45kW Full Bridge Converter with Discontinuous Primary Current for High Efficiency Airborne Application

Abstract

This paper presents and describes the design and optimization process of a high power density 45kW DC/DC converter for aircraft application. This onverter is a part of an isolated rectifier for a military aircraft pulsating load. It has to provide galvanic isolation and good stability when the load steps as high as 40 kW are applied. In order to obtain high efficiency, on the primary side of the converter a discontinuous triangular current modulation is implemented. High power density is obtained by relatively high switching frequency of 10 kHz and by implementation of the transformer using a nanocrystalline material that enables high magnetic flux density (up to 1T) and copper foils for conductors. The expected efficiency of the converter is 97.6% and the total weight of the system is 7.6 kg