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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

    Circuit protection is a frequently discussed topic, and the various types of circuit protection differ due to the various problems in the circuit. Short-circuit, overload, grounding, and lightning strikes are the most common faults in power supply systems. To ensure the safe and dependable operation of the power supply system, protection devices must be installed to monitor the working conditions of the power supply system, detect faults in time, and cut off the power supply of the faulty equipment, preventing the accident from spreading. In general, the protection circuit is made up of various relays, signal indicating devices, and other components. This blog provides an in-depth discussion on several circuit protections. Below is an introduction video about short circuit protection. DIY Short Circuit (Overcurrent) Protection   Catalog   I Introduction to circuit protection II Switching power principle and characteristics      2.1 Operational principle of switching power      2.2 Characteristic of switching power III DC Switching power supply protection      3.1 Overcurrent protection circuit      3.2 Overvoltage protection circuit      3.3 Soft start protection circuit        3.4 Overheat protection circuit IV Conclusion FAQ   I Introdcution to circuit protection The operation of electronic equipment can not be separated from electricity, so DC switching power supply which can control the electricity is playing a more and more important role. And it has entered various fields of electronics and electrical equipment: SPC exchange, communication, electronic testing equipment power supply and controlling equipment power supply, which are widely used DC switching power supply.  Meanwhile, with the development of many high-tech technologies, including high-frequency switching technology, soft-switching technology, power factor correction technology, synchronous rectifier technology, intelligent technology, surface installation technology, etc., switching power supply technology is constantly innovating. This provides a wide range of development for DC switching power supply.  DC current diagram   But the circuit is complex to control in the switching power supply, the transistor and the integrated device have poor resistance to electricity and thermal shock, which brings great inconvenience to the user in the process of using. In order to protect the safety of switching power supply itself and load, the overheat protection, over-current protection, over-voltage protection and soft start protection circuit are designed according to the principle and characteristics of DC switching power supply.   II Switching power principle and characteristics 2.1 Operational principle of switching power DC switching power supply is composed of input part, power conversion part, output part and control part. The power conversion part is the core of the switching power supply. It performs conversion which needed for the output on the high-frequency and unstable DC. It is mainly composed of switching transistor and high frequency transformer. Figure 1. DC Switching power supply principle Figure 1 shows the schematic diagram and equivalent schematic block diagram of DC switching power supply, which is composed of full wave rectifier, switching tube V, excitation signal, fly-wheel diode Vp, energy storage inductance and filter capacitance C. In fact, the core part of DC switching power supply is a DC transformer. 2.2 Characteristic of switching power   In order to meet the needs of users, the world's major switching power supply manufacturers are committed to the simultaneous development of new and highly intelligent components, especially by reducing the loss of the secondary rectifier. In order to improve the magnetic properties under high frequency and high magnetic flux density, power ferrite (Mn-Zn) materials have been developed. At the same time, the application of SMT technology in the field of switching power supplies has also made considerable progress. The components are arranged on both sides of the circuit board to ensure that the switching power supply is light, small and thin. Therefore, high frequency, high reliability, low power consumption, low noise, anti-interference and modularization are the development trends of DC switching power supplies. However, DC switching power supplies also have disadvantages. The DC switching power supply switch has serious interference, and its ability to adapt to harsh environments and sudden failures is weak. There is still a certain gap in microelectronics technology in developing countries. Specifically, the production technology of resistors and capacitors and the technology of magnetic materials are compared with those of some technologically advanced countries. Therefore, the manufacture of DC switching power supplies is very difficult. In most parts of the world, maintenance is difficult and the cost is high. III DC Switching power supply protection Based on the characteristics of DC switching power supply and the actual electrical condition, in order to make DC switching power supply work safely and reliably in bad environment and sudden fault, this paper designs a variety of protection circuits according to different conditions. 