Osborne designs every product to solve a specific technical challenge. Unlike most stock transformer manufacturers or distributors, an Osborne Custom Design Solution will identify the key features of your special application.

Next, Osborne engineers will design a component to address critical product specs that are generally ignored by an off-the-shelf product. These key features include:

• Temperature rise
• Voltage drops (regulation)
• Duty cycle ( time on / time off )
• Ideal mounting dimensions
• Multiple inputs and outputs
• Terminal style and location
• Degree of environmental protection
• Other physical constraints

The resulting product will combine appropriate design features to improve the performance of your equipment, the durability of your other components, and by extension, the efficiency of your entire operation.

OEM Recreational Vehicle Transformer

Customer had a generator. He knew the specs of the generator. He wanted to transform the available power available from 28 V to 120 V. The purpose was to make the power available for OEM recreational vehicle applications.

Osborne designed the transformer to meet the physical constraints of his control panel (size and shape) while exceeding the specific electrical performance characteristics.

Custom Automated Machinery Transformer

Customer was a designer and manufacturer of automation machinery. They wanted some relatively high power control transformers, and they wanted the units mounted on top of the control panel due to excess heat losses. Due to the nature of the circuit, the units were placed ahead of the main electrical disconnect for the machine. This is a useful design consideration to enable auxiliary power (for diagnostic equipment) even when the main disconnect is turned off.

Typical applications of this type would call for the cheapest commodity control transformer available. Fortunately the customer in this case recognized the advantage in working with Osborne to develop a better solution. Osborne recognized that the customer wanted higher amperage available for their diagnostic capabilities. The spatial constraints of the traditional control panel would not accomodate a commodity control unit with the desired performance specs.

Osborne designed a custom unit that could be mounted on top of the existing control panel. Next we designed and built a remote disconnect box to control the unusually high current auxiliary power supply.

The result to the end user was a very safe, high performance circuit to run their system diagnostic equipment.

Custom Silicon Processing Power Supply Transformer

Customer is a manufacturer of power supplies for silicon processing machines. Customer needed a high power inductor that would be used to filter the 30 kHz ripple current which was generated by a 600 A DC switch mode regulated power supply. These are difficult machines to regulate due to their relatively high power. To design a physically compact unit with the desired performance features, Osborne designed a series of high frequency inductors. This series includes the initial high power filter inductor, and later, a design known as a differential common mode inductor. The product solution has been effective in reducing the overall space requirements of the clients end product. This made everyone happy.

High Power Inductor for Research Lab

Customer is a prestigious university research lab. They wanted a load that would represent 10 kVar of inductive capacity at 480 V AC. Osborne has the technology and experience to design an inductor that will satisfy the needs of the project. As a result, the researchers were able to continue their studies.

Current Limiting Capacitor Charging Transformer

Customer is a manufacturer of magnetizing equipment. They needed a power supply to quickly charge capacitors, which they use to produce extremely high magnetizing forces. Osborne designed a current limiting transformer that could be integrated into an instantaneous short circuit of the capacitor bank. This type of short circuit would normally cause damage to the circuit's rectifiers. With the Osborne approach, however, the damage was avoided and the rectifiers maintained their longevity. This solution improved the customer's productivity, since it significantly reduced the need for rectifier maintenance.

Power Supply Transformer for Non-Destructive Product Testing

Customer is designer and manufacturer of non-destructive test equipment. They needed a power supply transformer as part of their process of using magnetic fields to test aircraft parts for stress fractures. Their machinery had size constraints, so Osborne studied the application to identify first, the required duty cycle and second, the correct rectifier configuration. Using this information, Osborne designed an optimally sized component, with the added performance benefits of a six phase star rectifier circuit.