High-Precision Simulation for Structure and Efficiency Optimization of High-Power High-Frequency Transformer

High-power high-frequency transformer is a crucial component of isolated DC-DC converters. To optimize the structure and efficiency of high-frequency high-power transformer, high-precision estimation of transformer parameters is necessary. This paper proposes to adopt high-precision FEA simulations in parameter estimation including the dielectric strength for insulation design and the core loss. In addition, the difference of core loss estimation principle between different types of core material is pointed out. The proposed methods are applied to a specific case of transformer design to demonstrate the effects of the proposed methods in structure and efficiency optimization. Experiments will be performed in future research to verify the accuracy of the proposed core loss estimation methods and the feasibility and high efficiency of the proposed design scheme.