Design of a 100 kVA Medium-Frequency Transformer with a Wound Amorphous Core for an EV Charging Station

This study introduces a preliminary design of a 100 kVA single-phase transformer integrated into a Dual Active Bridge (DAB) converter, a key component for enabling galvanic isolation in DC-DC conversion stages. Such applications play a pivotal role in supporting a sustainable energy transition, including automotive charging stations, renewable energy systems, railway traction, and advanced power supply units. The design methodology combines a finite element method (FEM) simulation-based analysis with experimental validation through prototype testing. The investigation explores multiple construction configurations, with particular emphasis on the application of amorphous ribbon materials for medium-frequency(MF) operation. The study examines both the potential benefits and constructive limitations of this approach, providing valuable in-sights for advancing transformer technology in high-performance power electronic systems.