Optimum design of a high-power, high-frequency transformer

A procedure for optimum design of a high-power, high-frequency transformer is presented. The procedure is based on both electrical and thermal processes in the power transformer and identifies: (a) the VA-rating of ferrite cores in relation to the operating frequency; (b) the optimum flux density in the core; and (c) the optimum current densities of the windings providing maximum transformer efficiency. Since the transformer is the major contributor to the volume and weight of the power supply, the results of transformer analysis can be used for entire power supply optimization as well. Two high-power, high-frequency transformers are optimally designed, built, and tested. Practical results show good agreement with the theory.