Prototype design for a high-voltage high-frequency rectifier transformer for high power use

The traditional high-voltage high-frequency transformer has a drawback of low power density owing to the rigorous requirements of high-voltage insulation. This study proposes a new configuration for the magnetic core based on planar EE cores. The parallel connection of planar cores was adopted as a unit, and several units were cascaded to form the high-voltage transformer. The electrical potential distribution of the proposed transformer is more uniform than a traditional transformer, and enables a decrease in the insulation distances. The mechanical configuration of a laboratory prototype is discussed, as well as the electrical, parasitic and thermal behaviours. A prototype transformer has been designed and built with the following characteristics: 30 kV output voltage, 60 kW output power and 20 kHz inverting frequency. The transformer was tested and found to have an efficiency of better than 96%. Compared with traditional high-voltage transformers, this transformer has good thermal behaviour, good line insulation properties and a high power density.