A novel transformer winding design strategy for efficiency improvement and harmonic suppression in industrial power system

Large-power industrial power supply system is generally recognized as high energy-consuming, while the rectifier transformer is the key for efficiency promotion. This article proposes a novel transformer winding design strategy with the aims of harmonic elimination and loss reduction. By means of the innovative impedance matching design, the harmonic magnetic potential self-balance between the secondary windings is realized for harmonic suppression. Considering the impedance constraint and the margin of structural parameters, the method of resistance loss reduction is explored for the proposed transformer by optimizing the dimension parameters. The transformer-filter combination is first modeled to reveal the filtering principle and obtain the impedance precondition. Then, the transformer efficiency is optimized within the constraints. At last, the transformer prototype together with the power supply system is tested. The experimental results show that the transformer efficiency can be improved by 0.81%, and the current total harmonic distortion at primary side is dropped by 50%.