Cases

A leading medical device manufacturer approached us to assist with electromagnetic compatibility (EMC) testing for their new medical instrument. Ensuring compliance with international EMC standards was critical for market approval and patient safety. Challenge: The device initially failed initial EMC tests due to electromagnetic interference (EMI) issues, which posed risks of malfunction and non-compliance. The challenge was to enhance the device’s EMI performance without significantly altering its design or increasing costs. Solution: Our team conducted a comprehensive EMC analysis to identify the primary sources of interference. Based on our findings, we recommended integrating our high-performance filters and magnetic rings into the device design. Filters: We supplied custom-designed filters to suppress conducted EMI effectively. Magnetic Rings: We incorporated magnetic rings to mitigate radiated emissions and improve overall electromagnetic immunity. Implementation: The filters and magnetic rings were seamlessly integrated into the device’s power and signal lines by the client’s engineering team, following our detailed guidance and specifications. Results: Following the modifications, the device underwent a second round of EMC testing, which it successfully passed. This achievement was confirmed by certification authorities, and the device obtained all necessary compliance certificates, paving the way for market entry. Summary: Our tailored EMC solutions, combining advanced filtering components and magnetic rings, significantly enhanced the electromagnetic compatibility of the medical device, ensuring safety, compliance, and performance. This case exemplifies our expertise in supporting medical clients through complex EMC challenges to achieve certification success.  

The EMC Challenge: How We Saved a Failing Single-Phase Power Filter When an industrial automation company approached us in a panic, their situation was dire. Their single-phase power filter—a critical component for protecting sensitive medical imaging equipment—had failed EMC testing three times at a certified lab. With their product launch deadline looming and penalties mounting, they needed a miracle. The Problem: A Filter That Couldn’t Filter The client’s filter was designed to clean up noise from variable frequency drives (VFDs) but failed spectacularly during: Conducted Emissions (CE) tests (EN 55011) – Noise spikes at 150kHz–30MHz exceeded limits by 12dB. Radiated Immunity (IEC 61000-4-3) – The filter’s own shielding was resonating at 50MHz, worsening interference. Their engineering team had tried everything: extra capacitors, toroidal chokes, even a full PCB redesign. Nothing worked. Our Breakthrough We took possession of the filter and assembled a SWAT team of EMC specialists. Here’s how we turned it around in 7 intense days: Day 1–2: Forensic Analysis Discovered the Y-capacitors were creating a ground loop via the chassis. Oscilloscope traces revealed ringing at 2MHz from poor damping in the LC stages. Day 3–4: Surgical Modifications Replaced generic X2 capacitors with low-ESR film types (reduced HF losses by 40%). Added a common-mode choke with nanocrystalline core (suppressed 30MHz+ noise). Redesigned the PCB layout to minimize parasitic coupling. Day 5–7: Validation & Victory Pre-tests showed a 15dB improvement at worst-case frequencies. Final lab test: Passed EN 55011 Class B with 6dB margin! Why This Matters for You Many filters fail not because of poor design, but due to hidden interactions between components. Our approach combines: Deep EMC expertise (we’ve fixed 200+ filter designs). Advanced tools like near-field probes and 3D EM simulation. Real-world solutions – no theoretical "textbook fixes." Need Your Filter to Pass EMC?Just provide:✅ Target standards (e.g., MIL-STD-461, CISPR 32).✅ One sample unit (or even just schematics). We’ll deliver:✔ Diagnostic report within 48 hours.✔ Modified design that actually passes.✔ Test-ready unit – no guesswork. Contact us today. Let’s turn your EMC nightmare into a compliance success story.

Medical Infusion Pump Passes EMC Testing with VIIP VIP1-1A-03 Filter Client: Manufacturer of a smart infusion pump (Class II medical device) EMC Challenges - Failed  Class B radiated emissions (peaks at 85MHz/220MHz) - Susceptibility to IEC 61000-4-5 surges (2kV line-to-ground caused system reset) - Required compliance with IEC 60601-1 Solution: Integrated VIP1-1A-03 Filter Key Specifications Applied: 1. Input Protection: - Installed VIIP VIP1-1A-03 IEC inlet filter with: - 3A current rating (250VAC) for pump motor load - 28dB common-mode attenuation @1MHz (critical for 85MHz harmonics suppression) - 2000VAC line-to-ground HIPOT rating (exceeds IEC 60601-1 safety requirements) 2. Enhanced Design: - Combined with  ferrite beads on DC motor cables - Added shielded enclosure using CON-SHIELD gaskets (grounded to filter's earth terminal) Test Results | Parameter | Pre-Modification | Post-Modification (VIP1-1A-03) | Standard | |--------------------|------------------|---------------------------------|----------| | Radiated Emissions | 12dB over limit | **8dB below limit** | CISPR 11 | | Surge Immunity | Failed @1kV | **Passed @4kV** | IEC 61000-4-5 | | Leakage Current | N/A | **0.8μA** (