3.1 Overcurrent protection circuit   Figure 2. Input Overcurrent protection circuit In DC switching power supply circuit, in order to avoid short circuit and overflow damage to protect the regulator tube in the circuit, the basic method is that, when the output current exceeds a certain value, the regulator tube is in the reverse bias state, thus the circuit current is cut off automatically. As shown in Fig. 2, the over-current protection circuit consists of transistor BG2 and divider resistor R4, R5. When the circuit works normally, the base potential of BG2 is lower than that of emitter through the partial voltage interaction between R4 and R5, and the emitter junction bears reverse voltage. So the BG2 is in the cutoff state (equivalent to open circuit), which is used to stabilize the voltage. But the voltage stabilizing circuit has no effect. When the circuit is short circuit, the output voltage is zero and the emitter of BG2 is equivalent to grounding, then the BG2 is in the state of saturation conduction (equivalent to short circuit), so that the regulator tube BG1 base and emitter are close to short circuit, and in the cut-off state, the circuit current is cut off to achieve the purpose of protection.   3.2 Overvoltage protection circuit The overvoltage protection of switching regulator in DC switching power supply includes input overvoltage protection and output overvoltage protection. If the voltage of the unstabilized DC power supply (such as batteries and rectifiers) used by the switching regulator is too high, it will cause the switching regulator to fail to work properly and even damage the internal devices. Therefore, it is necessary to use the input overvoltage protection circuit in the switching power supply. Fig. 3 is a protection circuit composed of transistors and relays, in which the voltage of the input DC power supply is higher than the breakdown voltage of the zener diode, at this condition, current flows through resistor R, making diode T conducts. Following these electrical actions, relay operates and common closed contact disconnected, inputting current. The polarity protection circuit of the input power supply can be combined with the input overvoltage protection to form the polarity protection identification and overvoltage protection circuit. Figure 3. Input overvoltage protection circuit 3.3 Soft start protection circuit The circuit of switching power supply is complex, the input end of switching regulator is usually connected with small inductance and large-capacitance input filter. At start-up instant, the filter capacitor flows through a large surge current that can be several times the normal input current. Such a large surge current melts the contacts of the normal power switch or the relay and melts the input fuse. In addition, surge current can also damage capacitors, shorten their life, cause premature damage. To this end, a current-limiting resistance should be connected in the circuit, through this current-limiting resistance to charge the capacitor. In order not to consume too much power by the current limiting resistance, and avoid affecting the normal operation of the switching regulator, therefore a relay is used to connect it automatically after the transient process is finished, which makes the DC power supply directly to the switching regulator. This is called the "soft start" circuit of DC switching power supply. Figure 4. Soft start-up protection circuit When the power supply is switched on, capacitor C is charged by input voltage through rectifier bridge (D1 ~ D4) and current-limiting resistance R1 to limit the surge current. The inverter works normally when the capacitor C is charged to about 80% rated voltage. The trigger signal of thyristor is generated by auxiliary winding of main transformer, which makes thyristor switch on and short circuit current-limiting resistance R1, and the switching power supply is in normal operation state. In order to improve the accuracy of the delay time and prevent the relay operation from shaking and oscillating. The delay circuit can replace the RC delay circuit by the circuit shown in figure 4(b). 3.4 Overheat protection circuit The high integration and light weight of switching regulator in DC switching power supply greatly increase the power density per unit volume, so if the internal components of the power supply do not have a corresponding increase in the temperature of its working environment, it will inevitably make the circuit performance damaged and components life service shortened prematurely. Therefore, overheating protection circuit should be installed in high power DC switching power supply. Figure 5. Overtemperature protection circuit In this paper, the temperature relay is used to detect the internal temperature of the power supply device. When the inside of the power supply device is overheated, the temperature relay operates, which makes the alarm circuit of the whole machine in the state of alarm and realizes the protection of the overheating of the power supply.  