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Now fast-paced world of electronics, engineers are constantly faced with the challenge of optimizing circuit performance while maintaining compactness and energy efficiency. One crucial, yet often overlooked, component in these designs is the magnetic core used in inductors. The material of the magnetic core can dramatically influence the inductor’s performance, particularly in high-frequency applications.

This blog will explore how different magnetic core materials impact inductor performance, why choosing the right material is critical, and how these materials affect the efficiency and longevity of your electronic devices.

The Importance of Magnetic Core Material

Magnetic cores play a vital role in the function of inductors. They influence inductance, energy storage, efficiency, and power losses. The performance of an inductor is highly dependent on the magnetic material it’s made from, and the right choice of material can make a significant difference in how well the device operates across different frequencies and power levels.

There are several materials commonly used for magnetic cores in inductors, such as ferrite, silicon steel, and nanocrystalline alloys. Each material comes with its own set of advantages and limitations, making it essential for engineers to understand the material properties in order to make the right choice for a given application.

How Different Magnetic Core Materials Affect Performance

Mn-Zn Ferrite Cores
Ferrite cores are made from iron oxide combined with other metals, and they are widely used in high-frequency applications like switch-mode power supplies and transformers. They offer relatively low eddy current losses at high frequencies, making them suitable for circuits operating in the kilohertz (kHz) to megahertz (MHz) range. Additionally, ferrite cores have high magnetic permeability, which means they can store more magnetic energy with relatively low losses, improving circuit efficiency.

However, Mn-Zn ferrite cores have limitations at very high frequencies, where losses can increase due to core material saturation. Ferrite cores are also less efficient at very low frequencies, which makes them less suitable for power transformers or circuits that require low-frequency performance.
Nanocrystalline Cores
Nanocrystalline cores, a newer material in magnetic technology, offer exceptional performance in high-frequency applications. These cores are made from iron and other elements arranged in a nanocrystalline structure, which allows them to exhibit significantly higher magnetic permeability compared to ferrite cores.

Nanocrystalline cores provide lower losses and higher efficiency in high-frequency circuits, such as power inductors in high-frequency switching power supplies. Their higher saturation flux density makes them particularly useful for high-power applications, where maintaining performance at higher current levels is essential.

The main advantage of nanocrystalline cores over ferrite is their ability to operate with up to 30% lower high-frequency losses. They also maintain low hysteresis losses even at very high frequencies (several hundred kHz), making them ideal for applications in the 5G telecommunications, electric vehicles (EVs), and data centers.
Silicon Steel Cores
Silicon steel is another material that has been used for decades in power transformers and other low-frequency applications. Its relatively low magnetic losses make it suitable for power transformers operating at 50-60Hz in traditional power grids.

However, silicon steel’s performance at higher frequencies is limited due to significant eddy current losses. This makes it less suitable for high-frequency applications, such as modern power electronics or devices that operate in the kHz-MHz range.

The Mechanism Behind Magnetic Core Performance

The performance of magnetic cores in inductors is largely determined by the following factors:

Magnetic Permeability: The ability of a material to support the formation of a magnetic field. Higher permeability means better energy storage capacity and lower losses.
Hysteresis Losses: The energy lost when the magnetic material is magnetized and demagnetized. Materials with lower hysteresis losses are more efficient.
Eddy Current Losses: Induced currents within the core material that cause heat loss. High-frequency applications require materials that minimize these losses.
Saturation Flux Density: The maximum magnetic field strength the material can handle before its magnetic properties break down. A higher saturation flux density means the material can handle higher currents without losing performance.

Quantifying the Performance Gains

Nanocrystalline materials reduce high-frequency losses by up to 30% compared to Mn-zn ferrite cores.
They also provide 2-3 times higher permeability, which means more efficient energy storage and enhanced inductor performance in high-power, high-frequency applications.
These materials are particularly useful in systems requiring low hysteresis loss and high-frequency operation (several hundred kHz), which are essential in modern electronics like switch-mode power supplies, 5G networks, and electric vehicles (EVs).

