Manufacturability improvements of high frequency transformers

M.Ing. (Electrical and Electronic Engineering)In order to improve the industrialisation of modern power converters, its physical size must be reduced, material must be utilised more efficiently and its manufacturability improved. Consequently, many converters are operated in the ultrasonic frequency range, where the size of its constituent components are considerably reduced. Even at high frequencies of operation, however, magnetic components are still the largest and heaviest components in converters, and do not utilise materials to their maximum benefit. The aim of this work is to investigate the possibility of improving the industrialisation of power electronic converters by making use of a novel, multiple core magnetic component structure, called the distributed transformer. Existing magnetic component structures are evaluated from a materials point of view and the concept of distributed magnetic components introduced. A generalised transformer model is developed for the distributed transformer and pertinent design considerations discussed. A 1.5 kw battery charger industrialised by Spoornet is based on the CukDC-DC converter and is used as a case study. A conventional monolithic isolation transformer is used in its construction after a complete mathematical analysis of the converter topology, and compared with the equivalent distributed transformer configuration. The distributed transformer is then compared with the conventional monolithic transformer and evaluated in terms of its physical and electrical performance, design and ease of manufacture