Research on the response characteristics and failure mechanism of low temperature co-fired ferrite transformers under high voltage and high impact environments

Low temperature co-fired ferrite (LTCF) transformers have attracted significant attention in complex application environments with high impact overload and high voltage conditions due to their compact surface area, low thickness and low magnetic leakage characteristics. This paper establishes a Machete hammer impact test platform and combines it with an X-ray detection system to achieve monitoring of electromechanical response characteristics and internal damage evolution in transformers. A stress transfer model based on stress wave transmission theory was developed, with finite element simulations revealing stress distribution patterns and crack initiation/propagation mechanisms. The relative error between theoretical calculations and numerical simulations of key interface stress amplitudes remains below 13.1 %. A novel model correlating crack dimensions with voltage boost time variation was proposed through voltage boosting simulation analysis, demonstrating prediction errors below 9.1 %. Experimental results demonstrate significant correlations between structural parameters and overload resistance performance. Furthermore, impact-induced crack propagation deteriorates energy transmission efficiency, prolongs voltage boost time, and degrades output characteristics and power consumption performance.