陈彬, 梁旭, 唐波, 黄力, 万妮娜, 钱晨悦. 大功率中频三相变压器优化设计方法[J]. 中国电机工程学报, 2021, 41(8): 2877-2889. DOI: 10.13334/j.0258-8013.pcsee.201665
引用本文: 陈彬, 梁旭, 唐波, 黄力, 万妮娜, 钱晨悦. 大功率中频三相变压器优化设计方法[J]. 中国电机工程学报, 2021, 41(8): 2877-2889. DOI: 10.13334/j.0258-8013.pcsee.201665
CHEN Bin, LIANG Xu, TANG Bo, HUANG Li, WAN Nina, QIAN Chenyue. Optimization Method of High-power Medium-frequency Three-phase Transformer[J]. Proceedings of the CSEE, 2021, 41(8): 2877-2889. DOI: 10.13334/j.0258-8013.pcsee.201665
Citation: CHEN Bin, LIANG Xu, TANG Bo, HUANG Li, WAN Nina, QIAN Chenyue. Optimization Method of High-power Medium-frequency Three-phase Transformer[J]. Proceedings of the CSEE, 2021, 41(8): 2877-2889. DOI: 10.13334/j.0258-8013.pcsee.201665

大功率中频三相变压器优化设计方法

Optimization Method of High-power Medium-frequency Three-phase Transformer

  • 摘要: 基于磁耦合的三相双有源全桥DC/DC变换器非常适合于大功率应用场合,尽管该型变换器具有诸多优势,但其内部核心磁性元件—大功率中频三相变压器的结构、工作模态、电磁特性更加复杂,容量、频率、损耗温升、漏电感相互制约,形成一个复杂的系统化设计难题。该文重点对大功率中频三相变压器整体优化方法和性能进行研究。结合三相双有源全桥DC-DC变换器的稳态电压和电流波形,采用基波分析法推导出中频三相变压器的各阶次谐波电流表达式,提出绕组损耗解析计算方法; 根据六电平阶梯电压波激励下分段线性磁通密度波形,提出改进的IGSE公式用于计算铁心损耗; 针对三相五柱式铁心拓扑结构,建立具有14个温度节点的集中参数热网络模型,用于计算中频三相变压器的最高温升; 研究绕组排布方式对漏电感的影响规律,并给出漏电感解析表达式。在此基础上,提出基于自由参数扫描法的大功率中频三相变压器优化设计流程。按照最优设计方案制作了一台5kHz/15kW纳米晶铁心中频三相变压器模型,并对其漏电感、铁心损耗、绕组损耗、温升进行有限元仿真和实验测试,验证所提设计方法的有效性。

     

    Abstract: The magnetically coupled three-phase dual- active-bridge (DAB3) DC/DC converter is highly suitable for high-power applications. Although the converter has many advantages, the structure, working mode and electromagnetic effect of its key magnetic component—high-power medium- frequency three-phase transformer (MFT3) is sophisticated, and the capacity, frequency, loss, temperature rise and leakage inductance restrict each other, forming a complex and systematic design problem. This paper focuses on the overall design method and performance of high-power MFT3. Based on the analysis of steady-state voltage and current waveforms of DAB3 converter, the expression of harmonic current of MFT3 is derived by using fundamental wave analysis, and the analytical calculation method of copper loss is proposed. According to the piecewise linear flux density waveform excited by six-step voltage wave, the improved IGSE formula is proposed to calculate the core loss. For MFT3 with three-phase five column core topology, a lumped parameter thermal network model with 14 temperature nodes is established to obtain the maximum temperature rise. The influence of winding arrangement on leakage inductance is analyzed, and the analytical expression of leakage inductance is presented. On this basis, the design method of high-power MFT3 is proposed based on the free parameter scanning method. A 5kHz/15kW MFT3 model with the nanocrystalline core material is made, and the leakage inductance, core loss, copper loss and temperature rise are extracted by finite element method (FEM) and experiment. The effectiveness of the proposed method is verified by comparing the design results with the FEM simulation and experimental results.

     

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