High Frequency Transformer Research Articles

Thermal runaway and induced electrical failure of epoxy resin in high‐frequency transformers: Insulation design reference

AbstractSolid‐state transformers (SSTs) have applications in medium‐voltage (MV) DC grids and compact power systems. High‐frequency transformer (HFT) is the core component of SSTs. High levels of high frequency high dv/dt voltage stresses challenged the integrity of the galvanic insulation of HFTs. However, dielectric thermal runaway and resultant electrical failure mechanisms in epoxy resin (EP) cast insulation remain unclear. Dielectric heating of EP across varying voltages, frequencies, rising edges, duty cycles and DC biases were measured and corroborated by simulation. The thermal runaway threshold mainly depends on the tangency point of the loss generation and heat dissipation curves below the glass transition temperature. Observations reveal that thermal runaway does not directly cause breakdown; instead, thermal decomposition above 200°C triggers discharge and eventual failure. Simulations demonstrate that temperature rise mainly depends on the average field within the electrode region and inter‐segment and inter‐layer distances within the HFT winding definitively impact insulation thermal runaway. By applying different criteria for MV and high‐voltage (HV) transformers, the reference electric fields for insulation design with unfilled and filled EP were obtained. For instance, limiting dielectric heating below 5 K at 50 kHz necessitates an RMS average field less than 0.44 V/mm, which is much lower than dry‐type transformer conventions. The authors prove the necessity of re‐evaluating the permissible field strength in HFT insulation design.

Direct single‐phase isolated improved gamma Z‐source AC–AC converter suitable for DVR application

AbstractA direct single‐phase isolated improved gamma Z‐source AC–AC converter is designed and manufactured in proposed paper. This converter contains an impedance source structure and its advantages. In general, these advantages are as follows. Firstly, the proposed structure has a wide range of output voltage as boost and buck as well as in‐phase or out‐of‐phase states. Secondly, the proposed converter is electrically isolated thanks to a high frequency transformer (HFT), which significantly reduces the volume of the structure; therefore, in applications such as dynamic voltage restorer (DVR), there is no need to install a coupling transformer with the grid frequency which is very bulky and full of losses. Furthermore, the HFT of the proposed converter is a three winding transformer which also acts as the inductance needed for impedance source network. In addition, the safe commutation method has been utilized, which reduces the voltage spikes on the power switches. Finally, the analysis and design of this converter has been done, and then confirmed by a small‐scale laboratory prototype.

Analysis of single switch step up DC-DC converter with switched inductor-switched capacitor cells for PV system

The presented work exhibits high gain and increased efficiency for DC-DC converter. Additionally, this topology significantly improves the voltage conversion ratio when compared with other DC-DC converters reported recently. The non-existence of high frequency transformer ensures compactness and low cost and henceforth, it is apt for clean energy applications. The analysis of the high gain converter in steady state is carried out in continuous conduction mode (CCM). Initially, the proposed converter performance is analyzed using MATLAB/Simulink platform and prototype of the same with a power rating of 200 V, 100 W is built and tested. The reliability and robustness of the converter is perceived from the experimental results and peak efficiency achieved is around 93%.

An Improved Calculation Method of Leakage Inductance for High-Frequency Transformer Based on Precise Analysis of Magnetic Field

An Improved Calculation Method of Leakage Inductance for High-Frequency Transformer Based on Precise Analysis of Magnetic Field

Research on the Prediction Method of Conducted Interference in Flyback Converters based on the High-frequency Transformer Model

Conducted electromagnetic interference (EMI) has always been a challenge for designers of switched-mode power supplies. Flyback converters are used in various applications. However, as the switching frequency of these converters increases, the issue of electromagnetic interference becomes progressively more severe. In light of this, this paper presents a predictive method for conducted interference in flyback converters, based on a high-frequency transformer model. A high-frequency transformer model topology is proposed, integrating traditional inductance models with a three-capacitor model. Subsequently, a self-organizing migrating algorithm (SOMA) is employed for the extraction of parameters from the high-frequency transformer model, and a high-frequency model is established for a transformer. Finally, the high-frequency model is applied to the prediction of conducted interference in flyback converters. The results demonstrate that the proposed predictive method can effectively forecast the actual conducted interference, thereby providing a reference for suppression of conducted electromagnetic interference.

