High–Frequency Transformer Development for Compact Dual Active Bridge Converters

This paper presents a methodology for designing high–frequency transformers operating at 20 kHz made for operation in dual active bridge converter with a voltage setup of 600V/3x100V. The paper begins by explaining the calculation process for the transformer's design, focusing on crucial aspects such as leakage and magnetizing inductances. Specific techniques for the transformer winding process are discussed, ensuring accuracy and efficiency. Furthermore, the paper analyzed into calculating the parameters that make up the transformer's equivalent circuit, offering insights into its electrical characteristics. It also explores the impact of transformer leakage inductance on the converter's active power performance. To ensure the transformer's robust thermal performance, a thorough thermal analysis using Ansys software is conducted by considering various cooling methods. Finally, the construction details of the transformer, bridging the gap between theoretical design and practical realization are presented. The research concludes with the development of the final transformer construction, harmonizing the theoretical design with practical realization. This study contributes to the field of high–frequency transformer design and highlights the significance of design considerations, particularly in applications where compact and highly efficient power conversion solutions are required.