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Amid the rapid growth of the global new energy industry, a reliable and cost-optimized controller is often the key to a company’s success in overseas markets. Recently, a company specializing in the R&D of new energy controllers encountered a critical bottleneck while developing a new product for the international market: how to replace the through-hole ferrite ring inductors in the existing design with surface-mount ferrite ring inductors that offer higher consistency and are better suited for automated production?

The Customer’s Dilemma: High Standards for Export Products and Confusion Over Component Selection

In the early stages of new product design, the client adopted a proven 1mH through-hole ferrite common-mode inductor solution. However, the product was primarily intended for overseas markets with extremely stringent consistency requirements. Through-hole inductors were increasingly failing to meet the client’s pursuit of exceptional product quality and cost control due to manual soldering, parameter variability, and low production efficiency. The client explicitly requested a “through-hole to SMD” conversion but was at a loss regarding how to select the appropriate components.

Precise Alignment: Gujing’s One-Stop Technical Service Delivers Rapid Response

Through an online search, the customer discovered Gujing Electronics’ successful case studies in the new energy sector regarding the transition from “through-hole to surface-mount” and immediately reached out. Gujing’s technical team promptly engaged in an in-depth technical consultation with the customer. Rather than limiting the discussion to simple parameter inquiries, they thoroughly examined core application details such as actual board space, operating current, voltage rating requirements, and temperature rise limits. This application-centric communication laid a solid foundation for precise component selection.

Professional Solution: Tailored Recommendation of High-Consistency SMD Inductors

Leveraging 23 years of inductor design and manufacturing experience, along with an extensive database of the new energy industry, Gujing’s technical team quickly identified the solution: recommending the GTCSM2311-102DB TSM2311 1.0mH Min SMD toroidal inductor. This solution directly addresses the customer’s pain points:

Exceptional consistency: Utilizing automated precision manufacturing processes ensures highly stable parameters across batch production, fully meeting export quality requirements.

Space and cost savings: The surface-mount design aligns with high-density PCB layouts while facilitating SMT automated production, significantly improving efficiency and reducing overall costs.

Reliable electrical performance: The design fully accounts for the customer’s actual current and voltage rating requirements, ensuring stable and reliable operation in the application.

Field Testing: Data Speaks for Itself—Perfectly Meets Requirements

To ensure the solution was flawless, Gujing promptly provided 10 samples for the customer to test. The customer conducted verification under strict test conditions (1 kHz/0.3 V, internal resistance 100 Ω), and the results were convincing:

DC Resistance (DCR): 9.34 – 11.61 mΩ

Inductance (L): 1.01 – 1.21 mH

Not only did all parameters fully meet the requirements, but they also demonstrated excellent consistency. The test data dispelled all of the client’s concerns and validated the feasibility and superiority of Gujing’s solution.

Core Value: More Than Just Products—We Provide Solutions

The success of this collaboration vividly demonstrates Guijing’s core values as a 23-year veteran in inductor manufacturing:

In-depth Technical Expertise: From scenario analysis to precise component selection, we provide professional technical decision-making support.

Rapid Response Capabilities: From requirements alignment to sample delivery, we efficiently advance our customers’ R&D processes.

One-Stop Service: We offer end-to-end services covering requirements analysis, solution design, sample support, and mass production assurance, truly serving as an extension of our customers’ R&D teams.

Conclusion

In the highly competitive global new energy sector, supply chain reliability and technological innovation capabilities are critical. Through this collaboration, Gujing Electronics not only helped the client successfully resolve specific inductor selection and replacement challenges but also enhanced the client’s core product competitiveness and market responsiveness through professional, efficient, one-stop technical services.

Moving forward, Gujing will continue to deepen its expertise in the magnetic component field, leveraging its extensive industry experience and solid technical capabilities to empower more clients to tackle challenges and create value together.