Three-Dimensional Semi-Finite Element Based Proximity Loss Calculation for Litz Wires in A High Frequency Transformer

Three-Dimensional Semi-Finite Element Based Proximity Loss Calculation for Litz Wires in A High Frequency Transformer

Development of Iterative Algorithm for High Frequency Transformer Used in Solid State Transformers and its Validation <i>via</i> Finite Element Analysis

Development of Iterative Algorithm for High Frequency Transformer Used in Solid State Transformers and its Validation <i>via</i> Finite Element Analysis

A Simple Power Loss Evaluation Method for High-Frequency Transformers Based on Surface Temperature Measurement Within Wide Operation Range

A Simple Power Loss Evaluation Method for High-Frequency Transformers Based on Surface Temperature Measurement Within Wide Operation Range

Design of High-power Density and High-frequency Transformers for Auxiliary Power Supply System in Electric Multiple Units

Design of High-power Density and High-frequency Transformers for Auxiliary Power Supply System in Electric Multiple Units

Impact of Power Electronic Converter Ripples on Vanadium Redox Flow Batteries

The worldwide effort to decarbonize the electricity grid has made battery energy storage system (BESS) an essential technology. A promising technology for long duration storage on the grid is Vanadium Redox Flow Batteries (VRFBs), which can support the grid by regulating peak load, reducing intermittency of large-scale renewables, and as emergency power supply. There are two primary methods of integrating a BESS to the grid. Frist, the BESS is directly connected to the DC-link of a DC-AC converter that interfaces with the grid. Second, the BESS is connected to a DC-DC converter that in turn interfaces with the DC-link of a DC-AC converter. These converters all have a characteristic ripple voltage and current during operation. The magnitude and frequency of the ripples depend on topology and switching frequency of a converter, controller design and protocol, type of connection to the grid, voltage magnitude and load characteristics. Currently, studies on the impact of ripples have been limited to Lithium-ion and Lead-Acid batteries. The impact of ripple current and voltage has not been studied in VRFBs. In a VRFB, potential impact includes excessive gassing of hydrogen and carbon corrosion of the bipolar plate and porous electrode and cell heating. To better integrate and operate VRFBs to the electricity grid, the impact of ripples needs to be studied in detail.Using a novel experimental platform, where both magnitude and frequency of ripples will be incorporated, we will emulate the performance of different power electronic converter configurations. It will comprise standard 5cm2 VRFB cells with a carbon felt electrode and Nafion ion exchange membrane. The various converter ripples in an electricity grid setting will be emulated by superimposing the signals from a potentiostat (constant current) and a high frequency transformer (modulated ripples), which will be connected to the cathode of the cells.The experimental testbed will be used to cycle the VRFB cells at various states of charge with ripples that emulate the performance of power electronic converters during grid operations and disturbances. Varied parameters will include ripple amplitude, ripple frequency, electrolyte flow rate, applied current density and state of charge. Measurement data from monitoring voltage of each electrode, cell voltage and current, gas generation, electrolyte crossover and electrolyte loss will be analyzed to determine the impact of ripples on VRFB cells. Finally, the cells will be monitored for signs of gas generation and postmortem signs of carbon corrosion.Our analysis will determine the impact of various ripple magnitude and frequencies on VRFBs in a simulated grid integration environment. This work will facilitate the development of design standards for power electronic converters that are intended for battery applications, while also informing future efforts to optimize VRFB cell and stack performance.

Effective Design Methodology of CLLC Resonant Converter Based on the Minimal Area Product of High-Frequency Transformer

In DC microgrids, CLLC topology is commonly applied for battery integration. It provides galvanic separation, the ability to integrate a high-frequency transformer into the resonance circuit, and the ability to operate in a wide range of voltage. Moreover, it assures zero voltage switching conditions for all switches and zero current switching conditions for secondary side switches, which enables obtaining high efficiency. This paper presents a clear and effective approach to design a methodology for a CLLC DC/DC converter, especially a resonant tank. High-frequency transformer is fully integrated in a resonant tank. Its size is minimal and based on area product parameter Ap. An equivalent scheme for first harmonic approximation analysis is presented with inclusion of parasitic elements. Based on it, the analytical formulas are provided, which enable graphical determination of working characteristics. It was proved that the model increases the accuracy of the results. The conditions of ZVS and maximal magnetizing inductance are established, including parasitic capacitances of secondary side switches and transformer parasitic capacitances. Based on the proposed design methodology, as the proof of concept, a small-power prototype with a GaN transistor was built operating at 364 kHz. Converter losses were determined through analytical expressions and compared with the experimental and simulation results.

A H-Bridge-Multiplexing-Based Novel Power Electronic Transformer

Cascaded H-bridge power electronic transformers (CHB-PET) play a pivotal role in distribution grids and their efficient operation. The input series and output parallel (ISOP) configurations result in a huge number of power switching devices, high-frequency transformers (HFT), and capacitors in high-voltage, high-capacity CHB-PET, leading to the need for high hardware costs and huge-sized CHB-PET, which further poses a significant challenge to the engineering feasibility and marketability of the CHB-PET. To address these issues, a CHB-PET topology is proposed in this paper. The novel topology exploits the concept of multi-frequency modulation to achieve power decoupling and power unit multiplexing through reasonable LC resonant frequency selection, which optimizes the ISOP structure and ultimately reduces the hardware cost and size of the CHB-PET. In this study, the effectiveness of reducing the number of power switching devices and HFT is firstly analyzed, and after describing its working principle, the control strategy of each power conversion link of PET is discussed before the correctness and effectiveness of the CHB-PET topology and control strategy proposed in this paper are verified via simulation.

