Transformer Design Optimization for Power Electronic Converters in Electric Aircraft

Power density and efficiency are the main concerns in power electronic converters of electric aircraft. Transformers are major contributors to the size of isolated converters. In this paper, an optimization design tool is developed to minimize both the volume and losses of high-frequency transformers, by optimizing the maximum flux density. Optimum switching frequency selection is considered for different core materials and number of cores in parallel. The analysis shows the trade-offs involving the selection of the switching frequency and the effects on the transformer weight and volume, and the overall converter efficiency. Numerical simulations are performed in JMAG to validate the analytical models.