Optimum Design Of High-Power High-Frequency Switching Power Supply Transformer

With the continuous development of power technology, high-frequency and high power density switching power supply has become the direction of the research and development trends. Transformer is an essential component in switching power supply, and its impact on the performance of the system also become increasingly important with higher frequency and higher power levels. Therefore, the optimal design of high-power high-frequency transformer design is quit pivotal to the goals above.The optimal design aims at high-power high-frequency resonant capacitor charging power supply(CCPS) transformer, and optimal method is sought from the reducing volume and improving efficiency of power supply system point of view in this thesis. First, the working state of resonant CCPS transformer is analyzed, and a guiding principle of core material selection is provided, which is based on the comparing material magnetic flux density working range with different rectangular ratio in this state. Secondly, on the basis of detailed analysis on the core and winding in transformer, a program to calculate losses, distribution parameters, volume and weight, is written using the Matlab software. Then optimal design of high-frequency transformer has been realized initially from the analytical point of view. Thirdly, three-dimensional simulation is studied to analyze distribution parameters, electric field and temperature field distribution which are difficult to calculate accurately using analytical method. From the simulation results, more accurate leakage inductance and distributed capacitance value can be gotten, besides temperature field and electric field spatial distribution can be observed directly, which shortening the design cycle, reducing the development cost, and providing data to support transformer insulation and cooling systems design. Then transformer design is completed after the adjustment of parameters gotten by initial optimal design. So the optimization results are obtained based on analytical method and ANSYS simulation analysis. Finally 42kW high-frequency transformers are produced, and the reasonableness of optimal design is verified through lab experiments.