Smoothing Chokes

Modern power conversion circuits—especially those using rectifiers and switching regulators—face excessive output ripple and current spikes due to high di/dt transients. These disturbances cause voltage instability, signal interference, and thermal stress on downstream components. Our smoothing chokes introduce controlled inductance in the DC path, limiting the rate of current change and effectively filtering out ripple frequencies. This ensures a clean, noise-free DC output essential for precision applications. 

Rated System Voltage

Up to 1000 V DC

Operating Frequency

DC with ripple components up to 10 kHz

Inductance Tolerance

±10% (measured at rated DC current with ripple superimposed)

Core Material

Ferrite / Iron powder / Amorphous

Insulation Class

Class H (180°C thermal endurance)

Product Description

When DC loads operate at high current levels, even minor inductive losses or saturation can cause performance degradation. We manufacture smoothing chokes with low core loss materials and precision winding techniques that ensure minimal eddy current and hysteresis losses, even at elevated operating temperatures. Each unit is designed for high saturation current capability, ensuring magnetic stability across full load conditions without flux collapse or distortion. 

Maximum Hot Spot Temperature

140°C continuous with 160°C short-duration withstand

Rated DC Current

Up to 1000 A

Total Power Loss

≤ 5 W per 100 A at rated ripple frequency and load

Dielectric Withstand Voltage

2.5 kV DC for 1 minute between winding and core

Magnetic Flux Density (Bmax)

≤ 1.4 Tesla under rated load to ensure non-saturation operation

Short Circuit Thermal Withstand

2.0 × Irms for 1 second

Ripple Attenuation Capability

> 80% attenuation for ripple frequencies up to 10 kHz

Winding Configuration

Copper, single or multi-strand/Litz wire, with high-frequency insulation coating

Mounting Configuration

Horizontal or vertical base-mount with thermal isolation and vibration damping

Acoustic Noise Level

≤ 60 dB at 1 meter under full ripple load

Technical Advantages

Excessive heat buildup is a key failure mode in continuous power systems. Our smoothing chokes are constructed with thermally rated insulation systems, high-conductivity windings, and magnetic cores selected for thermal efficiency. This design provides excellent heat dissipation, eliminates hot spots, and maintains long-term reliability in demanding industrial environments. 

Panel space limitations are common in today’s dense power systems. We offer high-energy-density choke designs that optimize core geometry and flux path to provide high inductance per unit volume. This ensures effective smoothing performance without consuming excess enclosure space, ideal for compact SMPS modules, servo drives, and automation panels. 

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Industry Applications

Inverter-Based Motor Drives

Minimizes ripple current and voltage distortion at the DC bus, enhancing inverter efficiency and protecting motor insulation systems. 

Battery Charging Systems

Smooths DC charging current, preventing ripple-induced battery heating, gas formation, and extending battery service life in critical systems. 

HVDC Transmission Systems

Controls ripple in high-voltage direct current links, ensuring stable voltage levels and protecting downstream converter and filter components. 

Solar Inverter Systems

Filters output ripple from MPPT converters and solar inverters to maintain clean DC bus for efficient grid synchronization. 

Telecommunication Power Equipment

Stabilizes 48V DC supply rails by attenuating high-frequency ripple and preventing electromagnetic interference in sensitive telecom circuits. 

UPS (Uninterruptible Power Supply) Units

Ensures steady DC output during charge/discharge cycles, reducing transient stress on power electronics in UPS power conditioning modules. 

Smoothing Chokes

Custom Winding and Core Configurations

Different load profiles demand different magnetic characteristics. We offer application-specific winding topologies (e.g., foil winding, Litz wire, interleaved layers) and core selections (e.g., ferrite, iron powder, amorphous, nanocrystalline) to match your frequency response, inductance tolerance, and current saturation needs. Each choke is tailored to exact load ripple profiles and thermal expectations. 

Our smoothing chokes are built for continuous duty cycles, with rugged construction that withstands vibration, ambient temperature fluctuations, and long-term magnetic fatigue. We offer full qualification support including thermal aging, electrical endurance, surge withstand, and in-circuit performance validation. 

Smoothing Chokes

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure thermal stability of smoothing chokes in continuous-duty DC applications?

Frigate uses thermally rated copper windings with low-loss core materials to minimize heat generation during continuous operation. All chokes are designed with calculated thermal resistance and tested for temperature rise at full load. Proper core selection ensures minimal hysteresis and eddy current losses. This guarantees long-term reliability even in high ambient conditions. 

What is Frigate’s approach to controlling core saturation in high-current smoothing choke designs?

Frigate incorporates optimized air-gaps in magnetic cores to extend the linear region of operation under DC bias. Core materials are selected based on saturation flux density and permeability requirements. Each choke is tested for peak current capability under real load conditions. This avoids flux collapse during transient load spikes. 

 

Can Frigate design smoothing chokes for wide switching frequency ranges in SMPS systems?

Yes, Frigate customizes core geometry and winding layout to maintain effective inductance over a broad frequency range. For high-frequency systems, ferrite or nanocrystalline cores are used to minimize core losses. Litz or foil windings are applied to reduce skin and proximity effects. This ensures stable ripple attenuation across variable operating conditions. 

How does Frigate address parasitic capacitance in compact smoothing choke designs?

Frigate uses optimized inter-winding spacing and layer insulation techniques to control parasitic capacitance. Winding arrangements are simulated and verified to minimize high-frequency coupling. This helps maintain clean filtering performance even in compact choke formats. Designs are validated through impedance and frequency response measurements. 

What testing methods does Frigate use to validate smoothing choke performance before dispatch?

Each choke undergoes inductance, saturation current, and thermal rise testing under simulated DC load conditions. Ripple attenuation is validated using frequency spectrum analysis. Core loss and insulation resistance are also tested to meet end-use standards. Frigate ensures every unit performs exactly as designed under practical operating conditions. 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Smoothing Chokes

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Smoothing Chokes

Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

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