Choosing the Right Core Material for Different Applications

When selecting a magnetic core for an inductor, engineers must consider the specific requirements of the application:

Switch-Mode Power Supplies (SMPS): Ferrite and nanocrystalline cores are ideal for high-frequency operation and minimizing losses.
Electric Vehicles (EV): Nanocrystalline cores, with their high saturation flux density and low losses, are essential for handling large currents in high-power applications.
5G Networks: High-performance cores, such as nanocrystalline, offer superior efficiency for handling high-frequency signals while minimizing power loss.
Data Centers: For high-speed communication and efficient power conversion, nanocrystalline cores are increasingly being used to improve system efficiency.

The Critical Role of Magnetic Core Material in Inductor Design

Magnetic core material plays a critical role in the performance of inductors and the overall efficiency of electronic circuits. By selecting the appropriate core material—whether it’s ferrite, nanocrystalline, or silicon steel—engineers can ensure that inductors function efficiently across different frequencies and power levels.

Understanding the benefits and limitations of each material is essential for optimizing circuit designs in today’s high-performance, energy-efficient electronic systems. As technologies like 5G, electric vehicles, and AI data centers continue to evolve, the importance of choosing the right magnetic core material will only grow.

What’s Your Biggest Challenge in High-Frequency Inductor Design?

In the fast-evolving world of electronics, engineers are continuously tasked with pushing the limits of technology. Whether you’re designing power supplies, communication systems, or next-gen EVs, understanding the relationship between magnetic core material and inductor performance is key to achieving optimal results.

Let us know your thoughts, DM us.

1. Industry Background: Why Do Critical Scenarios Urgently Need High-Reliability UPS?

With the rapid development of digitalization and AI technology, critical scenarios such as government affairs systems, financial transaction platforms, medical equipment, and data centers have put forward unprecedented high requirements for the "continuity, stability, and intelligence" of power supply. According to industry statistics, a single power outage lasting more than 10 minutes may cause financial institutions to lose over one million yuan, lead to the risk of equipment shutdown in medical systems, and even result in data loss and business interruption in data centers.

Traditional UPS has pain points such as "difficult expansion, long maintenance downtime, and low energy efficiency": the fixed-power design requires the overall replacement of equipment when business grows in the later stage; maintenance requires power outage; and the energy efficiency loss during long-term operation can reach more than 10%. Against this background, modular UPS has become the core choice to solve the power supply problems in critical scenarios due to its advantages of "flexible expansion, hot-swap maintenance, and high energy efficiency" — and the SY-M series modular UPS of Hefei Shuyi Digital Power is a representative product in this field.

2. Shuyi Technology: A Globally Recognized Expert in Digital Energy with 10 Years of Experience

As an enterprise based on core technologies of power electronics and integrated with innovative digital technologies, Shuyi Technology has always focused on the R&D of solutions in the fields of data centers, high-end power supply, and clean energy since its establishment. After more than 10 years of development, its products and solutions have been exported to 86 countries, with branches and offices in more than 50 countries and regions around the world. It has won wide recognition from global customers for its "high stability" and "high-quality after-sales service".

Shuyi Technology's core competitiveness stems from its strong R&D and testing capabilities:

R&D System: It has industry-leading power electronics R&D centers, testing centers, and laboratories, including electromagnetic compatibility laboratories, enthalpy difference laboratories, and environmental reliability laboratories, ensuring full-process control from product design to implementation.
Certification Guarantee: It has passed ISO9001 quality management system certification and ISO14001 environmental management system certification. Its products comply with international standards such as CE, IEC, and UL, and can meet compliance requirements in different regions around the world.
Corporate Mission: With "digital energy technology innovation" as the core, it is committed to building a green and intelligent energy future and providing reliable digital energy infrastructure support for global customers.

