to reduce water flow. They dissipate the excess energy as heat.3. Why are resistors important for Arduino/IoT?They are essential for voltage division (converting 5V logic to 3.3V) and current limiting for LEDs to prevent burnout.4. What is a 0-ohm resistor used for?It acts as a bridge or jumper on a printed circuit board (PCB), allowing designers to route traces over other tracks without using a multi-layer board.5. What is the difference between resistance and a resistor?Resistance is a physical property (measured in Ohms). A resistor is the physical component manufactured to provide a specific amount of that resistance.Frequently Asked Questions (2026 Update)What is the difference between thin-film and thick-film resistors?Thin-film resistors (sputtered metal) offer high precision (0.1% tolerance) and low noise for audio/medical tech. Thick-film resistors (printed paste) are cheaper and handle higher power surges but have lower precision (5% tolerance), suitable for general electronics.Why are shunt resistors critical for EV battery management?Shunt resistors with ultra-low resistance measure high currents in Electric Vehicles (EVs) with extreme accuracy. They enable the Battery Management System (BMS) to calculate state-of-charge and prevent over-current scenarios efficiently.How do I choose the right resistor power rating for PCB design?Calculate the power dissipation ($P = I^2 times R$) and choose a resistor with a rated power at least 50% higher than your calculation (derating). For enclosed 2026 IoT devices, a 2x safety margin is recommended to minimize heat.{ "@context": "https://schema.org", "@type": "Article", "headline": "Resistor Types and Classifications: The 2026 Engineering Guide", "datePublished": "2020-04-18", "dateModified": "2026-01-20", "author": { "@type": "Organization", "name": "ApogeeWeb" }, "mainEntity": { "@type": "FAQPage", "mainEntity": [ { "@type": "Question", "name": "What is the difference between thin-film and thick-film resistors?", "acceptedAnswer": { "@type": "Answer", "text": "Thin-film resistors (sputtered metal) offer high precision (0.1% tolerance) and low noise for audio/medical tech. Thick-film resistors (printed paste) are cheaper and handle higher power surges but have lower precision (5% tolerance)." } }, { "@type": "Question", "name": "Why are shunt resistors critical for EV battery management?", "acceptedAnswer": { "@type": "Answer", "text": "Shunt resistors with ultra-low resistance measure high currents in Electric Vehicles (EVs) with extreme accuracy. They enable the Battery Management System (BMS) to calculate state-of-charge and prevent over-current scenarios." } }, { "@type": "Question", "name": "How do I choose the right resistor power rating for PCB design?", "acceptedAnswer": { "@type": "Answer", "text": "Calculate the power dissipation (P = I^2 * R) and choose a resistor with a rated power at least 50% higher than your calculation (derating). For enclosed IoT devices, a 2x safety margin is recommended." } }, { "@type": "Question", "name": "What is the main function of a resistor?", "acceptedAnswer": { "@type": "Answer", "text": "A resistor opposes current flow to prevent short circuits and manage signal levels. It acts as a gatekeeper, ensuring downstream components receive the correct voltage and current." } } ] }}

 The heat sink has a thermal conductor that carries heat away from the device into fins that provide a large surface area for the heat to dissipate throughout the rest of the components, thus cooling both the heat sink and processor. Both a heat sink and a radiator require airflow and, therefore, both have fans built-in. At present, the main failure form of electronic equipment is thermal failure. According to statistics, 55% of failure of electronic equipment is caused by temperature exceeding the rated value. With the increase of temperature, the failure rate of electronic equipment increases exponentially. Therefore, the thermal design of power devices is most important in the structural design of electronic equipment, which directly determines the success of the products. Good thermal design is the basis for the stable and reliable operation of the equipment. Electronics Thermal Heatsink Design Tutorial CatalogI. Main Parameters of Thermal PropertiesII. Thermal Design of Power DeviceIII. Heat Dissipation CalculationIV. Calculation ExampleV. Selection of RadiatorVI. ConclusionFAQ I. Main Parameters of Thermal Properties The thermal stress of the power device can come from the inside of the device or from the outside of the device. If the heat dissipation capacity of the device is limited, the consumption of power will lead to the rise of temperature and junction temperature in the active region of the chip inside the device, reducing the reliability of the device lower and making the device unable to work safely. The main parameters to characterize the thermal capacity of power devices are junction temperature and thermal resistance. The active region of the device can be the PN junction region of the junction device (such as a transistor), the channel region of the field-effect device, the diffused resistor, or the thin film resistance of the integrated circuit, and so on.  