As shown in Fig. 5 (a), the P type control gate thermal thyristor is placed near the power switch transistor in the protection circuit. According to the characteristics of the TT102 (the on-on temperature of the device is determined by the Rr value, the larger the Rr is, The lower the conduction temperature), when the temperature of the power tube or the temperature inside the device exceeds the allowable value, the thermal thyristor is switched on and the LED is lighting to give an alarm. If cooperate with photoelectric coupler which can make whole machine alarm circuit operation, protecting switch power supply.  The circuit can also be designed as shown in Fig. 5 (b) to protect the power transistor from overheating. The base current of the switching transister is bypassed by the TT201 of the N type control gate thermal thyristor, and the switch tube is cut off, also the collector current is cut off, and the overheating is prevented. IV Conclusion This blog mainly discusses various protection methods of internal devices in DC switching power supply, and introduces some concrete circuits. For a given DC switching power supply, it is very important for the security and reliability of the power supply device whether the protection circuit is perfect and set up to work necessarily. Because the protection scheme and circuit structure of switching power supply are diverse, reasonable protection scheme and circuit structure should be chosen for specific power supply devices. In practical application, several protection methods are usually used to form a perfect protection system to ensure the normal operation of DC switching power supply.   FAQ   1. What is the purpose of circuit protection? The basic goals of circuit protection are to 1) localize and isolate the condition or fault and 2) prevent and minimize any unnecessary power loss. There are several types of abnormal conditions that may occur throughout a building's life, in which an electrical system must be designed to correct or overcome.   2. What protective devices are used in circuits? Fuses, MCBs, RCDs, and RCBOs are all devices used to protect users and equipment from fault conditions in an electrical circuit by isolating the electrical supply.   3. How do you protect a circuit design? The most basic device is a fuse, a type of low resistance resistor that acts as a sacrificial device to provide over current protection, of either the load or source circuit. A fuse protects the circuit, but once it's utilized, it's kaput.   4. What are the two main circuit protection devices? The two types of circuit protection devices discussed in this chapter are fuses and circuit breakers. A fuse is the simplest circuit protection device. It derives its name from the Latin word "fusus," meaning "to melt." Fuses have been used almost from the beginning of the use of electricity.   5. 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.   6. What are the differences between linear DC power supply and switching 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.   7. 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.   8. 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.   9. 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.   10. What is a switching mode power supply used for? Switched-mode power supplies are used to power a wide variety of equipment such as computers, sensitive electronics, battery-operated devices and other equipment requiring high efficiency.    

Regarding the design of a micropower isolated power supply for the two-wire transmitter, we must know what is the transmitter first. When the output of the sensor is a specified standard signal, it is called a transmitter. A sensor, usually composed of sensitive elements and conversion elements, is a floorboard for a component or device that can be measured and converted into a usable output signal according to certain rules. And the common types are power transmitters, current-voltage transmitters, and so on.How to Build a FM Radio Transmitter CatalogI. Brief Introduction to Internal Micro-power Supply DesignII. Overall DesignIII. Constant Current Voltage Stabilizing CircuitIV. DC/CD in CircuitV. Isolated Power Source WindingVI. ConclusionFAQ I. Brief Introduction to Internal Micro-power Supply Design The design of an internal micro-power supply is very important when developing a low-power intelligent two-wire transmitter. Firstly, in order to satisfy the power supply of the micro-controller, A/D, D/A, and communication circuit, the intelligent transmitter with microprocessor needs more power than that of an ordinary 4~20mA one), and its power supply efficiency of the internal power supply must be higher.  In addition, for capacitive sensors and thermocouples, it is necessary to consider the case of grounding or the possibility of the sensor earthing. So the input and output of the designed transmitter circuit must be isolated, only this way can guarantee the normal operation of the follow-up control system and the ability of anti-common-mode interference.  Since the external circuit provides the maximum working current of 4mA for the two-wire transmitter system, specific requirements like this bring great difficulties and challenges to the design of the power supply of the system. Adopting a full integrated circuit, the isolated two-wire transmitter power supply with micro-input power has the advantages of simple structure, stable performance, and low cost. And it takes the 12~35V DC as the input power, designing the simple input circuit of the constant current and stable voltage front end, fixing the consumption of 315mA current, and providing two sets of isolated 3V power supply. In this case, the not isolated imputing group with maximum 5mA load capacity and the isolated imputing group with maximum 3mA load capacity, which can meet the requirements of input and output isolating two-wire transmitters for power supply.  