Development and highly automated manufacturing of encapsulated PCB safety transformers for mains frequencies.
GERTH Transformatorenbau GmbH
Ludwigsfelde (Genshagen)New on Amplifa
About GERTH Transformatorenbau
GERTH Transformatorenbau GmbH has been developing and manufacturing encapsulated PCB transformers for mains frequencies since 1969 and has specialized in PCB safety transformers since 1995. The product range includes miniature transformers (series 150, 0.35–0.5 VA on EE20 cores) as well as PCB and flat transformers with EI cores from 0.35 VA to 25 VA in series such as 304, 387, 421, 480, 541 and 600. Production takes place at the Ludwigsfelde (Genshagen) site near Berlin using partially self-developed automation systems, including 6- and 12-spindle winding machines, a self-developed vacuum PU encapsulation machine with high cycle rates, and a central soldering system with an autonomous robotic system for lead-free protective gas soldering. Materials used are ferrite cores, enameled copper wire or micro wires, and polyurethane encapsulation compounds. Customers include suppliers for PCB assembly and electronics device manufacturers, in particular devices with standby function and mains-frequency applications. In addition to the standard range available from stock, the company offers customer-specific variants for small and medium volumes, 100% unit testing, and just-in-time delivery. In the shared building with the affiliated BREMER Transformatoren GmbH, ferrite, special, power and three-phase transformers as well as chokes are also produced there.
- Site
- Ludwigsfelde
- Processes
- Development and highly automated manufacturing of encapsulated PCB transformers (PCB, Transformer encapsulation (vacuum PU encapsulation), Soldering under protective gas (lead-free solder, central soldering system with autonomous robotic, Coil winding on 6- and 12-spindle machines (series 150, micro wires), Manufacturing of miniature transformers (series 150, 0.35–0.5 VA, EE20 cores), Manufacturing of PCB safety transformers with EI cores (0.35–25 VA, among others types 304,, Testing for safety transformers: heating, output values, overload, short circuit and, Product development and technical design of transformers (customer-specific variants)
- Materials
- Ferrite (transformer cores EE/EI), Enameled copper wire / micro wires (windings), Polyurethane (PU encapsulation compound), Lead-free solder, Enameled copper wire / micro wires
- Certificates
- ISO 9001:2015, VDE monitored manufacturing facility (Safety isolating transformers), VDE test mark (majority of standard type series), ISO 9001, VDE monitored manufacturing facility
- Founded
- 1969
- Industries
- Suppliers for PCB assembly / electronics device manufacturers (devices with
- 01
Product development and technical design
- 02
Coil winding on 6-/12-spindle machines
- 03
Lead-free soldering under protective gas (robotic system)
- 04
Vacuum PU encapsulation
- 05
Final inspection as 100% unit testing
- 06
Stock storage and shipping from stock / just-in-time delivery
Materials and Processes
Ferrite (transformer cores EE/EI)
Used as core material for miniature transformers and PCB flat transformers.
Enameled copper wire / micro wires
Used for winding the coils; in series 150, micro wires are wound on 6- and 12-spindle machines.
Polyurethane (PU encapsulation compound)
Used in the self-developed vacuum encapsulation process to encapsulate the transformers.
Lead-free solder
Used since 2004 in the central soldering system under protective gas for RoHS compliance.
Sites
Ludwigsfelde (Genshagen)
DEFactory/administration (production, development, warehouse, sales; shared building with BREMER Transformatoren GmbH)
- Lot size
- Small and medium volumes (customer-specific variants)
- Materials
- Ferrite, enameled copper wire/micro wires, polyurethane, lead-free solder
- Vacuum PU encapsulation machine for transformer encapsulation (self-developed, high cycle rates)
- 6-spindle winding machines
- 12-spindle winding machines
- Central soldering system with autonomous robotic system (protective gas soldering, process-computer monitored)
- Automatic production systems for PCB transformers (partially self-developed)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Development and highly automated manufacturing of encapsulated PCB transformers (PCBAssembly | – | 81.5 mm × 53.5 mm × 54.2 mm | – | small and medium volumes | Ferrite, Copper wire (micro wires), Polyurethane (encapsulation compound) |
| Transformer encapsulation (vacuum PU encapsulation)Plastics | – | – | – | – | Polyurethane (PU) |
| Soldering under protective gas (lead-free solder, central soldering system with autonomous roboticJoining | – | – | – | – | lead-free solder |
| Coil winding on 6- and 12-spindle machines (series 150, micro wires)Assembly | – | – | – | – | micro wires (enameled copper wire) |
| Manufacturing of miniature transformers (series 150, 0.35–0.5 VA, EE20 cores)Assembly | – | 24 mm × 22 mm × 19 mm | – | – | Ferrite, Copper wire |
| Manufacturing of PCB safety transformers with EI cores (0.35–25 VA, among others types 304,Assembly | – | 81.5 mm × 53.5 mm × 54.2 mm | – | – | Ferrite, Copper wire |
| Testing for safety transformers: heating, output values, overload, short circuit andTesting | – | – | – | – | – |
| Product development and technical design of transformers (customer-specific variants)Engineering | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Vacuum PU encapsulation machine for transformer encapsulation (self-developed, high cycle rates) | – | – | – | – | Ludwigsfelde |
| 6-spindle winding machines | – | – | – | – | Ludwigsfelde |
| 12-spindle winding machines | – | – | – | – | Ludwigsfelde |
| Central soldering system with autonomous robotic system (protective gas soldering, process-computer | – | – | – | 2004 | Ludwigsfelde |
| Automatic production systems for PCB transformers (partially self-developed) | – | – | – | – | Ludwigsfelde |
Additional services
Quality
During the multi-stage manufacturing process, continuous quality monitoring is carried out through automated intermediate inspections and a documented final inspection as 100% unit testing; every transformer is tested. The plant is a VDE-monitored manufacturing facility subject to annual surveillance, complemented by type tests in its own laboratory, and production is certified to ISO 9001:2015 (TÜV Rheinland).
| Evidence | Ludwigsfelde (Genshagen) |
|---|---|
| ISO 9001 | |
| VDE monitored manufacturing facility | |
| VDE test mark (majority of standard type series) |
History
- 1969
Helmut Gerth founds a company for the manufacture of enclosures in Berlin-Schöneberg; production area initially 100 m²
- 1975
Relocation to Berlin-Kreuzberg; focus on encapsulated transformers; 500 m²; development of a vacuum PU encapsulation machine
- 1984
Relocation to Berlin-Wedding; 900 m²; further development of automation
- 1995
Acquisition of a site in the Brandenburgpark in Ludwigsfelde; shared factory building with 2500 m² of production space; specialization in PCB safety transformers
- 2004
Eric Leysner and Thomas Bremer become partners and managing directors; switchover to lead-free soldering (RoHS) with a robotic system
- 2011
Market launch of the eco-transformer 153 (< 0.5 W no-load power consumption)
- 2012
Development laboratory certified by the VDE for the Test Data Acceptance Program
- 2014
VDE test mark for series 480; first recertification of the test laboratory
- 2016
Comprehensive overhaul of the homepage and data sheets
- 2022
GERTH passes entirely into the hands of the Bremer family
- 2025
Dr. Lucas Bremer takes over the management