Simulation and Experimental Research on Cooling Performance of Fully-Immersed Evaporative Cooling High-Frequency Transformer

Efficient and reliable cooling scheme design is non-trivial for high-power high-frequency transformer (HFT). Traditional air cooling HFT faces the problem of low heat dissipation efficiency and high temperature rise. To tackle this problem, fully-immersed evaporative cooling technology is applied in the cooling of HFT in this paper. A fully-immersed evaporative cooling HFT prototype and two air cooling HFT prototypes are made. The power losses of HFT are calculated. A finite element (FE) simulation model for the fully-immersed evaporative cooling HFT is established to calculate the steady state temperature distribution. A HFT temperature test platform is built to measure HFT temperature rise. The proposed FE model can accurately calculate the steady-state temperature of fully-immersed evaporative cooling HFT. In addition, the temperatures of evaporative cooling HFT and air cooling HFTs are compared. Experimental results show that evaporative cooling technology can significantly decrease the steady-state temperature rise of HFT and improve the uniformity of HFT temperature distribution.