II. Overall Design Fig.1 is a schematic diagram of the power supply. It consists of three main parts: 315mA/812V constant current voltage stabilizing circuit composed of U1, R1, and Z1; DC/DC converter circuit composed of U2 as the core; and a set of isolated power supply composed of L2 and U3. The system is designed to be concise and highly integrated, and all selected components can work at -40 ~ 85 ℃, which can ensure the reliable application of the power supply to field transmitters.Fig.1 Schematic Diagram of Power Supply III. Constant Current Voltage Stabilizing Circuit As a power supply to the two-wire transmitter, the maximum working current is 4mA. The transmitter with this power supply needs some low zero output indication, so the general system power supply standard is usually below 315mA, meanwhile, this type of power supply must have constant current characteristics to meet the operating requirements of the two-wire transmitter. And there are many ways to design constant-current sources. The design in Fig.2 adopts the three-terminal adjustable voltage stabilizer LM317L to design a constant-current source. LM317L is a three-terminal adjustable voltage stabilizer, and its application is as follows in Fig.2. Its basic application as a standard regulator is shown in Fig.2 (a), where a steady pressure difference is generated between the output and adjustment terminal, the typical value is 1125V, so its output voltage is VO=1125 (1+Ra/Rb). Because of the stable pressure difference of LM317, it is often used to design the constant-current source. Fig.2 (b) is a typical application circuit, which generates a current of I=1125 / R, consulting Fig.1; the R1 value in the design is 360Ω, so you can obtain a constant current of about 315mA.  Considering the working voltage range of the subsequent DC/DC chip is 4~11V and the actual out the power supply, a voltage stabilizer Z1 with 812V is used to parallel the voltage stabilizing function while providing a stable inlet voltage for U2. It requires that the U2 total current consumption is less than 314mA and Z1 must be the high-quality voltage stabilizer with the breakdown current less than 011mA (Philips products can be used, the lowest static stable current is only dozens of μA). Fig.2 Typical Application of LM317LThe D1 of the front end of the circuit is an anti-inversion diode( as shown in Fig.1), generally using 1N4148. The fuse is the PTC device self-recovery fuse, its parameter is 100mA/ 60V, which ensures that the external power supply will not be affected when the power supply fails. The field transmitter is the final application of the power supply. Its changing ambient temperature is in a wide range, so the temperature drift must be taken into account. The main temperature drift of the power supply is the constant current drift, which is caused by the temperature drift of the reference voltage difference of LM317L and the temperature drift of the constant current resistance R1. In reality, the temperature drift can be neglected when the temperature coefficient is below 5*10-6/℃.  The relationship between the reference pressure difference and temperature coefficient of LM317L is shown in Fig.3: The temperature effect is obvious in the temperature range of - 40-85%, thus compensation must be made in the high precision application. In intelligent transmitter systems, in order to correct sensors and compensate circuits, temperature sensors are commonly designed in the transmitter circuits, because the practical applications of power supply are aimed at intelligent transmitters. But the digital thermometric chip, like LM75 or TC77, does not design a special hardware compensation, while a software compensation algorithm provided when applying power supply to deal with temperature drift.  Fig.3 LM317L Benchmark Temperature CurveAs shown in Fig.3, the curve of the relationship between the reference pressure difference and temperature of LM317L is approximate to a simple cubic polynomial function. It only needs to design a compensation function for the reverse Y-axis, and the system is calibrated at 20 ℃ as the basic compensation. The specific compensation formula is ΔI=A (t-20)2+B (t-20) in which “t” is the ambient temperature. The coefficients A and B can be derived from the reference voltage temperature curve provided by the LM317L chip manual, the simplest method is to obtain two binary linear equation groups for solving A and B by taking two points of -20 ℃ and 60 ℃. In this way, it is easy to obtain an approximate function of the compensation curve with a good fitting degree, and the effect of compensated temperature drift can be neglected basically. The biggest difficulty of power supply design is that the input power is very small, thus the isolated feedback mode with high power consumption should be avoided in the design of the isolation terminal, and the open-loop auxiliary side should be used in the actual circuit. The specific process is