Design and Optimization of a 200-kW Medium-Frequency Transformer for Medium-Voltage SiC PV Inverters

Guo, Zhicheng; Yu, Ruiyang; Xu, Wei; Feng, Xianyong; Huang, Alex Q.

doi:10.1109/tpel.2021.3059879

Design and Optimization of a 200-kW Medium-Frequency Transformer for Medium-Voltage SiC PV Inverters

Journal Article · Tue Feb 16 23:00:00 EST 2021 · IEEE Transactions on Power Electronics

DOI:https://doi.org/10.1109/tpel.2021.3059879· OSTI ID:1848748

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Univ. of Texas, Austin, TX (United States). Semiconductor Power Electronics Center; Univ. of Texas, Austin, TX (United States)
Univ. of Texas, Austin, TX (United States). Semiconductor Power Electronics Center

This paper presents a design and optimization methodology for a 200-kW medium-frequency transformer (MFT) based on low-loss magnetic core (FINEMET FT-3TL). The proposed optimal design methodology consists of predesign, preliminary design, and optimal design. In the preliminary design, the parallel-concentric winding structure is selected to increase the current carrying capability and reduce the leakage inductance. Based on the parallel-concentric winding concept, a novel cooing and insulation structure with 3-D printed bobbins are proposed. The optimal designed MFT prototype achieves a power density higher than 19.23 kW/L. The electrical insulation system is tested at 12 kV ac peak voltage. In addition, the partial discharge (PD) test is conducted at 7.5 kV ac peak voltage to ensure the PD-free design. The high-frequency bipolar pulsewidth modulation voltage insulation (PD) test is the first time applied in MFT design and test process. Finally, the transformer is applied in a dual-active-bridge (DAB) converter with 200 kW rated power. The peak efficiency of the DAB converter is 99.53%, and the efficiency at 200 kW is 98.85%. The peak efficiency of MFT is 99.844%, and the efficiency at 200 kW is 99.842%.

View Accepted Manuscript (DOE)

Research Organization:: University of Texas, Austin, TX (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0008348

OSTI ID:: 1848748

Alternate ID(s):: OSTI ID: 2229090
OSTI ID: 2242490

Journal Information:: IEEE Transactions on Power Electronics, Journal Name: IEEE Transactions on Power Electronics Journal Issue: 9 Vol. 36; ISSN 0885-8993

Publisher:: IEEECopyright Statement

Country of Publication:: United States

Language:: English

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