3. SY-M Series Modular UPS: Core Advantages and Full-Scenario Adaptation

Shuyi Technology's SY-M series modular UPS covers the full power range of 20kVA-1600kVA, adopts the "three-in three-out, dual-conversion online operation" mode, and can provide flexible product choices according to the power requirements and installation environments of different scenarios. Its core advantages can be summarized into four dimensions: "reliability, flexibility, intelligence, and efficiency".

(1) High Reliability: Ensuring Zero Power Outage Risk in Critical Scenarios

N+X Redundant Design: It supports parallel operation of multiple modules. Even if a single module fails, the remaining modules can automatically take over the load to avoid power supply interruption, which is especially suitable for "zero-tolerance" scenarios such as finance and medical care.
Core Component Upgrade: It adopts integrated packaged IGBT modules, which have fast switching speed, low loss, and strong impact resistance, and can cope with grid voltage fluctuations and load mutations.
Wide Input Voltage Range: The input voltage supports 304~485VAC (full load). Even if the grid voltage fluctuates greatly (such as in remote areas or industrial scenarios), it can still output stably, reducing frequent charging and discharging of the battery and prolonging the battery life.
Battery Cold Start Function: In emergency situations without commercial power, the UPS can be started directly through the battery to quickly restore power supply, which is suitable for emergency scenarios of sudden power outages.

(2) Flexibility: On-Demand Expansion to Adapt to Different Installation Environments

Full Power Range Coverage: From 20kVA small computer rooms to 1600kVA large data centers, the SY-M series can meet the power requirements of different scenarios and avoid resource waste caused by "using a large device for a small load".
Modular Hot-Swap: The power modules and static bypass monitoring modules support hot-swap. Maintenance does not require shutdown, and the replacement time of a single module is only 5 minutes, which greatly reduces the risk of business interruption.
Multiple Installation Methods: It provides multiple installation methods such as rack-mounted (compatible with 19-inch standard cabinets), tower-type, and container-type, adapting to different site conditions such as data centers, base stations, and industrial workshops.
Flexible Parallel Expansion: It supports direct parallel operation of multiple UPSs. When the business grows in the later stage, the power can be increased only by adding modules without replacing the overall equipment, reducing the expansion cost.

(3) Intelligence: Remote Management and Precise Operation and Maintenance

Large-Screen Touch Interaction: Equipped with a 5.7-inch/10.4-inch color LCD touch screen, it supports more than 10 languages including Chinese, English, Russian, and French. It can display real-time data such as load rate, battery status, and fault information, with intuitive and convenient operation.
Powerful Remote Management: It is equipped with RS232 and RS485 interfaces as standard, and an SNMP network communication card is optional. It supports remote monitoring, parameter setting, and fault alarm (such as SMS alarm and email alarm), so that operation and maintenance personnel can grasp the equipment status without being on-site.
Intelligent Battery Management: It adopts the "three-stage charging" technology to avoid over-charging and over-discharging of the battery, prolonging the battery life (the life of lead-acid batteries can be extended by more than 20%). At the same time, it supports battery status self-test and fault early warning.
System Self-Diagnosis: It has built-in fault recording and historical data storage functions, which can automatically identify problems such as module faults and power grid abnormalities, and generate diagnosis reports, reducing the difficulty of operation and maintenance.

(4) High Efficiency: Green and Energy-Saving to Reduce Long-Term Operating Costs

Ultra-High Operating Efficiency: The efficiency is ≥95% in normal mode and up to 99% in economic mode. Compared with traditional UPS, it can reduce a large amount of power loss every year, which is especially suitable for scenarios such as data centers that "operate 24 hours a day".
Intelligent Sleep Mode: It automatically adjusts the number of operating modules according to the load rate. When the load is low, some modules sleep to reduce useless power consumption. For example, when the load rate is less than 40%, 50% of the modules can be turned off, and the energy efficiency is increased by 10%-15%.
Low Harmonic Pollution: The input power factor is >0.99, and the input harmonic current THDi is <3%, which avoids interference to the power grid, meets the environmental protection requirements of green data centers, and reduces electromagnetic interference to other equipment.