using MAX639 to design the core circuit of DC/DC, which realizes the high power efficiency conversion. For example, when the input of 315mA is supplied, it can supply the circuit with a current much larger than that of 315mA, thus solving the need for a large current in an intelligent system. According to the requirements of the system, the core chip must have the advantages of low power consumption, high efficiency, wide input voltage range, and simple peripheral devices. The DC/DC chip in Fig.1 is MAXIM's MAX639, which is a step-down converter chip. Its main features are wide input voltage range (4~115V), high conversion efficiency (up to 90%) and low static current (10 μ A); fixed output or an adjustable output. IV. DC/CD in Circuit The circuit is designed for adjustable output and the output is set to 3V. Output current: Io=（Vi Ii η）/Vo, Vi is the input voltage; Ii is the input current, and η is the conversion efficiency and Vo is the output voltage. In the circuit, Vi=812V, Ii=315mA,η= 90%, Vo=3V, getting an approximation Io=816mA without considering the isolating side output, this output current is already a relatively large supply capacity in the low-power system. But the calculation of the above Io is only theoretical, if you want to make the circuit operate reliably under the condition of micro-input power such as 315mA/812V, and to obtain more than 90% conversion efficiency, it is necessary to design the circuit very carefully. The reliable operation of DC/DC is restricted by many conditions, the necessary condition is providing sufficient start-up pulse current. A 10μF tantalum electrolytic capacitor C2 in parallel to Z1 provides an operation guarantee, also it can effectively avoid the interference of DC/DC work on the constant current of LM317. The inductance L1 plays a decisive role in the conversion efficiency of DC/DC. The algorithm provided by the MAXIM manual is L1=50/I0, μH is the unit of L1 and A is the unit of I0. In the practical circuit, the value of L1 is 4mH, which can ensure the circuit work stably under the maximum output power, and it can keep the high conversion efficiency at the same time. what should be emphasized is that if L1 is small, the conversion efficiency of the circuit will be reduced, the starting current will increase and even can not operate. If L1 is larger, the output capacity will decrease and the DC/DC circuit will oscillate. To ensure the stability of the circuit, DC / DC chip has a high requirement for output capacitor C3, the most important is that its equivalent series resistance ESR must be smaller, and it must have enough capacity at the same time. So a 10μF tantalum electrolytic capacitor with excellent performance is used in the circuit design, which can guarantee a stable output. The DC/DC chip is the core of the circuit, and the actual circuit layout has a great influence on the performance of the circuit, especially on the output ripple. The unreasonable layout design of the circuit board will even bring extra parasitic oscillation in the output, so much more attention should be paid to the design. Thus the most important principle is that the ends of C2 and LI lead should be as close as possible to the MAX639 pin, and the grounding pins of C2, D2, MAX639, R3, and C3 should be as close as possible to each other, linking with thick wires. The setting input voltage of DC/DC is 812V, which is guaranteed by Z1. If the actual transmitter requires a lower power supply, Z1 can choose a lower stable voltage, which makes the whole power supply require a lower input voltage. The low threshold of the inlet voltage is 12V; if Z1 selects 612V, the threshold voltage can be reduced to 10V. V. Isolated Power Source Winding The main feature of the circuit is to provide an isolated power supply winding, which uses the method of "stealing" electricity on the DC/DC output energy storage inductor. In Fig.1, the L2 is the power supply coil for this isolated power supply. Because the isolating power supply is a secondary coil loaded on the energy storage coil of DC/DC, and its structure is an open loop, therefore its output stability is relatively poor. In order to obtain satisfactory results, it is necessary to consider the whole design from different angles.First of all: determine its output power. Because of the method of "stealing" electricity from the energy storage coil, its output power is limited and can only be smaller than the original side output power. The output of this set of isolated power supply is mainly supplied by sensor conversion circuit, front-end A/D converter, and isolated circuit in the application of specific transmitters. And the power consumption of analog measuring circuits of differential capacitance sensors, thermocouple sensors, and thermal resistance sensors reaches μA level. The front-end A/D is usually multi-integral or Σ-Δ, the power consumption is less than 1 mA, and the whole low power dissipation optoelectronic isolation can be below 1mA. Therefore, isolated windings provide 3mA that can meet the actual needs. It has been calculated that the maximum output of the circuit is 816mA without the secondary winding, so it is obvious that the 3mA current can be supplied in the case of the secondary winding. Secondly: Avoid working / hibernating rotation for devices with high power