This work presents the design and analysis of two Litz wire transformers for a 500 kHz, 18 kW input­parallel output­series partial power processing converter (IPOS PPP). Because the two power paths in the IPOS PPP operate as “dc transformers” (DCX), both transformers are designed with the goal of leakage inductance minimization in order to reduce gain variation around the resonant frequency. The selected winding topology with the lowest leakage inductance results in an impedance mismatch among parallel secondaries used in the majority power path transformer, resulting in poor current sharing. In order to balance the goals of leakage inductance minimization and even current sharing, a new winding technique called “intra­leaving” is presented which reduces current sharing error from 50%, to 5%. A design rule for “intra­leaving” is also established which extends the winding method to different winding configurations and higher numbers of parallel winding. A novel cooling duct designed with computational fluid dynamics is used for transformer thermal management. The cooling duct uses two 30 mm 7.7 CFM fans to cool the transformer winding and achieves a small height of 43 mm and only 6.8 W power consumption. Using the cooling duct, 106 °C peak winding temperature and 76 °C peak core temperature is achieved at 15 kW load, an ∼ 8% reduction compared to using a conventional 120 mm fan 41 CFM fan. The two transformers with the cooling system achieve 635 W/in3 power density, 1U height compliance, and 99.4% peak efficiency. / M.S. / As society moves towards the electric grid of the future, there have been increased calls for the research and development of resonant power converters due to their high efficiency, high power density, and low electromagnetic interference. The high frequency transformer is one of the main components of the resonant converter system as it contributes substantially to the converters volume, power loss, and thermal management risks. This work seeks to address the trade­offs between leakage inductance minimization and transformer current sharing and proposes a winding method called “intra­leaving” which achieves both. Using “intra­leaving” current sharing error was reduced from 50%, to 5%. Operating transformers at high frequency reduces their volume in accordance with Faraday’s law but also increases thermal risks due to decreased core surface area, higher winding fill factor, and higher loss per unit volume. A novel cooling duct designed using computational fluid dynamics is presented using two 30 mm 7.7 CFM fans and achieves a small height of 43 mm and only 6.8 W power consumption. Using the cooling duct, 106 °C peak winding temperature and 76 °C peak core temperature is achieved at 15 kW load, an ∼ 8% reduction compared to using a conventional 120 mm fan 41 CFM fan. The transformers with the cooling system designed in this work achieve 635 W/in³ power density, 1U height compliance, and 99.4% peak efficiency.

To achieve higher power density, converters and components must be able to handle higher voltage and current ratings at higher percentages of efficiency while also maintaining low cost and a compact footprint. To meet such demands, medium-voltage resonant converters have been favored by researchers for their ability to operate at higher switching frequencies. High frequency (HF) operation enables soft switching which, when achieved, reduces switching losses via either zero voltage switching (ZVS) or zero current switching (ZCS) depending on the converter topology. In addition to lower switching losses, the converter operates with low harmonic waveforms which produce less EMI compared to their hard switching counterparts. Finally, these resonant converters can be more compact because higher switching frequencies imply decreased volume of passive components. The passive component which benefits the most from this increased switching frequency is the transformer. The objective of this work is to design a >400 kHz, 100 kW transformer which will provide galvanic isolation in a Solid-State Transformer (SST) based PEBBs while maintaining high efficiency, high power density, and reduced size. This work aims to present a simplified design process for high frequency transformers, highlighting the trade-offs between co-dependent resonant converter and transformer parameters and how to balance them during the design process. This work will also demonstrate a novel high frequency transformer insulation design to achieve a partial discharge inception voltage (PDIV) of >10 kV. / Master of Science / As the world's population expands and countries progress, the demand for electricity that is high-powered, highly efficient, and dependable has increased exponentially. Further, it is integral to the longevity of global life that this development occurs in a fashion that mitigates environmental consequences. The power and technology sectors have been challenged to address the state of global environmental affairs, specifically regarding climate change, carbon dioxide emissions, and resource depletion. To move away from carbon emitting, non-renewable energy sources and processes, renewable energy sources and electric power systems must be integrated into the power grid. However, the challenge lies in the fact that there is not an easy way to interface between these renewable sources and the existing power grid. Such challenges have undermined the widespread adoption of renewable energy systems that are needed to address environmental issues in a timely manner. Recent developments in power electronics have enabled the practical application of the solid-state transformer (SST). The SST aims to replace the current, widespread form of power transformation: the line frequency transformer (50/60 Hz). This transformer is bulky, expensive, and requires a significant amount of additional circuitry to interface with renewable energy sources and electric power systems. The SST overcomes these drawbacks through high frequency operation (>200 kHz) which enables higher power at a reduced size by capitalizing on the indirect proportionality between the two parameters. The realization of the SST and its implementation has the ability to greatly advance the electrification of the transportation industry which is a top contributor to carbon emissions. This work aims to demonstrate a >400 kHz, 100 kW SST with a novel magnetic design and insulation structure suited for electric ship applications.

