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Title: High-Frequency Transformer Design for Modular Power Conversion From Medium-Voltage AC to 400 VDC

Abstract

This paper presents a high-frequency modular medium-voltage AC (4160 VAC or 13.8 kVAC) to low-voltage DC (400 VDC) system that is scalable in order to be used for different scale microgrids. A 15 kW, 500 kHz DC/DC converter is demonstrated as the most important stage of the system overall, which can be scalable to a 225 kW 4160 VAC to 400 VDC system. Motivation of a CLLC resonant converter and its design parameters determination is carefully illustrated. The high-frequency transformer is the key element for the DC/DC converter. Then, the paper focuses on high-frequency transformer design to realize high-voltage insulation, high efficiency, and high density at the same time. Based on a split winding UU core transformer structure, transformer insulation materials and dimension parameters are determined referring to the IEEE insulation standard. The transformer magnetic loss model is reviewed based on which loss design tradeoff is carefully analyzed. Different working frequency impact on transformer design over three different core materials is also presented. Finally, a 500 kHz transformer prototype has been developed and demonstrated with the IEEE standard required insulation tests. A whole CLLC resonant converter is also present with experiments results. Here, the converter holds outstanding 98% efficiency andmore » 2.9 kW/L power density.« less

Authors:
ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1]
  1. Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
Publication Date:
Research Org.:
PowerAmerica, Raleigh, NC (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office
OSTI Identifier:
1574433
Grant/Contract Number:  
EE0006521
Resource Type:
Accepted Manuscript
Journal Name:
IEEE Transactions on Power Electronics
Additional Journal Information:
Journal Volume: 33; Journal Issue: 9; Journal ID: ISSN 0885-8993
Publisher:
IEEE
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; CLLCresonant converter; high frequency; magnetic loss analysis; medium voltage; transformer insulation

Citation Formats

Zhao, Shishuo, Li, Qiang, Lee, Fred C., and Li, Bin. High-Frequency Transformer Design for Modular Power Conversion From Medium-Voltage AC to 400 VDC. United States: N. p., 2017. Web. doi:10.1109/TPEL.2017.2774440.
Zhao, Shishuo, Li, Qiang, Lee, Fred C., & Li, Bin. High-Frequency Transformer Design for Modular Power Conversion From Medium-Voltage AC to 400 VDC. United States. https://doi.org/10.1109/TPEL.2017.2774440
Zhao, Shishuo, Li, Qiang, Lee, Fred C., and Li, Bin. Thu . "High-Frequency Transformer Design for Modular Power Conversion From Medium-Voltage AC to 400 VDC". United States. https://doi.org/10.1109/TPEL.2017.2774440. https://www.osti.gov/servlets/purl/1574433.
@article{osti_1574433,
title = {High-Frequency Transformer Design for Modular Power Conversion From Medium-Voltage AC to 400 VDC},
author = {Zhao, Shishuo and Li, Qiang and Lee, Fred C. and Li, Bin},
abstractNote = {This paper presents a high-frequency modular medium-voltage AC (4160 VAC or 13.8 kVAC) to low-voltage DC (400 VDC) system that is scalable in order to be used for different scale microgrids. A 15 kW, 500 kHz DC/DC converter is demonstrated as the most important stage of the system overall, which can be scalable to a 225 kW 4160 VAC to 400 VDC system. Motivation of a CLLC resonant converter and its design parameters determination is carefully illustrated. The high-frequency transformer is the key element for the DC/DC converter. Then, the paper focuses on high-frequency transformer design to realize high-voltage insulation, high efficiency, and high density at the same time. Based on a split winding UU core transformer structure, transformer insulation materials and dimension parameters are determined referring to the IEEE insulation standard. The transformer magnetic loss model is reviewed based on which loss design tradeoff is carefully analyzed. Different working frequency impact on transformer design over three different core materials is also presented. Finally, a 500 kHz transformer prototype has been developed and demonstrated with the IEEE standard required insulation tests. A whole CLLC resonant converter is also present with experiments results. Here, the converter holds outstanding 98% efficiency and 2.9 kW/L power density.},
doi = {10.1109/TPEL.2017.2774440},
journal = {IEEE Transactions on Power Electronics},
number = 9,
volume = 33,
place = {United States},
year = {Thu Nov 16 00:00:00 EST 2017},
month = {Thu Nov 16 00:00:00 EST 2017}
}

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Works referencing / citing this record:

Nanocrystalline and Silicon Steel Medium-Frequency Transformers Applied to DC-DC Converters: Analysis and Experimental Comparison
journal, May 2019

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