consumption. The isolation winding adopts an open-loop structure, and the change of load on the primary side directly affects the stability of the secondary side, so it is required that the power consumption stability of the original circuit system should be guaranteed as much as possible when the circuit is used in practice. What’s more, the circuit can provide the maximum 5mA current for the original edge and can fully meet the requirements of the commonly used low-power MCU control system without the use of sleep mode. In this way, the maximum system running speed can be obtained. Finally:  the low-voltage difference linear regulator and the DC/DC converter should be used in the design. The isolated power winding mainly supplies power to the front-end small-signal analog circuit, therefore, the quality of the power supply requires high. Noise reduction and voltage stabilization treatment of low voltage output converted by DC/DC through low dropout linear regulator(LDO), which can not only improve the efficiency of power supply but also meet the requirement of small ripple voltage. Specifically, LDO uses MAX1726 chip, its working current is the only 2μA, the output is 313V; The output amplitude before voltage stabilization depends on the output power of the original edge and the inductance of L2, the experiment confirmed that L2 is 3mH. When the primary current varies between 3~5mA and the secondary current is 2mA, the voltage fluctuates between 318V and 418V before the voltage stabilizes, which meets the input requirements of the LDO voltage stabilizer. VI. Conclusion The isolated power supply of two-wire transmitter is stable and reliable, and can meet various complex requirements of the use of two-wire transmitter. It has the characteristics of wide temperature range, wide input voltage range, high output efficiency, high integration, good isolation performance, small volume and low cost. And this power supply has been applied to the integrated intelligent temperature transmitter, after a long period of field test, finding that it has excellent performance and can fulfill the requirements of the isolated two-wire transmitter completely. FAQ 1. What does a transmitter do?In the Telecommunications world, a Transmitter is a device that produces radio waves radiating from an antenna. In the world of process control, a Transmitter is a device that converts the signal produced by a sensor into a standard instrumentation signal representing a process variable being measured and controlled. 2. What is called transmitter?In electronics and telecommunications a transmitter or radio transmitter is an electronic device which produces radio waves with an antenna. The transmitter itself generates a radio frequency alternating current, which is applied to the antenna. 3. What is transmitter and its types?Pressure transmitters are divided into three types: Absolute Transmitter: This transmitter take vacuum pressure as its base, and then measures process pressure. Gauge Transmitter: This type measures process pressure with the location's atmospheric pressure as a base. 4. What are the main features of transmitter?Some of the main features which make the transmitter complex are higher clock speed, higher transmit power, directional antennas and need for a linear amplifier. 5. What is transmitter frequency?A radio transmitter or just transmitter is an electronic device which produces radio waves with an antenna. Radio waves are electromagnetic waves with frequencies between about 30 Hz and 300 GHz. The transmitter itself generates a radio frequency alternating current, which is applied to the antenna. 6. What is the difference between transmitter and antenna?A transmitter is a different kind of antenna that does the opposite job to a receiver: it turns electrical signals into radio waves so they can travel sometimes thousands of kilometers around the Earth or even into space and back. Antennas and transmitters are the key to virtually all forms of modern telecommunication. 7. What is difference between transmitter and transducer? Transducers and transmitters are virtually the same thing, the main difference being the kind of electrical signal each sends. A transducer sends a signal in volts (V) or millivolt (mV) and a transmitter sends a signal in milliamps (mA). 8. What is transmitter PLC?Transmitters are also referred to as stationary instruments and convert measurement parameters into an electrical signal that is then sent to a BMS ( Building Management System), PLC ( Programmable Logic Controller), SCADA ( Supervisory Control and Data Acquisition). 9. What is the pressure transmitter?A Pressure Transmitter is an instrument connected to a Pressure Transducer. The output of a Pressure Transmitter is an analog electrical voltage or a current signal representing 0 to 100% of the pressure range sensed by the transducer. 10. Which oscillator is used in transmitter?Crystal oscillators are the most common type of linear oscillator, used to stabilize the frequency of most radio transmitters, and to generate the clock signal in computers and quartz clocks. You May Also LikeThe 3W PowerSpot transmitter for Power Over-the-air from PowercastBuild a Remote RC Firecracker and Firework lgniter Using RF Transmitter4 Channel 2 Core Twisted Pair Remote Controller Using PT2262