The medium-frequency power transformer (MFPT) is one of the key elements of an isolated, bi-directional DC-DC converters in applications such as future all-DC offshore wind farms, traction and solid state transformers. This paper describes a design methodology taking into account the loss calculation, isolation requirements and thermal management. Incorporating this design methodology, an optimization process with a wide range of parameter variations is applied on a design example to find the highest power density while the efficiency, isolation, thermal and leakage inductance requirements are all met.

The high power medium frequency transformer (HPMFT) is one of the key elements of an isolated, bi-directional DC-DC converters in applications such as future all-DC offshore wind farms, traction and solid state transformers. This paper describes a design methodology taking into account the loss calculation, isolation requirements and thermal management. Incorporating this design methodology, an optimization process with a wide range of parameter variations is applied on a design example to find the highest power density while the efficiency, isolation, thermal and leakage inductance requirements are all met.

Moving towards higher power density in magnetic components, which is often realized by increasing the operating frequency, leads to the need for development of more accurate design tools, for example more accurate expressions for core losses, winding losses and leakage inductance calculations. This paper presents a new analytical expression intended to accurately evaluate the leakage inductance of transformers in the high frequency range in which the behavior of the magnetic field within the windings is altered. Unlike conventional expressions, which usually overestimate the leakage inductance at higher frequencies, this expression accounts for high frequency behavior of the magnetic field and provides high accuracy when operating at high frequencies. These high accuracy and applicability makes the derived expression of interest for designers to avoid time consuming finite element simulations without compromising with accuracy. The expression is validated by 2-D FEM simulation, as well as by measurements.

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