{"id":10354,"date":"2026-05-05T09:00:00","date_gmt":"2026-05-05T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?post_type=case_studies&#038;p=10354"},"modified":"2026-04-30T04:20:21","modified_gmt":"2026-04-30T02:20:21","slug":"troubleshoot-high-frequency-transformer-failures","status":"publish","type":"case_studies","link":"https:\/\/tps-elektronik.com\/en\/case-studies\/troubleshoot-high-frequency-transformer-failures\/","title":{"rendered":"How to Troubleshoot High-Frequency Transformer Failures in TPS Industrial Power Supplies"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>System integrators, panel builders, and electrical engineers know that the reliability of an industrial power supply hinges on its magnetic components. When a leading European manufacturer of industrial motor drives experienced unpredictable field failures, the root cause was traced back to thermal breakdown and insulation failure within their power modules. The culprit? A poorly optimized <strong>high frequency transformer<\/strong>.<br \/>This customer case study explores how TPS Elektronik\u2019s EMS winding goods division partnered with the client to troubleshoot these failures. By re-engineering the coil design, upgrading the insulation, and implementing advanced overmoulding techniques, we delivered a robust solution that eliminated downtime and accelerated their time-to-market.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Request a consultation for your custom winding goods \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc\">Table of contents<\/h2>\n<ol>\n<li><a href=\"#the-challenge\">The challenge: Unpredictable power supply failures in motor drives<\/a><\/li>\n<li><a href=\"#root-cause-analysis\">Root cause analysis of high-frequency transformer issues<\/a>\n<ol>\n<li><a href=\"#insulation-breakdown\">Insulation breakdown and thermal stress<\/a><\/li>\n<li><a href=\"#parasitic-capacitance\">Parasitic capacitance in coils and transformers<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#the-tps-solution\">The TPS solution: Advanced winding goods engineering<\/a>\n<ol>\n<li><a href=\"#optimizing-coils\">Optimizing toroidal coils and air coils<\/a><\/li>\n<li><a href=\"#overmoulding-techniques\">Superior insulating wire and overmoulding techniques<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#electric-assembly\">Integration into the electric assembly and motor ASM<\/a><\/li>\n<li><a href=\"#results\">Results: Enhanced reliability and compliance<\/a><\/li>\n<li><a href=\"#faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"the-challenge\">\n<h2>1. The challenge: Unpredictable power supply failures in motor drives<\/h2>\n<p>Our client, a prominent manufacturer of industrial automation equipment, was facing a critical issue. Their latest generation of motor drives (<strong>motor asm<\/strong>) was failing during high-load operations. Field returns indicated that the switch-mode power supplies (SMPS) were shutting down prematurely. For procurement and engineering teams, these failures meant delayed project timelines, increased warranty claims, and a damaged reputation.<\/p>\n<p>Initial diagnostics revealed that the standard off-the-shelf <strong>high frequency transformer<\/strong> used in the design could not withstand the harsh dv\/dt transients and thermal cycling typical of industrial environments. The client needed a partner capable of not just manufacturing, but deeply analyzing and redesigning the magnetic components.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-10366\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/04\/High-Frequency-Transformer-Failure-Analysis-1-1.jpg\" alt=\"Electrical engineer inspecting a failed high frequency transformer on an industrial power supply PCB. Elektroingenieur untersucht einen ausgefallenen Hochfrequenztransformator auf einer industriellen Netzteil-Leiterplatte.\" width=\"1408\" height=\"768\" \/><\/p>\n<\/section>\n<section id=\"root-cause-analysis\">\n<h2>2. Root cause analysis of high-frequency transformer issues<\/h2>\n<p>Upon receiving the failed units at our facility, TPS Elektronik\u2019s engineering team conducted a thorough teardown and failure analysis of the <strong>coils and transformers<\/strong>.