When the junction temperature Tj is higher than the ambient temperature Ta, the heat through the temperature difference to form a diffusive heat flow, which is emitted from the chip through the tube shell, and the heat emitted increases with the increase of the temperature difference (Tj-Ta).  In order to ensure that the device can work properly for a long time, an allowable maximum junction temperature Tj max has been made. Tj max is determined by chip materials, packaging materials, and reliability of devices. The heat dissipation ability of power devices is usually characterized by thermal resistance, called Rt. The larger the thermal resistance is, the worse the heat dissipation ability is. Thermal resistance is also divided into internal thermal resistance and external thermal resistance.  Internal thermal resistance is the inherent thermal resistance of the device itself, which is related to the thermal conductivity, thickness, and cross-sectional area of the tube core, shell material, and processing technology, while external thermal resistance is related to the form of tube package. Generally speaking, the larger the shell area, the smaller the external thermal resistance. The external thermal resistance of the metal shell is obviously lower than that of the plastic. When the power consumption reaches a certain level, the junction temperature of the device goes up and the reliability of the system decreases. In order to improve the reliability, the thermal design of the power device should be carried out.  II. Thermal Design of Power Device The thermal design of the power device is mainly to prevent thermal failure caused by overheating or alternating temperature. It can be divided into the thermal design of the internal chip, thermal design of the package, thermal design of the tube, and thermal design in practical use. For general power devices, only the thermal design of the device's interior, package, and the tube should be considered. But when the power consumption is high, the appropriate radiator should be installed, through which the heat can be effectively dissipated to ensure the device works normally and reliably within the safe junction temperature.   III. Heat Dissipation CalculationThe most commonly used heat dissipation method is to install the power device on the radiator, using the radiator to disperse the heat into the surrounding, if necessary, to add the fan to strengthen the heat dissipation with a certain wind speed.  Flow cold water cooling plate is also used in some large power devices, which has a better heat dissipation effect. Heat dissipation calculation is to determine the appropriate heat dissipation measures and radiators through calculation under certain working conditions. There is a certain thermal resistance in the heat transfer process. The thermal resistance from the core of the device to the bottom is Rjc, between the bottom and the radiator is Rcs, a radiator that spreads heat into the surrounding is Rsa, the total resistance is Rja=Rjc+Rcs+Rsa.  If the maximum power loss of the device is Pd, and the permitted junction temperature of the device is Tj, ambient temperature is Ta, the reasonable total thermal resistance Rja can be obtained by the following formula.Rja ≤(Tj-Ta)/Pd The thermal resistance of the maximum allowable Rsa is: Rsa ≤(Tj-Ta)/Pd-(Rjc+Rcs) For design consideration, Tj is generally set to 125℃, Ta=40℃ ~ 60℃ generally used in the case of bad ambient temperature. The size of Rjc depends on the size of the core and the package structure, which can be found from the parameter list. Rcs size depends on the installation technology and device packaging. If the device adopts heat conducting grease or heat transfer pad, installing with the radiator, the typical value of Rcs is 0. 1 ℃/W / ~ 0. 2 ℃/W; If the bottom surface of the device is not insulated and additional mica insulation is required, the Rcs can reach 1 ℃/W. Pd is the maximum power loss calculated according to the working conditions of different devices. In this way, Rsa can be calculated to select an appropriate radiator. IV. Calculation ExampleA power operational amplifier PA02 as low-frequency power amplifier, the device is 8-pin and TO-3 metal shell package. The operating conditions are as follows: the operating voltage Vs is 18 V, the load impedance RL is 4Ω, the ambient temperature is 40 ℃, and the natural cooling is adopted. According to the data of PA02: the typical value of static current Iq is 27mA, the maximum value is 40mA, and the typical value of Rjc (from tube core to shell) is 2.4 ℃/W, and the maximum value is 2.6 ℃/W. The power consumption of the device is Pd=Pdq+ Pdout(Pdq is the internal power consumption