Design and Construction of 60kVA Prototype of High-Frequency Transformer for Dual-Active-Bridge Converters Devoted to DC Distribution Networks Applications

This paper deals with the design methodology and construction solutions adopted for a prototype of high-frequency transformer (HFT) that would be used for the accomplishment of active nodes (i.e. distributed electrical generators including energy storage) in distribution DC networks. The proposed design methodology is developed starting from the system requirements and dealing with the electromagnetic design of the HFT for estimation of the expected performance and thermal behavior. Further to that, the paper describes the mechanical solutions and the manufacturing process adopted for the construction of a 60 kVA rated power prototype. The HFT prototype described in the paper has 23.2kW/l power density, overall dimensions 22x15x16cm and weight equal to 13.7kg. The design approach and construction solutions have been validated by means experimental tests that were conducted by using the HFT prototype in a Dual Active Bridge converter laboratory set up.