<\/p>\n<h3 id=\"insulation-breakdown\">2.1 Insulation breakdown and thermal stress<\/h3>\n<p>The primary failure mode was insulation breakdown. High-frequency switching generates significant heat due to core losses and skin effect in the windings. The original transformer utilized standard enameled wire that degraded under continuous thermal stress. Once the insulation weakened, inter-turn short circuits occurred, leading to catastrophic failure. Understanding the right materials is crucial; you can learn more in our guide on <a href=\"https:\/\/tps-elektronik.com\/en\/wire-insulation-materials-types-applications\/\">wire insulation materials, types, and applications<\/a>.<\/p>\n<h3 id=\"parasitic-capacitance\">2.2 Parasitic capacitance in coils and transformers<\/h3>\n<p>Furthermore, the winding geometry of the original transformer resulted in high parasitic capacitance. In high-frequency applications, this causes ringing and voltage spikes that exceed the breakdown voltage of the components. Whether dealing with a standard bobbin or a complex <strong>toroid coil<\/strong>, managing these parasitic elements is essential for EMC compliance and system stability.<\/p>\n<\/section>\n<section id=\"the-tps-solution\">\n<h2>3. The TPS solution: Advanced winding goods engineering<\/h2>\n<p>To resolve these issues, TPS Elektronik proposed a complete redesign of the magnetic components, leveraging our expertise in custom winding goods.<\/p>\n<h3 id=\"optimizing-coils\">3.1 Optimizing toroidal coils and air coils<\/h3>\n<p>We replaced the traditional E-core design with optimized <strong>toroidal coils<\/strong>. A <strong>toroid coil<\/strong> offers superior magnetic flux containment, significantly reducing electromagnetic interference (EMI) which is vital for sensitive motor control circuits. For specific high-frequency filtering stages, we also integrated custom-wound <strong>air coil<\/strong> inductors to prevent core saturation during peak current surges. For insights into how magnetic fields are managed, see our <a href=\"https:\/\/tps-elektronik.com\/en\/helmholtz-coil-uniform-magnetic-field-guide\/\">Helmholtz coil uniform magnetic field guide<\/a>.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-10362\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/04\/Precision-Toroid-Coil-Winding-Process-2-1.jpg\" alt=\"Precision CNC winding machine manufacturing a custom toroid coil with high-grade insulating wire. Pr\u00e4zisions-CNC-Wickelmaschine fertigt eine kundenspezifische Ringkernspule mit hochwertigem Isolierdraht.\" width=\"1408\" height=\"768\" \/><\/p>\n<h3 id=\"overmoulding-techniques\">3.2 Superior insulating wire and overmoulding techniques<\/h3>\n<p>To combat thermal stress and mechanical vibration, we upgraded the winding material to triple-insulated wire (TIW), which meets stringent safety standards without requiring interleaved margin tape. More importantly, we implemented a vacuum potting and <strong>overmoulding<\/strong> process. Overmoulding encapsulates the entire <strong>high frequency transformer<\/strong> in a thermally conductive, flame-retardant resin. This not only improves heat dissipation but also provides ultimate protection against moisture, dust, and vibration.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Discover our custom overmoulding and winding capabilities \u2192<\/a><\/p>\n<\/section>\n<section id=\"electric-assembly\">\n<h2>4. Integration into the electric assembly and motor ASM<\/h2>\n<p>A transformer does not operate in isolation. The final step was ensuring seamless integration into the client&#8217;s broader <strong>electric assembly<\/strong>. We redesigned the lead-outs, utilizing protective and <strong>decorate wire sheathing<\/strong> for clear color-coding and abrasion resistance. This ensured that during the final <strong>motor asm<\/strong> process at the client&#8217;s facility, the connections were foolproof and mechanically secure.<\/p>\n<p>Our approach ensures that components are not just wound, but are production-ready. Read more about our capabilities in delivering <a href=\"https:\/\/tps-elektronik.com\/en\/ems-winding-goods-toroidal-coils-dv-dt-chokes-production-ready-transformers\/\">production-ready transformers and dv\/dt chokes<\/a>.<\/p>\n<\/section>\n<section id=\"results\">\n<h2>5. Results: Enhanced reliability and compliance<\/h2>\n<p>The redesigned <strong>high frequency transformer<\/strong> underwent rigorous testing, complying with international standards such as <a href=\"https:\/\/webstore.iec.ch\/publication\/6234\" target=\"_blank\" rel=\"nofollow noopener\">IEC 61558<\/a> for safety of transformers. The results were immediate: thermal performance improved by 30%, parasitic ringing was virtually eliminated, and field failure rates dropped to zero.