Thermal Analysis of 2.2kW Transformer of On-Board Charger for Electric Vehicles

In recent years, many countries are adapting Electric Vehicle (EV) to mitigate the effect of climate change. In EV, On Board Charger (OBC) is an important component. It is used for charging and monitoring the health of battery. The OBC board consists of power electronics devices and magnetic component such as MOSFET, Diode and Transformer and Inductors. During the operation different kind of losses occurs in these components. These losses generate heat which causes of temperature rise in components, which alter the operating conditions of devices that affect the performance OBC board. Therefore, the proper working of OBC board thermal considerations is a basic part of power electronics design. The inductor and transformer play significant role in OBC board and they are designed for significant temperature rise in order to optimize the cost, size, and performance. The magnetic designer should consider the behavior of magnetic core at high temperatures. This understanding is important for selecting the best type of material for each application which ensure that the magnetic device will function safely at its maximum operating temperature. For the prediction of losses and temperature, a tool is required, the simulation tools based in FEA provide accurate prediction of losses as well as temperature. This paper presents the comprehensive study of 2.2 kW transformer. A Multiphysics environment using Ansys Maxwell Ansys, Icepack and Simplore is used for the analysis.