A High Power 200kW Medium Frequency Transformer With Improved Thermal Management

High insulation voltage and thermal management are the two major challenges in designing a high-power medium frequency transformer (MFT) for medium voltage power electronics applications. This paper proposes a novel insulation and cooling structure with potted windings and aluminum nitride (AlN) ceramic cooling plates in a 200 kW MFT with ferrite (3C94) magnetic cores and split winding structure. The MFT achieves a power density of 18.15 kW/L and a partial discharge inception voltage (PDIV) higher than 17 kV. The estimated efficiency is higher than 99.715% with superior thermal performance predicted at 200 kW.