and Pdout is the output power consumption). The calculation is as follows: Pdq=Iq(Vs+|-Vs|)  Pdout=Vs2/(4RL)  Iq=37mA                                                                                 Pd=Iq(Vs+|-Vs|)＋Vs2/(4 RL)                                                                                     =0.037×(18+18)＋182/(4×4)                                                                                     =21.6 W Radiator thermal resistance: Rsa ≤(Tj-Ta)/Pd-(Rjc+Rcs) Tj=125℃, Ta=40℃, Rjc=2.6℃/W, Rcs=0.2℃/W(PA02 installed directly on radiator with heat conductive grease in the middle) Substitute the above data into the formula to get Rsa≤ (125-40)/21.6-(2.6+0.2)≤ 1.135℃/W The thermal resistance HSO4 in natural convection is 0. 95 ℃/W, which can meet the requirement of heat dissipation. V. Selection of RadiatorRadiators are generally standard parts, but also provide customization. The surface of the radiator is treated by electrophoretic coating or black oxygen polarization, which aims to improve heat dissipation and insulation performance.  In natural cooling can be increased by 10%~15%, in ventilation cooling can be increased by 3%, and electrophoretic coating can withstand pressure 500V~800V. The heat resistance of different types of radiators in different heat dissipation conditions is given by the radiator manufacturers. The radiator is used to control the temperature of the power device, especially the junction temperature (Tj), making is lower than the safe junction temperature of the power device, so as to improve the reliability of the power device.  Conventional radiators tend to be standardized, serialized, universal, and new products develop towards low thermal resistance, multifunction, small volume, lightweight, and suitable for automatic production and installation.  The internal thermal resistance of various power devices is different and the difference of contact surface and installation torque will lead to the thermal-resistance difference between the contracts.  The main factor of selecting a radiator is the heat resistance Rtf. Under different environmental conditions, the heat dissipation of power devices is also different. Therefore, environmental factors, the matching between radiator and power device, and the volume and quality of the whole electronic equipment should be taken into account in selecting the appropriate radiator. First of all, according to the performance parameters and environmental parameters of the power device in normal operation, calculate whether the junction temperature of the power device is within the safe condition, determine whether it is necessary to install the radiator, and calculate the corresponding thermal resistance of the radiator if it needs to be installed.  The junction temperature of the power device is recalculated to determine whether the junction temperature of the power device is within the range of safe junction temperature, so as to judge whether the selected radiator meets the requirements. For the radiator that meets the requirements, the optimum design should be carried out according to the actual engineering requirements.   VI. ConclusionThrough the analysis and calculation of the heating principle of the power device, it can guide the design of the heat dissipation mode and the selection of the radiator, ensure the power device work in the safe temperature range, reduce the quality problem, and improve the reliability of the electronic products.  The reliability of electronic equipment is also related to the components, structure, assembly, process, processing quality, and so on. In practical engineering applications, feedback data should be obtained through various tests to perfect the design and further improve the reliability of electronic equipment. FAQ 1. What is a heat sink and how does it work?A heat sink (also commonly spelled heatsink) is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant, where it is dissipated away from the device, thereby allowing regulation of the device's temperature. 2. What is a heat sink used for?A heat sink is a component that increases the heat flow away from a hot device. It accomplishes this task by increasing the device's working surface area and the amount of low-temperature fluid that moves across its enlarged surface area. 3. Does a heat sink need a fan?Most heatsinks have denser fins, which requires a fan to be mounted directly on the cooler. If your heatsink has heat pipes (copper tubes running through the fins), then it's most likely designed to be used with a fan. It's simple to test whether or not a heatsink can safely be run without a fan on it. 4. What material dissipates heat the best?Thermal conductivity is the measure of a metal's ability to conduct heat. What this means is that that the metal acts to cool temperatures, through a process of dissipation. The metals with the highest thermal conductivity are copper and aluminium. The lowest are steel and bronze. 