Constructional design, manufacturing and evaluation of high power density medium frequency transformer prototypes

Abstract

The aim of this project is to manufacture and test two 60 kW, 1.2/3.6 kV, 6 kHz 46/28 μH prototype transformers. • Based on the prepared high power medium frequency transformers’ design data, the constructional design of two prototype transformers is performed. During the constructional design, determination of the type, shape and volume of the suitable magnetic, thermally conductive and dielectric materials available in the market was done. The materials were bought and processed, and two prototype transformers were manufactured. The important technical data regarding the insulation characteristics of insulation materials was examined at nominal wave shape and frequency considered for the transformer application and the insulation coordination of the transformers was updated accordingly. At the same time, to prepare for the design validation tests, evaluation of the available high voltage, high current and medium frequency square wave shape supplies and the voltage and current measuring equipment was performed. The transformers were subjected to a set of design validation tests and the results were recorded, analysed and compared with the calculated values. • Key Words: Solid state transformer, Medium frequency Power transformer, DC-DC converter, DC grid collection, Transformer testing and design validation