期刊
IEEE TRANSACTIONS ON POWER ELECTRONICS
卷 36, 期 9, 页码 10548-10560出版社
IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC
DOI: 10.1109/TPEL.2021.3059879
关键词
Windings; Magnetic cores; Power transformer insulation; Inductance; Core loss; Partial discharges; Wires; Cooing; dual active bridge (DAB); medium-frequency transformer (MFT); optimal design; partial discharge (PD)
资金
- U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE) under Solar Energy Technologies Office (SETO) [EE0008348]
This article presents a design and optimization methodology for a 200-kW medium-frequency transformer based on low-loss magnetic core, achieving high power density and efficiency through a parallel-concentric winding structure and innovative cooling and insulation design.
This article presents a design and optimization methodology for a 200-kW medium-frequency transformer (MFT) based on low-loss magnetic core (FINEMET FT-3TL). The proposed optimal design methodology consists of predesign, preliminary design, and optimal design. In the preliminary design, the parallel-concentric winding structure is selected to increase the current carrying capability and reduce the leakage inductance. Based on the parallel-concentric winding concept, a novel cooing and insulation structure with 3-D printed bobbins are proposed. The optimal designed MFT prototype achieves a power density higher than 19.23 kW/L. The electrical insulation system is tested at 12 kV ac peak voltage. In addition, the partial discharge (PD) test is conducted at 7.5 kV ac peak voltage to ensure the PD-free design. The high-frequency bipolar pulsewidth modulation voltage insulation (PD) test is the first time applied in MFT design and test process. Finally, the transformer is applied in a dual-active-bridge (DAB) converter with 200 kW rated power. The peak efficiency of the DAB converter is 99.53%, and the efficiency at 200 kW is 98.85%. The peak efficiency of MFT is 99.844%, and the efficiency at 200 kW is 99.842%.
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