Abstract
The medium frequency transformer (MTF) is a key component of various new DC–DC converters that are designed for applications in modern electrical power grids at medium and high voltage. To attain the high performance that are necessary for targeting these applications, MFTs should have high power density and high efficiency as characteristics. For this endeavor, newly designed MFT procedures, which also take advantages of new core materials, are under investigation. Differently to other design proposals, most of which use conventional transformer design procedures based on equating core losses to copper conduction losses, in this paper, an MTF with a nanocrystalline (VITROPERM 500F) core is designed with a new procedure that is oriented in aiming the maximum flux density (Bmax). The characteristics of the MFTs that are obtained by using this procedure are compared with those of the MFTFs that are designed with a conventional procedure. The results show that by using the proposed technique, we get a 25% reduction in the winding size, a higher power density, and a lower MTF building cost while maintaining a high efficiency (>98%). The design methodology is developed through a rigorous mathematical analysis that is verified with computer simulations in Matlab-Simulink and validated with experimental results from two MTF laboratory prototypes designed at a flux density of 0.9 T (75% Bmax) and 1.2 T (Bmax).
Highlights
One of the leading research goals regarding high or medium frequency transformers is the increase power density while maintaining a high efficiency (98%) [1,2,3,4,5,6]
It is worth mentioning that a high-power density that is maintained at a reasonably high efficiency is desired in DC–DC converters, as well as in medium frequency transformer (MTF)
All together this implies a higher power density and a lower building cost. These results show the excellence performance of the MTF that was operating at Bmax
Summary
One of the leading research goals regarding high or medium frequency transformers is the increase power density while maintaining a high efficiency (98%) [1,2,3,4,5,6]. It must be stressed that previous research efforts have overlooked the opportunity to design nanocrystalline cores for MFT-based DC–DC converters with a maximum flux density under certain conditions Besides this latter consideration, it is possible to get a reduction in the number of winding turns of the MTF and a higher power density while maintaining a high efficiency (98%) by using a new design procedure. Further research efforts are required to determine the conditions for which power density can be increased while maintaining a high efficiency in nanocrystalline cores This point is addressed in the present paper. The results were: 1) a 25% reduction in the transformer winding, 2) a higher power density, and 3) a lower MTF building cost These values were achieved while maintaining a high efficiency (> 98%).
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