The introduction of inverters utilizing wide band-gap semiconductors allow for higher switching frequency and improved machine drive energy efficiency. However, inverter switching results in fast voltage surges which cause overvoltage at the stator terminals and uneven voltage distribution in the stator winding. Therefore, it is important to understand how next generation machine drives, with higher switching frequency, affect the voltage distribution. For this purpose, a lumped-parameter model capable of simulating winding interturn voltages for the wide frequency range of 0-10 MHz is developed for a slotless PMSM. The model includes both capacitive and inductive couplings, extracted from 2D finite element simulations, as well as analytically estimated resistive winding losses. The developed model of a single phase-winding is used to investigate how machine design aspects such as insulation materials and winding conductor distribution affects both voltage distribution and winding impedance spectrum. Validation measurements demonstrate that the model is accurate for the wide frequency range. The sensitivity analysis suggests that the winding conductor distribution affect both impedance spectrum and voltage distribution. For the slotless machine, capacitance between the winding and the stator is several times smaller than capacitance between turns. Therefore, the high-frequency effects are dominated by the capacitance between turns. Insulation materials that affect this coupling does therefore have an impact on the impedance spectrum but does not have any significant impact on the voltage distribution. / Nästa generations inverterare för styrning av elektriska maskiner, baserade på bredbandgaps komponenter, tillåter högre switchfrekvenser vilket skapar en energieffektivare drivlina. Nackdelen är att snabba spänningsflanker från den höga switchfrekvensen skapar överspänning på stators anslutningar och en ojämn spänningsfördelning i statorlindningen. Det är därför betydelsefullt att förstå hur dessa nya drivlinor påverkar lindningens spänningsfördelning. I denna rapport används en modell kapabel att simulera lindningens spänningsfördelning i det breda frekvensspektrumet 0-10 MHZ. Modellen är framtagen för en faslindning av en PMSM, utan statoröppning, som inkluderar både kapacitiva och induktiva kopplingar samt analytiskt beräknade lindningsförluster. Modellen används för att undersöka spänningsfördelningen i lindningen samt inverkan från designparametrar som isolationsmaterial och lindningsdistribution. Känslighetsanalysen visar att lindingsdistributionen har en signifikant påverkan på både impedansspektrumet och spänningsfördelningen. För den studerade maskintypen är det kapacitansen mellan varv som är dominerande för högfrekventa fenomen. Isolationsmaterial som påverkar denna koppling har en påverkan på impedansspektrumet men är liten för spänningsfördelningen.

