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Design optimisation of an inductor-integrated MF transformer for a high-power isolated dual-active-bridge DC–DC converter

机译:用于大功率隔离双有源桥式DC-DC转换器的电感器集成中频变压器的设计优化

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摘要

Medium-/high-frequency isolated power conversion systems are continuously evolving towards higher power densities. A comprehensive design strategy is required to find a medium-frequency (MF) transformer design that maximizes efficiency and power density while complying with material, electrical, and temperature limits. The proposed approach takes the optimum size of winding conductor conducting harmonic currents into account. The influence of the winding interleaving configuration on the leakage magnetic field is discussed and a method to tune the leakage inductance in a transformer is proposed. A novel semi-empirical expression providing an improved accuracy of an AC resistance factor is introduced. Two well-known configurations of transformers utilised in MF high-power applications are also investigated, namely shell type and core type. The design methodology is established based on the parameter sweep method, and many candidate solutions are enumerated and tested one by one to determine the solution set that satisfies various constraints. Two prototypes of 5 kHz/10 kW nanocrystalline-based transformers are designed and manufactured. The results show that the natural-cooled shell-type prototype can reach a power density of 17.6 MW/m(3) at an efficiency of 99.36%, and the natural-cooled core-type prototype can reach a power density of 14.2 MW/m(3) at an efficiency of 99.33%.
机译:中/高频隔离式功率转换系统正朝着更高的功率密度发展。需要一种全面的设计策略来找到一种中频(MF)变压器设计,该设计可以在满足材料,电气和温度限制的同时,最大化效率和功率密度。所提出的方法考虑了绕组导体传导谐波电流的最佳尺寸。讨论了绕组交织结构对漏磁场的影响,提出了一种调节变压器漏电感的方法。介绍了一种新型的半经验表达式,可提高交流电阻系数的精度。还研究了中频大功率应用中使用的两种众所周知的变压器配置,即壳式和铁芯式。在参数扫描法的基础上建立了设计方法,并逐一枚举并测试了许多候选解,以确定满足各种约束条件的解集。设计并制造了两个基于5 kHz / 10 kW纳米晶体的变压器原型。结果表明,自然冷却壳型原型可以达到99.36%的功率密度,达到17.6 MW / m(3),自然冷却芯型原型可以达到14.2 MW / m的功率密度。 m(3),效率为99.33%。

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