Design Methodology for Inductor-Integrated Litz-Wired High-Power Medium-Frequency Transformer With the Nanocrystalline Core Material for Isolated DC-Link Stage of Solid-State Transformer

A comprehensive design methodology is required to maximize the power capacity, the efficiency, and the power density of medium-frequency transformer (MFT), while complying with material, insulation, leakage inductance, and temperature limits. Different from the previous work, an analytical expression for the optimum conductor size of rectangular litz-wire conducting harmonic currents, which ensures best use of the available copper is proposed. A method to tune the leakage inductance with different winding configurations is presented. An insulation design scheme considering the influence of short-term power frequency sinusoidal wave and long-term square wave voltage excitations is put forward. Method to acquire the optimal dimension of fin array heat exchanger under forced air-cooling condition is presented. On this basis, the design methodology is established using the multiobjective nondominated sorting genetic algorithm II. A 1 kV, 200 kVA, 10 kHz nanocrystalline core MFT is designed and prototyped for a 10 kV, 2.5 MW solid-state transformer. The optimal design achieves an efficiency of 99.45%, a power density of 8 MW/m³, and a forced air-cooling temperature of 62 °C.