Research on Magnetic-Thermal-Force Multi-Physical Field Coupling of a High-Frequency Transformer with Different Winding Arrangements

In order to clarify the magnetic-thermal-force changing rule of high-frequency transformers under different winding arrangements, this paper tests the magnetization and loss characteristics of nanocrystalline materials at different temperatures, and based on the magnetization and loss data, establishes a magnetic-thermal-force coupling calculation model of 15 kVA, 5 kHz nanocrystalline high-frequency transformers, and calculates and analyzes the magnetic flux density, loss and temperature rise distributions of high-frequency transformers with three different winding arrangements under no-load and short-circuit conditions, respectively. Through comparative analysis, it was found that under no-load conditions, the cross-transposition of winding has less influence on the magnetic flux of the high-frequency transformer core, but it can reduce the iron-core loss and transformer temperature rise. The cross-transposition of winding under short-circuit conditions can significantly reduce the leakage magnetic field strength of high-frequency transformers; complete cross-transposition weakens the high-frequency transformer losses and temperature rise better than partial cross-transposition. According to the winding current density and core leakage field distribution under short-circuit conditions, we calculated and analyzed the distribution of its the axial and radial electromagnetic forces. The results show that the axial electromagnetic force causes the winding to be squeezed from both ends to the middle, the radial electromagnetic force causes the primary winding to shrink inward and the secondary winding to expand outward, so cross-transposition can greatly reduce electromagnetic force and weakening the deformation of the winding. Therefore, high-frequency transformers of winding cross-transposed should be used in actual projects to reduce transformer temperature rise and improve efficiency and security. This research has theoretical significance for the multi-physical field coupling of high-frequency transformers and its structural design.

Loss Analysis of Nanocrystalline Cores for High Frequency Transformer in Power Electronics Circuits

Loss Analysis of Nanocrystalline Cores for High Frequency Transformer in Power Electronics Circuits

A VSC-Based Isolated Matrix-Type AC/DC Converter Without Bidirectional Power Switches

In this paper, a three-phase voltage-source converter (VSC) based isolated matrix-type AC/DC converter is proposed for wind energy conversion system (WECS). The line-frequency transformer (LFT) is replaced by the high-frequency transformer (HFT), and there is no need for the intermediate electrolytic capacitors used in conventional two-stage power conversion system. Moreover, the bidirectional switches used for conventional matrix converter (MC) are eliminated in the proposed topology. Consequently, the complicated four-step commutation scheme is avoided and the additional conduction loss caused by serial connection of power switches can be eliminated. The proposed isolated matrix-type AC/DC can be regarded as the dual VSC circuit, where two VSCs alternately work during each switching cycle. Hence, the voltage vectors based space vector modulation (SVM) can be employed and the control schemes for non-isolated VSCs can be used for the proposed converter. For safe operation, the commutation strategy is proposed for the leakage-inductor current of HFT. Both simulations and experiments are conducted to verify the performance of the proposed converter.

An Improved Modulation Scheme of Isolated Matrix Converter for Common-Mode Voltage Reduction and DC-Bias Current Mitigation

In this paper, an optimized space vector modulation (SVM) method is proposed for the isolated three-phase matrix-type AC/DC converter, where the four-quadrant operation ability of the bidirectional power switch can be fully used. The primary-side transformer current can be eliminated naturally during zero current vectors without extra switching actions. Therefore, the conduction loss of matrix converter (MC) is reduced and the efficiency can be increased. Moreover, the proposed method can avoid the shoot-through operation in MC, and the common-mode voltage can be mitigated effectively. As the zero current vector is kept with the proposed modulation strategy, the current harmonics will not be increased. Thirdly, both the DC-link inductor current and DC-bias current of high-frequency transformer (HFT) are measured through the secondary-side current of HFT. Therefore, the DC-bias current and the saturation of HFT are avoided by closed-loop control with the proposed modulation strategy. The experiments have been carried on a 1-kW laboratory prototype to verify the validity of the proposed modulation scheme.

An Improved High Voltage Winding Internal Shielding Structure With Lower Eddy Loss for Medium Voltage High-Frequency Transformer

An Improved High Voltage Winding Internal Shielding Structure With Lower Eddy Loss for Medium Voltage High-Frequency Transformer

Modeling and Evaluation of Ferrite Eddy Losses in High-Frequency Transformers Based on Loss-Effective Conductivity Extraction

Modeling and Evaluation of Ferrite Eddy Losses in High-Frequency Transformers Based on Loss-Effective Conductivity Extraction

Modeling and Design of Insulation Structure for High Power Density Medium Voltage High-Frequency Transformers

Modeling and Design of Insulation Structure for High Power Density Medium Voltage High-Frequency Transformers

Multiphysics Digital Model of the High Frequency Transformer for Power Electronics Application Considering Electro-Thermal Interactions

Multiphysics Digital Model of the High Frequency Transformer for Power Electronics Application Considering Electro-Thermal Interactions