Simulation of a Custom Core, 15kV Isolated Gap Transformer Optimized for High Power Density

Designing medium voltage transformers with a high power density requires a multidisciplinary effort, combining electric field stress control, magnetics design, and thermal mitigation. In this paper, an interleaved, isolated core-gap transformer is optimized for power density and losses using a genetic algorithm. The transformer construction is based on a 15 kV partial discharge (PD) free isolation structure that separates the high voltage and low voltage cores. Included is an overview of the Pareto front designs, showing the trade-offs fundamental to the isolated gap topology. The result is three custom core transformer design points that show the trade-offs of a planar isolation system. An experimental prototype is constructed using off-the-shelf components to validate the simulated results.