Vf-constrained ηρ-pareto optimization of medium frequency transformers in ISOP-DAB converters

This study deals with ηρ (efficiency-power density) pareto optimisation of medium frequency transformers (MFTs) with considerations of voltage and frequency ( Vf) constraints of semiconductors for mega-watt range input-series output-parallel (ISOP) connected dual-active bridges (DABs). A simple design methodology to include the Litz wire configuration in the optimisation process is proposed. Based on the presented design methodology, the effects of the semiconductors blocking voltage and switching frequency on the ηρ -pareto optimisation are evaluated. First, an idealised optimisation is carried out to understand the general behaviour of the optimum point. Second, brute-force optimisation is utilised to find the practical optimum solution based on the market availability of MFT components. Designing MFTs for a 1 MW 10 kV/600 V ISOP-DAB converter is the subject of numerical studies. The best trade-off between ηρandVf is selected as the final optimal solution and its design correctness is validated using three-dimensional finite-element analysis. Experimental tests on a 3 kW downscaled MFT prototype show that the proposed method is valid in practice

High Power, Medium Frequency, and Medium Voltage Transformer Design and Implementation

Many industrial applications that require high-power and high-voltage DC-DC conversion are emerging. Space-borne and off-shore wind farms, fleet fast electric vehicle charging stations, large data centers, and smart distribution systems are among the applications. Solid State Transformer (SST) is a promising concept for addressing these emerging applications. It replaces the traditional Low Frequency Transformer (LFT) while offering many advanced features such as VAR compensation, voltage regulation, fault isolation, and DC connectivity. Many technical challenges related to high voltage stress, efficiency, reliability, protection, and insulation must be addressed before the technology is ready for commercial deployment. Among the major challenges in the construction of SSTs are the strategies for connecting to Medium Voltage (MV) level. This issue has primarily been addressed by synthesizing multicellular SST concepts based on modules rated for a fraction of the total MV side voltage and connecting these modules in series at the input side. Silicon Carbide (SiC) semiconductor development enables the fabrication of power semiconductor devices with high blocking voltage capabilities while achieving superior switching and conduction performances. When compared to modular lower voltage converters, these higher voltage semiconductors enable the construction of single-cell SSTs by avoiding the series connection of several modules, resulting in simple, reliable, lighter mass, more power dense, higher efficiency, and cost effective converter structures. This dissertation proposes a solution to this major issue. The proposed work focuses on the development of a dual active bridge with high power, medium voltage, and medium frequency control. This architecture addresses the shortcomings of existing modular systems by providing a more power dense, cost-effective, and efficient solution. For the first time, this topology is investigated on a 700kW system connected to a 13kVdc input to generate 7.2kVdc at the output. The use of 10kV SiC modules and gate drivers in an active neutral point clamped to two level dual active bridge converter is investigated. A special emphasis will be placed on a comprehensive transformer design that employs a multi-physics approach that addresses all magnetic, electrical, insulation, and thermal aspects. The transformer is designed and tested to ensure the system’s viability

Advanced power converters for railway traction systems

This thesis presents a new traction drive suitable for fuel-cell powered light rail vehicles based on a multilevel cascade converter with full-bridge cells. The converter provides dc-ac power conversion in a single stage, while compensating for the variation of fuel cell terminal voltage with load power. The proposed converter can replace the conventional combination of dc-dc converter, as it benefits from having a multilevel ac voltage waveform and much smaller power inductors, compared to conventional solutions. The converter numerical and analytical models are derived showing that the converter can be modelled as a cascaded boost converter and 3-phase inverter. The design methodology for the energy storage capacitors and power inductors is presented, showing that inductance is reduced at a quadratic rate with the addition of more sub-modules, while total converter capacitance remains constant. A simulation of a full-scale traction drive in a fuel cell tram demonstrates that the proposed converter is a viable solution for light rail applications. The concept of a boost modular cascaded converter is fully validated through a bespoke laboratory prototype driving a small induction machine. The experimental inverter achieves operation from standstill, with full motor torque, to field weakening with constant power, boosting a 50V dc supply to 200V peak line-to-line voltage