How to design MW-level medium frequency transformers

DC transformers are regarded as the key enabling components for future MVDC power distribution networks. Such a device unifies power conversion, insulation and protection into a single power electronics system. The voltage adaptation and galvanic isolation are provided by the transformer.
This paper presents the design and development of a 1 MW, 5 kHz medium frequency transformer prototype, which combines specific technologies regarding cooling and insulation. The design is achieved with the help of a model-based optimization tool, built around elaborate analysis and modeling of transformer specific phenomenon concerning its electrical operation.

 

This whitepaper presents a MW-rated medium frequency transformer design and explains:

• how to design and implement liquid-cooled hollow copper conductors as windings,
• what to keep in mind when windings are oil-immersed for insulation purposes,
• how to use nanocrystalline as magnetic core material.