1 MHz Isolation Transformer Design, Using the Core Geometry Approach

In this paper, the design of a 1 MHz isolation transformer using a core geometry optimization approach is presented. The transformer is designed with a unity turn ratio, making it ideal for isolation transformers in dual active bridge DC-DC converters. Key parameters, including input power, frequency, regulation, maximum duty cycle, window utilization, operating flux density, waveform factor, minimum input voltage, and efficiency, are optimized. The optimization process involves the random generation of these parameters within specified ranges, followed by detailed design calculations to minimize total loss and maximize power density and efficiency. The method utilizes MATLAB and Python for modeling and Monte Carlo simulations, ensuring a comprehensive analysis of the transformer performance. The designed transformer has been tested with simulations and experimental results on a 250W model, verifying the effectiveness of the proposed method. Detailed design considerations, numerical values, and experimental results are included, demonstrating significant improvements in transformer performance. This method provides valuable insights for the design of high-frequency isolation transformers, contributing to the advancement of efficient and reliable systems. The comprehensive approach and thorough validation underscore the practical applicability and robustness of the proposed design optimization technique.