Geometry optimization and characterization of three-phase medium frequency transformer for 10kVA Isolated DC-DC converter

Three-phase Dual Active Bridge converter is advisable for the High-power DC-DC conversion system. In the ac link, galvanically isolated transformer operated at a medium frequency range provides stepping up or down of the secondary bridge voltage. This paper provides a magnetic design optimization of the medium frequency transformer for maximizing its efficiency when excited by a non-sinusoidal waveform. In this paper, a mathematical design of a 10kVA non-sinusoidal transformer had been developed and validated using two-dimensional (2D) transient finite element analysis (FEA). The set of selected design variables is defined in order to enhance the power density and efficiency of the targeted transformer and an optimization is carried out. Finally, a 10kVA transformer is prototyped and the results of core losses for non-sinusoidal excitation is confirmed experimentally.