Lightweight Design of Magnetic Integrated Transformer for High Voltage Power Supply in Electro-Aerodynamic Propulsion System

Electro-aerodynamic unmanned aerial vehicles (EAD-UAVs) have strict requirements for lightweight. Due to the heavy weight of magnetic components and insulation materials, the power source of the EAD-UAV, an
LCC
high voltage power supply (HVPS)'s specific power cannot meet the minimum requirements. To improve the specific power of
LCC
HVPS, this article will optimize the magnetic core, insulation materials, and magnetic integrated transformer structure. First, the weight-frequency relation of the high-voltage transformer core is derived, and it is shown that there is an optimal frequency to minimize the weight of the high-voltage transformer core. Then, for insulation material optimization, the existing method points out that the input parallel output series (IPOS) array structure can reduce the amount of insulation material. This article uses the structure. But this article combined with the optimal frequency proposed the number of array transformers and insulation design method. Next, for each transformer in the array, an asymmetric magnetic integrated transformer structure is proposed. Which realizes the resonant inductance integration. At the same time, the magnetic shunt can be adjusted according to the needs of the winding. So, this structure can improve the utilization rate of the transformer window, and reduce the weight of the magnetic core. Finally, a 619 W-rated laboratory prototype is designed to convert 140 V input to 40 kV output. The designed IPOS transformer array weighs is 213.5 g, the total weight of the HVPS is 423.9 g, and the specific power is 1.46 kW/kg, working at the optimal frequency of 101.2 kHz.