Custom Reactors
KATOY designs and manufactures custom reactors for power-electronic, power-conversion and specialized industrial OEM equipment. Core structure, inductance, winding, conductor, insulation, terminal and mounting configurations can be developed according to customer electrical and mechanical requirements.
Magnetic Components Developed Around the Power Circuit
A reactor is an inductive magnetic component used in power and industrial electrical systems where controlled inductance is required as part of the circuit. The final reactor design depends on the actual current waveform, inductance requirement, operating frequency, magnetic core, conductor structure, insulation, temperature rise and mechanical installation conditions.
Unlike a standard catalog component, a custom reactor is normally evaluated together with the surrounding power circuit. Rated current alone is not sufficient to define the magnetic design. Peak current, ripple or harmonic content, thermal conditions, allowable dimensions and terminal configuration can all influence the final structure.
KATOY can develop custom reactors from customer specifications, drawings, reference samples or existing component information.
- Inductance requirements: defined according to the intended electrical function and operating condition.
- Current conditions: rated, peak and waveform information are reviewed where relevant to the application.
- Core design: selected according to inductance, current, losses, saturation margin and dimensional constraints.
- Winding and conductor design: developed around current density, losses, temperature and terminal requirements.
- Insulation and mechanical design: customized according to voltage, mounting, clearance and equipment integration requirements.
Custom Reactor Constructions
KATOY manufactures reactors in different core, winding, conductor, terminal and mechanical configurations. The structures shown below represent custom manufacturing capability rather than fixed catalog models or universally defined application types.
Core, Winding and Mechanical Structures for Different Power-Electronic Circuits
Reactor construction is determined by the actual electrical and mechanical operating conditions. Core geometry, conductor size, winding arrangement, air gap, insulation, terminals and mounting structure should be considered as one complete design.
Core geometry and magnetic material are selected according to inductance, current, operating frequency, losses, thermal conditions and available installation space.
Where required by the magnetic design, controlled air gaps can be used to establish the required inductance and energy storage characteristics under operating current.
Wire conductor size, winding arrangement and connection structure can be developed according to current, thermal and dimensional requirements.
For higher-current designs, conductor and terminal structures can be evaluated together with current density, losses, temperature rise and assembly requirements.
Terminals, wire leads, mechanical connection points and other interfaces can be customized to simplify equipment assembly.
Reactor frames, mounting points and mechanical structures can be developed according to the equipment chassis and available space.
Information for Custom Reactor Development
Accurate electrical and operating information is important for evaluating a custom reactor because inductance, current, magnetic saturation, loss and thermal performance are interrelated.
Custom Reactors for Power Electronics
Reactors are used in many power-electronic and industrial equipment circuits, but the electrical role differs by circuit. KATOY therefore develops reactors according to the actual circuit requirement rather than applying one universal application label to every construction.
Reactor Performance Depends on the Actual Current and Magnetic Operating Point
A reactor cannot be specified accurately from inductance alone. The measured or required inductance may change with current, magnetic operating point, frequency and core structure. Temperature rise and loss also depend on the combined magnetic and conductor design.
For this reason, a custom reactor project should include the electrical conditions at which the reactor is expected to operate. Providing current, waveform, frequency, voltage, dimensional and thermal information allows the magnetic design to be evaluated more accurately.
Custom Reactor Development from Requirement Review to Production
As a custom reactor manufacturer, KATOY supports OEM projects from magnetic and electrical requirement review through core and winding design, prototype manufacturing, sample validation and recurring production.
Verification According to Reactor Design Requirements
Reactor inspection and testing depend on the electrical, magnetic, insulation and mechanical requirements defined for the product. Test conditions should correspond to the relevant design and customer specification.
KATOY applies product-specific inspection and production quality controls rather than treating every reactor as an identical catalog component.
- Inductance and electrical parameter verification
- Winding and connection inspection
- Insulation-related testing as specified
- Visual and dimensional inspection
- Mechanical and terminal configuration verification
- Production process and quality control
Reactor Design and Sourcing Questions
Common questions about custom reactor specifications, magnetic design, prototype development and OEM manufacturing.
What information is required to design a custom reactor?
Useful information includes required inductance, rated and peak current, operating frequency, waveform information, circuit voltage, insulation requirements, allowable temperature rise, maximum dimensions, mounting structure and terminal requirements. Drawings or reference samples can also support technical evaluation.
Why is current information important for reactor design?
Reactor inductance and magnetic operating conditions are affected by current. Rated current, peak current and waveform information help evaluate core saturation margin, winding losses, thermal performance and the required magnetic structure.
Can KATOY manufacture reactors from customer drawings or samples?
Yes. Reactor projects can be evaluated from customer specifications, drawings, existing component information or reference samples. Additional circuit or operating information may be required before prototype development.
Can the reactor core and mounting structure be customized?
Yes. Core structure, winding arrangement, terminals, frame and mounting configuration can be developed according to the electrical design and equipment installation requirements.
Are all reactors line reactors, DC reactors or output reactors?
No. These terms describe particular circuit applications. A reactor should be identified according to its actual electrical function and operating conditions. KATOY develops custom reactor structures based on the customer’s specific circuit requirements.
Can KATOY support prototypes and recurring reactor production?
Yes. KATOY supports custom reactor projects from requirement review and prototype development through sample validation and recurring manufacturing.
Need a Custom Reactor?
Send your inductance, current, operating frequency, waveform, voltage, thermal, dimensional and mounting requirements for engineering evaluation and quotation.