Development of High Power, High Frequency Magnetics for the Future Power Electronics Applications

Abstract:
In this paper the optimum design of high power high frequency magnetics is discussed based on a 50kW application operating at 50 kHz. An in depth theoretical explanation on minimizing the losses at high frequency is discussed. A novel approach to the windings that makes the high frequency conductor losses due to proximity effect almost frequency independent is presented. Theoretical explanation of this phenomenon is given. Further how this approach will make it possible to develop a new generation of magnetics that enable power electronics designers to go for significantly high operating frequencies is discussed. The challenge of handling high temperature rise due to high power density of such high power high frequency magnetics is addressed in this paper with a practical solution for that. The theoretical findings are verified based on a set of prototypes developed for a 50kW DC DC converter operating at 50kHz.