A comprehensive design approach for a three-winding planar transformer

Abstract

In this paper, a new three-winding planar transformer design with the integrated leakage inductor is proposed for a triple-active-bridge converter. It enables two output voltage levels: a high voltage (HV) output port and a low voltage (LV) output port. The primary and secondary windings are split unevenly in both side legs while the tertiary winding is connected in parallel. The unique winding configuration enables: (i) enhanced efficiency with low volume; and (ii) suppressed parasitic capacitances. Detailed transformer reluctance and loss models are developed in the design process. The core geometry is optimized using a reluctance-model-based mathematical computation. Moreover, comprehensive high-fidelity simulations are conducted to analyse the trade-offs among parasitic capacitances, losses, and inductances. The customized core and the non-overlapping winding boards are assembled, characterized, and tested under various power flow conditions.