Modeling and Design of High-Power Enhanced Leakage-Inductance-Integrated Medium-Frequency Transformers for DAB Converters

Xinsheng Zhang, Fei Xiao, Ruitian Wang, Wei Kang and Beichao Yang
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Xinsheng Zhang: National Key Laboratory of Science and Technology on Vessel Integrated Power System, Naval University of Engineering, Wuhan 430033, China
Fei Xiao: National Key Laboratory of Science and Technology on Vessel Integrated Power System, Naval University of Engineering, Wuhan 430033, China
Ruitian Wang: National Key Laboratory of Science and Technology on Vessel Integrated Power System, Naval University of Engineering, Wuhan 430033, China
Wei Kang: National Key Laboratory of Science and Technology on Vessel Integrated Power System, Naval University of Engineering, Wuhan 430033, China
Beichao Yang: National Key Laboratory of Science and Technology on Vessel Integrated Power System, Naval University of Engineering, Wuhan 430033, China

Energies, 2022, vol. 15, issue 4, 1-23

Abstract: For dual active bridge (DAB) converters, integrating the phase-shifting inductance (PSI) in the medium-frequency transformer (MFT) is an effective way to improve the overall power density. Different from the existing leakage-inductance-integrated (LII) structure, a concentric-winding (CW) enhanced leakage-inductance-integrated (ELII) structure, which includes an additional core, is proposed in this paper. In order to explain the operating mode of CW ELII MFT, a magnetic circuit model is established, and the analysis is carried out under the typical DAB excitation. The total leakage inductance of CW ELII MFT is divided into the winding leakage inductance and the additional leakage inductance for calculation. The integrated structure makes the heat dissipation of the MFT challenging. Therefore, the air–water combined cooling method is adopted in the design. A thermal resistance model is built for the winding air channel under forced convection. On this basis, MFT designs with different integration structures for different leakage inductance requirements are compared. Finally, a 200 kW/4 kHz/200 ?H MFT prototype was designed and manufactured, which achieved the power density of 5.16 kW/dm 3 and the efficiency of 99.30%. The prototype was tested in a DAB converter, which is a module of a 2 MW modular multilevel converter-bidirectional DC–DC converter (MMC-BDC).

Keywords: medium-frequency transformer; inductor integration; DAB converter; optimal design (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2022
References: View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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