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-10358\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/04\/Overmoulded-Transformer-in-Electric-Assembly-3-1.jpg\" alt=\"Fully overmoulded high frequency transformer integrated into a robust electric assembly for motor drives. Vollst\u00e4ndig vergossener Hochfrequenztransformator, integriert in eine robuste Elektromontage f\u00fcr Motorantriebe.\" width=\"1408\" height=\"768\" \/><br \/>By partnering with TPS Elektronik, the client transformed a critical point of failure into a competitive advantage. Whether you need components for industrial drives or highly regulated sectors, our expertise scales to your needs. See how we apply similar rigor in our <a href=\"https:\/\/tps-elektronik.com\/en\/ems-winding-goods-medical-high-frequency-transformer-coil-winding\/\">medical high-frequency transformer coil winding<\/a> services.<\/p>\n<\/section>\n<section id=\"faq\">\n<h2>6. FAQ<\/h2>\n<div class=\"faq-container\">\n<div class=\"faq-item\">\n<h3>Why do high-frequency transformers fail in industrial power supplies?<\/h3>\n<div class=\"faq-answer\">Common causes include insulation breakdown due to thermal stress, inter-turn shorts caused by voltage spikes (parasitic capacitance), and mechanical failure from vibration. Using proper <strong>insulating wire<\/strong> and <strong>overmoulding<\/strong> mitigates these risks.<\/div>\n<\/div>\n<div class=\"faq-item\">\n<h3>What are the benefits of overmoulding coils and transformers?<\/h3>\n<div class=\"faq-answer\"><strong>Overmoulding<\/strong> encapsulates the component in resin, providing excellent thermal dissipation, mechanical stability against vibrations, and protection from environmental factors like moisture and dust.<\/div>\n<\/div>\n<div class=\"faq-item\">\n<h3>Why choose a toroid coil over a standard E-core?<\/h3>\n<div class=\"faq-answer\">A <strong>toroid coil<\/strong> provides a continuous magnetic path, which significantly reduces electromagnetic interference (EMI) and core losses, making it highly efficient for high-frequency switch-mode power supplies.<\/div>\n<\/div>\n<div class=\"faq-item\">\n<h3>Can TPS integrate winding goods into a complete electric assembly?<\/h3>\n<div class=\"faq-answer\">Yes. TPS Elektronik offers end-to-end EMS services. We not only manufacture the magnetic components but can also integrate them into your final <strong>electric assembly<\/strong> or <strong>motor asm<\/strong>, complete with custom connectors and <strong>decorate wire sheathing<\/strong>.<\/div>\n<\/div>\n<\/div>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n  <p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\">\n    <strong>Experiencing failures with your magnetic components?<\/strong> \n    Don&#8217;t let a faulty transformer delay your project. Partner with TPS Elektronik for expert troubleshooting, custom winding, and robust electro-mechanical assembly. \n    <a style=\"color: #ffffff; font-weight: 600; text-decoration: underline;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Submit your RFQ for custom winding goods today \u2192<\/a>\n  <\/p>\n<\/footer><\/article>\n\n<style id=\"wpforms-css-vars-4659-block-e2a7b678-ad3a-4729-b75b-764c7f0990eb\">\n\t\t\t\t#wpforms-4659.wpforms-block-e2a7b678-ad3a-4729-b75b-764c7f0990eb {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 15px;\n--wpforms-field-size-font-size: 16px;\n--wpforms-field-size-line-height: 19px;\n--wpforms-field-size-padding-h: 14px;\n--wpforms-field-size-checkbox-size: 16px;\n--wpforms-field-size-sublabel-spacing: 5px;\n--wpforms-field-size-icon-size: 1;\n--wpforms-label-size-font-size: 16px;\n--wpforms-label-size-line-height: 19px;\n--wpforms-label-size-sublabel-font-size: 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When a leading European manufacturer of industrial motor drives experienced unpredictable field failures, the root cause was traced back to thermal breakdown and insulation failure within their power modules. The culprit? A poorly optimized\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/troubleshoot-high-frequency-transformer-failures\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":12611,"template":"","class_list":["post-10354","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Troubleshoot High-Frequency Transformer Failures in TPS Industrial Power Supplies - TPS<\/title>\n<meta name=\"description\" content=\"Learn how TPS resolves high frequency transformer failures with custom winding goods and expert electric assembly. 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