Design and Construction of a High-Frequency Transformer of a Power Inverter

Abstract

Research has been done on the design of transformers at a variety of power densities and operating frequency ranges. The power level, efficiency and power density target are used to define the core material type, as well as the operating frequency. Also, the power converter topologies that were discussed previously call for the addition of inductors in order to function correctly. However, in most cases, if the transformer leakage inductance is designed appropriately, it is possible to do rid of this additional inductance requirement. This results in an increase in the system's power density as well as its efficiency and a decrease in its overall cost. As a result of this, and particularly at high power levels, it is possible to see that the design stages of a power converter and a transformer affect one another. So, the primary objective of this study is to carry out research on the design and construction of a high-frequency power inverter transformer. In this investigation, the design of a single-phase transformer with 330 kW of capacity (equivalent to 1 MW in three phases) that operates at 50 kilohertz is described. Core materials along with their performance at high switching frequencies are now under investigation. To simulate a transformer's behaviour, a 3D model is analysed using a Finite Element Analysis (FEA) programme. To simulate the intended transformer's magnetics, electrostatics, and transients, Maxwell-3D may be used. In respect to leakage inductance, along with voltage regulation, and also total transformer efficiency (98.608%), the results showed that the Shell-type transformer performed well. Additionally, a design that is compact and has a power density of 40.376 kW/L can be developed.