In this work, a 25 kW all silicon carbide (SiC) series-resonant converter (SRC) design is proposed to enable a single stage dc to dc conversion from 3kV to 540V (±270V) for future electric aircraft applications. The proposed SRC consists of a 3-level neutral-point-clamped (NPC) converter using 3.3kV discrete SiC MOSFETs on the primary side, a H-bridge converter using 900V SiC MOSFET modules on the secondary side and a high frequency (HF) transformer. The detailed design methods for the SRC power stage and the HF transformer are presented. Especially, a tradeoff between the complexity for the cooling system and the need for power density is addressed in the transformer design, leading to a novel multi-layer winding layout. To validate the effectiveness of the proposed SRC design, a converter prototype has been developed and comprehensive experimental studies are performed.
Design and Optimization of the High Frequency Transformer for 100kW CLLC Converter
The CLLC converter is widely used in the power electronic applications as a DC transformer, which can provide galvanic isolation, bidirectional power flow and an adjustable output voltage with the use of proper controls. As the most critical component in the CLLC converter, the high frequency (HF) transformer should be optimized according to the design targets, such as efficiency and power density. Starting with the analysis of the CLLC operating characteristics, this paper proposes a formal approach to design the HF transformer of a 100kW CLLC converter for a grid-tied application. The optimization method for the HF transformer is presented and the effect of the resonant inductor is analyzed. The optimized transformer is simulated with the finite element analysis (FEA) and Matlab/Simulink.
- Award ID(s):
- Publication Date:
- NSF-PAR ID:
- Journal Name:
- 2021 IEEE Applied Power Electronics Conference and Exposition (APEC)
- Sponsoring Org:
- National Science Foundation
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