Isolated DC-DC converters are considered the building blocks of modern aircraft electrical power networks. The high-frequency transformer utilized in such converters is the major contributor to the size and weight besides the thermal management system. In this paper, an optimization design methodology aims to minimize the transformer core size and improve the converter performance through optimized winding configurations. The transformer core selection is based on optimizing the maximum flux density while considering different magnetic materials and number of cores in parallel. The transformer core is selected for an interleaved winding configuration and to keep the windings current density below a certain limit. The trade-offs between the converter efficiency and core weight in selecting an optimum switching frequency are presented. Multi-layer minimum gradient (MLMG) winding configurations are proposed to eliminate the high-frequency oscillations (HFO) caused by the transformer parasitics. The proposed configurations resulted in a reduction of the intra-winding capacitance by 15 times with 20%\% improvement in the transformer volume as compared to a similar conventional double-layers spiral configurations. Numerical simulations are performed in ANSYS Maxwell to validate the proposed design and the developed analytical models. The effect of the different configurations on the converter performance is verified in the PLECS simulation environment. PLECS simulation results are validated experimentally for the conventional and proposed configurations highlighting the improvements on the performance of the converter.

中文翻译：

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多电动飞机平面变压器的设计优化方法


隔离式 DC-DC 转换器被认为是现代飞机电力网络的构建模块。除热管理系统外，此类转换器中使用的高频变压器是造成尺寸和重量的主要因素。在本文中，优化设计方法旨在通过优化绕组配置来最小化变压器铁芯尺寸并提高转换器性能。变压器磁芯的选择基于优化最大磁通密度，同时考虑不同的磁性材料和并联磁芯数量。变压器铁芯被选择为交错绕组配置，并保持绕组电流密度低于一定限度。提出了在选择最佳开关频率时转换器效率和磁芯重量之间的权衡。提出了多层最小梯度（MLMG）绕组配置来消除变压器寄生效应引起的高频振荡（HFO）。与类似的传统双层螺旋配置相比，所提出的配置使绕组内电容减少了 15 倍，变压器体积提高了 20%\%。在 ANSYS Maxwell 中进行数值模拟，以验证所提出的设计和开发的分析模型。不同配置对转换器性能的影响在PLECS仿真环境中得到验证。 PLECS 仿真结果针对传统配置和建议配置进行了实验验证，突出了转换器性能的改进。