Design Algorithm for and Validation of Winding Losses in Large-Capacity Medium-Frequency Distribution Transformers

Abstract

Accurately calculating winding losses has always been a significant challenge in the design of large-capacity medium-frequency transformers. This paper presents an accurate design algorithm for calculating the winding losses of a large-capacity medium-frequency distribution transformer. First, the peculiarities of winding losses in medium-frequency distribution transformers are analyzed. Various commonly used winding conductor types for medium-frequency transformers are introduced. The mechanisms of and differences between AC and DC winding losses in medium-frequency transformers are explained, and an effective analytical method for calculating the AC-to-DC resistance ratio is provided. Finally, the analytical calculation results of different types of winding losses are compared with those obtained through finite element simulations and experimental methods applied to a real transformer prototype. The discrepancies between the analytical results and those obtained using the other two methods were found to be within acceptable error margins, thereby validating the accuracy and effectiveness of the proposed algorithm.

Keywords

• large-capacity medium-frequency transformer
• winding losses
• design algorithm
• Litz wire
• copper foil