5. How many types of heat sinks are there?The Two Major Heat Sink Categories. All heat sinks can be broken down into two major categories… active and passive. 6. What is the difference between active and passive heat sinks?An active heat sink has a fan attached to it, to actively pull heat away from the heat sink and chip that lies underneath it. A passive heat sink is just a heat sink, a piece of flat metal with fins on top that directs heat away from the chip set it is installed on. 7. Which is better heat sink or fan?Generally though, with good airflow provided by the fan heatsinks can often be a lot smaller. The only benefit to a heatsink-only arrangement is less noise. ... Out of preference you want the heatsink fins to be standing upwards so that hot air can immediately rise off of it and cool air be pulled in. 8. What is the difference between a heatsink and a CPU fan?The heatsink draws the heat away from the CPU, and the fan ensures a steady stream of air for the heatsink to pass the heat to. However, there is more to selecting a heatsink and fan than just looking for a good price or one that looks cool. 9. What is the difference between a heat sink and a heat pipe?Vapor chambers are most often used to spread heat to a local heat sink, whereas heat pipes are generally better for moving heat to a remote sink. ... If you need a heat sink that's minimally 10 times, but usually closer to 20 times, the area of the heat source, consider vapor chambers. 10. How is a heat sink attached to an electrical component?A heat sink is a mechanical component that is attached to an electrical component for the sake of transferring heat from the electrical component into the surrounding environment. This environment is most commonly air, but it can also be other fluids, such as water or coolant. 

Many engineers who have not used the switching power supply may have some worry about it, such as the PCB layout, the parameter and type selection of components, and so on. In fact, as long as you understand the basic principle, the use of switching power supply design is very convenient. In today's article, we will introduce you to some basic knowledge of switch-mode power supply, along with some experience sharing when using the switch-mode power supply. SMPS Tutorial: Switch Mode Power Supplies and Power Conversion  Catalog I. What is the Switch Mode Power SupplyII. How to Debug the Switching Power Supply Circuit?III. What Needs to Be Grounded?3.1 Definition of Grounding3.2 Grounding Mode3.3 How is the Signal of the Single Board Grounded?3.4 How Do the Single Board Interface Devices   Grounding?3.5 How to Grounding the Shield Layer?IV. Introduction of Signal Backflow and TranspartitionV. Should Analog Separate from the Digital , and How?FAQ I. What is the Switch Mode Power Supply  A switch-mode power supply usually consists of a controller and an output part. Some controllers integrate MOSFET into the chip, which makes it easier to use and simplify the PCB design, but the flexibility of components is weakened. The switching controller is actually a closed-loop feedback control system, so there is a sampling circuit of output-voltage feedback and a feedback-loop control circuit. Therefore, this part of the design is to ensure an accurate sampling circuit and to control the feedback depth, because if the feedback loop response is too slow, it will have a great impact on the transient response-ability. The output parts include output capacitance, output inductor, MOSFET, and so on. The selection of these devices is basically to balance the performance need and cost. For example, the high switching frequency can use small inductance (which means small package and low cost), but a high switching frequency will increase interference and the switching loss of MOSFET, result in reducing efficiency and increasing cost. Lower switching frequency has the opposite effect. The selection of Rds_on parameters of MOSFET and the ESR for output capacitance is also very important. ESR is small can reduce output ripple, but the cost of the capacitor will increase. And It is important to note that switching power controllers can not be well driven with too much MOSFET. In general, suppliers of switching power supply controllers will provide specific formulas and usage options for engineers. Figure. 1 Switch Mode Power Supply Circuit   II. How to Debug the Switching Power Supply Circuit? （1）The output of the power supply circuit is installed to the board through the low resistance and high power resistor, so that the power circuit can be debugged first before welding resistance, avoiding the influence of the latter circuit.  （2）The switching controller is a closed-loop system. If the output deterioration beyond the range that the closed-loop can control, the switching power supply will work improperly. This situation requires careful examination of feedback and sampling circuits. Especially, if the output capacitance with a large ESR, lots of ripple of power supply will be produced, which will also affect the operation of switching power supply.  