Magnetic components by Exxelia SVM: From design to manufacturing

Transforming concepts into reliable magnetic components requires more than just manufacturing—it demands design expertise, advanced simulation, and a deep understanding of application needs. With extensive know-how in inductors, transformers, actuators, solenoids, and current sensors, Exxelia SVM provides tailored solutions that integrate seamlessly into product development where magnetics are a critical element.

From early-stage design to rigorous testing and full-scale production, the team works alongside innovation and engineering teams to ensure specifications, timelines, and performance criteria are met. Leveraging advanced modeling tools, reliability testing, and state-of-the-art manufacturing facilities, Exxelia SVM turns complex ideas into practical, high-performance components ready for demanding applications in medical, industrial, and power electronics.

To convert your concepts in to reality in Magnetic Components. Exxelia SVM can play a significant role in your Product Design where Magnetics is a vital component; in simple words Exxelia SVM can be your Strategic Solution Provider for your Special Magnetic components.

Exxelia SVM Design and Technology group works as an extended arm of customers Innovation Team in understanding the Specification, Criticality and the time lines of the Project implementation.

Design Organization

• Electrical, Electronics, Mechanical (Bobbin, Clamps and brackets)
  Design and simulation Capability for Inductors, Transformers, Hall Effect Current Transformers, Actuators, Solenoids.
• Power Converters, Stabilizer for Medical Equipment’s.
• Design and Development for Molded , Laminated , Epoxy powder coated , Nickel& Golde plated, Silver Plated , Brazing&Tin Plated , Flexible busbars and other Press Components.

Knowledge, Expertise & Techniques

• The Team at Exxelia SVM can Engineer your ideas and convert them into End use Components
• MATLAB, FEMM Modelling and Thermal Simulation of Magnetic components
• Reliability of components evaluated using Thermal Cycle, Random Vibration Test and Packaging Drop Test for Shipping and Handling
• Load Test for High Current Inductors and Linear Power transformers to check the temperature rise at actual loading pattern

Support for End use and Application

The Team at Exxelia SVM Interact with Customers and provide solutions for End use and Application

Functional test set up developed for Variable Frequency High power test bench to test the transformers and inductors
Topologies – Full Bridge, Half Bridge, Push-Pull, Forward with loading facility.

Flyback Transformer Testing Set up

• Frequency – Up to 133 kHz
• Rating - Up to 250VA

High frequency Transformer Testing set up

• Frequency – Up to 100 kHz
• Rating - Up to 25kVA

Waveforms:

Lab Facility as per UL Safety Requirements

• Partial Discharge Test up to 100kV AC
• Impulse Testing Facility upto 100kV DC (Both Lighting and Switching Impulse)
• Load Test up to 50kVA (50HZ operating frequency)
• Dielectric Strength Test both AC and DC
• Precision LCR Magnetic Analyzer for measuring Inductance, Capacitance and Resistance
• DC Bias Test up for Inductors
• Temperature Data Logger

Magnetics Manufacturing Facility

• Multi spindle CNC Winding Machines
• Automatic Test equipment’s (ATE)
• Copper Foil Winding Machines
• Vacuum Impregnation plant

Busbar Manufacturing Facility

• Automatic Pressure Gelation Machine ( Resin Cast)
• Amada CNC Turret Punching Machine
• Amada CNC Bending Machine
• AIDA Pneumatic Press for Blanking and forming
• CNC PET Film Cutting Machine
• Hot Press for Lamination
• Powder Coating Plant
• Plating Plant
• Resistance Brazing and Pressure Welding Setup
• PEM Nut and Stud insertion Machine.

Backward Integration

• Round Litz Wire up to 350A Current Rating
• Rectangular Type 8 Litz wire up to 350A Current Rating
• Press Components
• Bobbin manufacturing both Thermoset and Thermoplastic
• Sophisticated Tool room
• Lamination Stamping Facility
• Thermoforming Packaging Trays

Special Purpose Machines (SPM)

Builds special jigs, Fixtures, Machines to bring out Customized Products