Assessment of heat transfer mechanisms of a novel high-frequency inductive power transfer system and coupled simulation using FEA

Abstract

The calculation of the temperature fields in solid state transformers is a critical step of the design process in order to ensure the stable and efficient operation of the device. Transformers operating in high frequencies can develop increased temperatures that potentially may result in the failure of the components due to the associated thermal stresses. This paper investigates the heat transfer mechanisms of a novel inductive power transfer (IPT) system submerged in a dielectric oil and operating at 50 kHz, in the context of SSTAR, a Horizon Europe project. The commercial software ANSYS is employed to implement a one-way coupled electromagnetic-thermal finite element simulation model in order to calculate the temperature field of the IPT components based on the electromagnetic losses. To cross-validate the model, the results obtained from ANSYS are benchmarked against the COMSOL software, revealing accepted temperature deviations between the two software. A comprehensive parametric analysis explores the impact of rated power, operating frequency, and dielectric gap on generated heat, highlighting their direct correlation with temperature increase. The findings underscore increased temperature levels, approximately reaching 224 °C under nominal operating conditions, with the temperature distribution concentrated around the transformer's windings.