This thesis deals with wireless power transfer from an external source to embedded small devices (such as for conditioning monitoring, control etc.) located at different distances from the source. The proposed designs can be used in a variety of applications, including mobile phones, electric cars, unmanned aerial vehicles, robots, etc. where it could be very convenient to transmit power without wires/cables. The wireless charging method which avoids using conventional cables and wires for energizing or charging electrical devices has been one of the fastest developed recent technologies. The inductive coupling technique is one way to transfer power wirelessly and works fairly well over very short distances. For distances greater than the radius of the emitter, however, inductive coupling rapidly declines. An improved approach is to create inductive-capacitive resonance which improves efficiency and transfer distance, which was proposed by Tesla. Other methods using more than two coils have lately been proposed, which improve transfer characteristics even further. Several designs were proposed consisting of two, three and four coil combinations, with different shapes and sizes. A ferrite cored solenoid was also chosen as emitter in some setups over air cored solenoid, for better field enhancement in longitudinal energy transfer applications. To have low resistive high energy transfer, coil-capacitor designs were proposed. Several simulations were performed using COMSOL Multiphysics software to understand the magnetic field distribution and transfer to the adjacent coils in air medium. Based on this power transfer efficiency graphs were plotted for every proposed design. For validation, few simulations were contrasted with lab experiments. The focus was to develop and contribute to the improvement of existing techniques. For this, it is sometimes enough to transfer a small amount of power (e.g., 0.5 W) at different distances and frequencies with different set ups. The results obtained from the simulation and measurements were used to evaluate the impact of frequency and transfer distance on energy transfer in wireless power transfer techinque for proposed design. The analysis was used to suggest the improvements or part of future work in the designs such as use of Litz wire and ferrite concentrators with thin conductive laminates. / Detta examensarbete behandlar trådlös kraftöverföring från en extern källa till inbyggda små enheter (såsom för tillståndsövervakning, kontroll etc.) placerade på olika avstånd från källan. De föreslagna designerna kan användas i en mängd olika applikationer, inklusive mobiltelefoner, elbilar, obemannade flygfordon, robotar, etc. där det kan vara mycket bekvämt att överföra ström utan ledningar/kablar. Den trådlösa laddningsmetoden som undviker att använda konventionella kablar och ledningar för att strömsätta eller ladda elektriska apparater har varit en av de snabbast utvecklade nya teknologierna. Den induktiva kopplingstekniken är ett sätt att överföra ström trådlöst och fungerar ganska bra över mycket korta avstånd. För avstånd större än sändarens radie avtar emellertid den induktiva kopplingen snabbt. Ett förbättrat tillvägagångssätt är att skapa induktiv-kapacitiv resonans som förbättrar effektiviteten och överföringsavståndet, vilket föreslogs av Tesla. Andra metoder som använder mer än två spolar har nyligen föreslagits, vilka förbättrar överföringsegenskaperna ytterligare. Flera konstruktioner föreslogs bestående av två, tre och fyra spolar kombinationer, med olika former och storlekar. En solenoid med ferritkärna valdes också som sändare i vissa inställningar framför solenoid med luftkärna, för bättre fältförstärkning i longitudinella energiöverföringstillämpningar. För att ha låg resistiv hög energiöverföring föreslogs spolkondensatorkonstruktioner. Flera simuleringar utfördes med COMSOL Multiphysics programvara för att förstå magnetfältets distribution och överföring till intilliggande spolar i luftmedium. Baserat på detta ritades grafer för effektöverföringseffektivitet för varje föreslagen design. För validering kontrasterades få simuleringar med labbexperiment. Fokus var att utveckla och bidra till förbättringen av befintliga tekniker. För detta räcker det ibland att överföra en liten mängd effekt (t.ex. 0,5 W) på olika avstånd och frekvenser med olika uppsättningar. Resultaten från simuleringarna och mätningarna användes för att utvärdera effekten av frekvens och överföringsavstånd på energiöverföring i trådlös kraftöverföringsteknik för föreslagen design. Analysen användes för att föreslå förbättringar eller delar av framtida arbete i designen, såsom användning av Litz-tråd och ferritkoncentratorer med tunna ledande laminat.