III. What Needs to Be Grounded? At the very start, the introduction of grounding technology is a protective measure to prevent lightning strikes on electric power or electronic equipment. The purpose is to introduce lightning current through the lightning rod to the earth to protect buildings. And meanwhile, grounding is also an effective way to protect personal safety.  When the phase line touches the shell of the equipment causing by some reason (such as poor insulation of the wire, line aging, etc.), there will be a dangerous voltage in the shell of the equipment. Having grounding, the resulting fault current will flow to the earth, thus it plays a protective role.  For example, in communication systems, the interconnection of signals between a large number of devices requires each device to have a point as a reference, and with the complication of electronic equipment, the signal frequency is becoming higher and higher, therefore, grounding design as special attention paid to the electromagnetic compatibility problems such as mutual interference between signals.  In addition, improper grounding will seriously affect the reliability and stability of system operation. Recently, the concept of "grounding" has also been introduced into high-speed signal backflow technology.  3.1  Definition of GroundingIn the modern concept of grounding, for line engineers, the term usually means "reference point for line voltage"; for system designers, it is often a cabinet or frame; for electrical engineers, it is a green and safe ground line or a wire connected to the earth. A more general definition is that "grounding is the low impedance channel which the current returns its source." Noting that the points are "low impedance" and "channel".  3.2  Grounding ModeThere are many ways of grounding: single-point grounding, multi-point grounding, and mixed type of grounding. Single-point grounding is divided into a series of single-point grounding and parallel single-point grounding. In general, single-point grounding is used in simple circuits, and low frequency (f10MHz) circuits use multipoint grounding or multilayer (complete a ground plane layer).  3.3   How is the Signal of the Single Board Grounded?For the general device, the near ground is the best. After adopting the multilayer design with a complete ground plane, the grounding of the general signal is very easy. The basic principle is to ensure the continuity of the line, reduce the number of holes, approach the ground plane or the power plane, etc. 3.4  How Do the Single Board Interface Devices  Grounding?Some veneers will have external input-output interfaces, such as serial port connectors, RJ45 connectors, etc. If their grounding is not well designed, it will also affect normal operation, such as error codes, packet loss, etc. And it will become an external source of electromagnetic interference sending the noise out. In general, a single interface grounding will be made, and the signal is connected by a thin wire connection, string 0 ohms, or small resistance. Thin lines can be used to block signal ground noise. At the same time, the interface and the interface power filter should also be considered seriously.  3.5  How to Grounding the Shield Layer? The shielding layer of cables is connected to the interface grounding instead of the signal grounding, because there are various noises on the signal grounding. If the shield layer is connected to the signal ground, the noise voltage will drive the common-mode current to interfere outward along the shield layer. Therefore, the poorly designed cable is generally the maximum noise output source of electromagnetic interference. Of course, the interface ground should keep clean. IV. Introduction of Signal Backflow and TranspartitionFor an electronic signal, it needs to find a way with the lowest impedance to return current to the ground, so how to deal with the signal backflow becomes very important. First, according to the formula, we can know that the radiation intensity is proportional to the area of the loop. Specifically, the longer the path the return is, the bigger the ring is formed, and the greater the external radiation interference is, thus the power-circuit flow back and signal loop area should as small as possible when design PCB. Second, for a high-speed signal, providing a good signal backflow can guarantee its signal quality. Because the characteristic impedance of the transmission line on the PCB is generally calculated by reference to the ground (or power layer), if there is a continuous ground plane near the high-speed line, the impedance of this line can be kept continuous, and if there is no ground reference near the section line, the impedance will change and the signal will be affected as well. Therefore, the high-speed lines should be distributed to the layer near the ground plane, or they should be walked in parallel next to each other, to shield interference and provide backflow nearly.  