A High Power High Frequency Transformer Design for Solid State Transformer Applications

In this study, design of a 330kW single-phase transformer (corresponding to 1MW three-phase) operating at 50kHz is presented. Possible core materials and their performances are investigated under high switching frequency operation. Core volume, area, configuration, and market availability are studied to achieve the optimal compact and cost-effective transformer model. Next, transformer winding type, size, placement, and cost are analyzed. These steps will result in a complete transformer electromagnetic design and modelling. Afterwards, a 3D transformer model is created and simulated using a Finite Element Analysis (FEA) tool. ANSYS Maxwell-3D is used to simulate the magnetics, electrostatics, and transients of the designed transformer. This model is integrated with a power electronics circuit in ANSYS Simplorer to make a co-simulation for the entire system. Results obtained will include core maximum flux density, core/copper losses, leakage/magnetizing inductances, windings parasitic capacitances, and input/output voltage, current, and power values. Finally, the systems' overall efficiency is calculated and presented.