(5) Full-Scenario Adaptation: Covering More Than 10 Key Industries

With its high adaptability, the SY-M series modular UPS has been widely used in:

Government and Finance: Government affairs systems, bank transaction platforms, and securities servers to ensure data security and business continuity.
Medical Industry: ICU equipment, nuclear magnetic resonance, and testing instruments to avoid medical accidents caused by power outages.
Communication and Transportation: Base stations, rail transit signal systems, and airport dispatching centers to cope with high loads and frequent voltage fluctuations.
Industry and Energy: Industrial automation equipment, photovoltaic energy storage systems, and power dispatching centers to adapt to harsh industrial environments.
Education and Radio and Television: University data centers and TV station broadcasting systems to support long-term stable operation.

4. Typical Cases: How Does the SY-M Series Solve Pain Points in Actual Scenarios?

Case 1: Transformation of a Provincial People's Hospital Data Center

Pain Points: The original UPS was a traditional tower-type model with a power of 30kVA. With the increase of medical equipment (such as electronic medical record systems and teleconsultation equipment), the load rate reached 90%, making expansion difficult; and maintenance required shutdown, affecting the transmission of medical data.
Solution: Adopt the SY-M series 60kVA modular UPS, equipped with 3 20kVA modules (N+1 redundancy), supporting hot-swap maintenance.
Effects: The load rate was reduced to 50%, and modules can be added on demand in the later stage; maintenance does not require shutdown, ensuring zero interruption of medical data transmission, and the battery life was extended by 1.5 years.

Case 2: Asian Logistics Data Center of a Multinational E-Commerce Company

Pain Points: The data center is located in a seismic-prone area, requiring power supply equipment with high seismic resistance; and the load fluctuates greatly during peak business periods (such as Double 11), which is difficult for traditional UPS to cope with.
Solution: Adopt the SY-M series 400kVA modular UPS, equipped with 8 50kVA modules, and install anti-seismic components; enable the intelligent sleep mode to automatically adjust the number of modules according to the load.
Effects: The seismic grade reaches IP20 standard, which can resist earthquakes below magnitude 6; the energy efficiency remains above 96% during peak periods, saving about 200,000 yuan in electricity bills every year.

5. How to Choose the Suitable SY-M Series Product?

According to the three dimensions of "power demand, installation environment, and scenario priority", you can quickly match the suitable model:

Scenario Type	Power Requirement	Recommended Model	Core Considerations
Small computer rooms (such as enterprise server rooms, university laboratories)	20kVA-60kVA	SY-M 20-60kVA Rack-mounted	Save space and support later expansion
Medium-sized data centers (such as municipal government clouds, hospital data centers)	120kVA-300kVA	SY-M 120-300kVA Modular	N+X redundancy to ensure zero interruption
Large data centers/industrial scenarios	400kVA-1600kVA	SY-M 400-1600kVA Container-type	High power density to adapt to harsh environments
Critical scenarios such as medical/finance	Any power range	Models with isolation transformers (such as SY-M 20-60kVA TX)	Reduce zero-ground voltage and improve power supply quality

Parameter	Value	Condition
Maximum Power Consumption	1480 W	Full load operation
Solar Irradiance	800 W/m²	Simulated peak sunlight
Ambient Temperature	35 °C	Outdoor standard
Internal Airflow Velocity	2.3 m/s	Simulated convection
Aluminum Thermal Conductivity	205 W/m·K	6063-T5 Aluminum Alloy

Scenario	Success Rate	Notes
Clean, dry fingerprints	99.9%+	Optimal conditions
Wet fingers	98.5%	Advanced moisture resistance
Cold environments	97.2%	-10°C tested performance
Children's fingerprints	96.8%	Smaller fingerprint patterns

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