From 50 Hz to Inverter:

Power Conversion Innovation for Industrial Battery Chargers

1. Customer Profile

  • Sector: Battery chargers for forklifts and industrial vehicles
  • Initial technology: 50 Hz magnetic components
  • Goal: Transition to inverter-based systems
  • Relationship with Sirio: Full co-development of a complete range of inductive components

2. The Challenge

The customer, a manufacturer of industrial battery chargers, decided to migrate from traditional 50 Hz technology to a more efficient, compact inverter solution.

They needed a partner who could:

  • Develop a series of custom transformers and inductors
  • Handle multiple input voltages (for both EU and US markets)
  • Support various output voltage and current configurations, depending on battery pack designs

3. The Sirio Solution

Sirio approached the project with a full design and simulation process

  • The R&D team defined the product concept alongside the customer

Then, using finite element method (FEM) electromagnetic simulation tools, each component was:

  • Efficiency-optimized
  • Simulated to reflect real operating conditions within the customer’s converter

This process led to the development of a complete power component family, covering 6 kW to 15 kW output range.

4. Industrialization and Production

Following the market success of the new chargers, Sirio invested in automation, purchasing four dedicated automatic winding machines equipped with:

  • Very low setup time
  • High process repeatability
  • Flexibility to switch between products quickly

This enabled:

  • Quick adaptation to production needs
  • Reliable, consistent product quality
  • Industrial scalability for global demand

5. The Results

  • A flexible and efficient product family that meets diverse market needs
  • Long-term technical collaboration on product evolution
  • A production system ready for growth and customization