Third, do not divide wires when having power supply in wiring way, this is because the signal backflow path across different power layers will be longer, and be vulnerable to interference. For low-speed signals, it is not strictly required that, because the resulting interference signal can not be concerned about. But for high-speed signals should be checked carefully, do not cross as far as possible, you can adjust the power part of the wire. (this is for multiple power supplies on multilayer boards).  V. Should Analog Separate from the Digital , and How? Whether analog signal or digital signal should return to the ground. Because the digital signal changes quickly and the noise caused by the digital signal will be very large, if analog and digital mixing, the noise will affect the analog signal.  In general, the grounding of analog and digital processing must be separated, then connected by a thin line, or a single point. The general idea is to try to block the noise from the digital ground to the analog ground. But it is not a very strict requirement that analog and digital ground must be separated, if the analog section near the digital ground is still very clean, they can be combined. FAQ 1. What are the 3 types of power supply?There are three subsets of regulated power supplies: linear, switched, and battery-based. Of the three basic regulated power supply designs, linear is the least complicated system, but switched and battery power have their advantages. 2. What is meant by switch mode power supply?A switch mode power supply is a power converter that utilises switching devices such as MOSFETs that continuously turn on and off at high frequency; and energy storage devices such as the capacitors and inductors to supply power during the non-conduction state of the switching device. 3.What are the advantages and disadvantages of switch mode power supply?Advantages & disadvantages of switch mode power supply (SMPS)a. The switch mode power supply has a smaller in size.b. The SMPS has light weight.c. It has a better power efficiency typically 60 to 70 percent.d. It has a strong anti interference.e. SMPS has wide output range.f. Low heat generation in SMPS. 4. What is a DC switching power supply?A Switching DC power supply (also known as switch mode power supply) regulates the output voltage through a process called pulse width modulation (PWM). The PWM process generates some high frequency noise, but enables the switching power supplies to be built with very high power efficiency and small form factor. 5. What is the difference between a switching power supply and a linear power supply?Linear power supplies deliver DC by passing the primary AC voltage through a transformer and then filtering it to remove the AC component. Switching power supplies feature higher efficiencies, lighter weight, longer hold up times, and the ability to handle wider input voltage ranges. 6. Do I need a switching power supply?The switching power supply implies higher efficiency due to the high switching frequency, enabling it to use a smaller, less-costly high-frequency transformer as well as lighter, less-costly filter components. Switching power supplies contain more overall components, therefore are usually more expensive. 7. Is a switching power supply regulated?A switch mode power supply regulates an output voltage with pulse width modulation (PWM). This process creates high-frequency noise but it provides a high-efficiency rating in a small form factor. ... The low DC voltage is finally converted into a steady DC output with another set of diodes, capacitors, and inductors. 8. How do I know if my power supply is regulated?You can generally stick one probe into the middle of the connector, and hold the other against the outside. With a few exceptions, the middle is positive, so use the red lead there, and use the black lead on the outside shell. Regulated supplies, without any load, should measure very close to the target voltage of 12v. 9. Can I use a switching power supply to drive a DC motor?A simple unregulated analog power supply may be easier and be able to supply the large starting under load current more that the switching one. DC motors are not too fussy about the supply, and will usually run quite well on unfiltered DC. 10. Are switch mode power supplies any good?Switch mode power supplies, SMPS provide improved efficiency & space saving over traditional linear supplies, but care has to be taken to ensure noise on the output is low. Switch mode power supplies are widely used because of the advantages they offer in terms of size, weight, cost, efficiency and overall performance. You May Also LikeSwitching Power Supply Guide: Protection CircuitSwitching Power Supply Tutorial: 4V～16VSwitched Mode Power Supply Tutorial: Principles & Functions of SMPS Circuits