Novel Developments in Magnetics that Enable the High-Power High Frequency Power Conversion

Abstract:
The development of high-power high frequency magnetic components is one of the major challenges that the power electronics industry faces when the power levels of converters are now expected to be in the hundreds of kW range. In this paper a number of innovative technologies developed to overcome these barriers are discussed. The technologies outlined have enabled the development of transformers with power levels of 500kW, for example, and 20kHz operating frequencies. The discussion is carried out based on a high-frequency transformer manufactured for a 250kW 30kHz application and designs developed for 500kW and 2MW transformers with operating frequencies of 20kHz. Emphasis is given to the technologies used in the mitigation of high-frequency losses, thermal management of high-power density high-frequency transformers, management of leakage inductance and partial discharge conditions.