Design and Verification of a Medium-Frequency

Transformer in a Three-Phase Dual-Active Bridge

DC-DC Converter for Medium-Voltage Grid
Connection of Offshore Wind Farms
Murat Kaymak and Rik W. De Doncker Takushi Jimichi
E.ON Energy Research Center Advanced Technology R&D Center
Institute for Power Generation and Storage Systems Mitsubishi Electric Corporation
RWTH Aachen University Hyogo, Japan
Email: post [email protected] Email: [email protected]

Abstract—This paper covers the development of a medium- and inductors with nanocrystalline cores [2]. Commonly, these
frequency transformer (MFT) for a high-power three-phase dc- magnetic components are the largest components in high-
dc converter submodule of a modular converter system to inter- power dc-dc converters, leading to a major proportion of
connect offshore wind farms with medium-voltage dc collector
grids. Here, a low-loss MFT is needed. Therefore, a new MFT cost, volume and efficiency loss [3]. In recent years, many
design concept for a high-efficient dc-dc converter is proposed. papers realized SST prototypes with MFTs [3]–[5]. In former
To meet the required series inductance of the converter, usually publications [2], [6], the authors have discussed the design
additional bulky inductors are used in series to the MFT. This and experimental verification of the first MFT prototype with
paper presents the design of a MFT with an increased leakage available nanocrystalline magnetic cores and standard coaxial
inductance avoiding the extra series inductor to realize a high-
efficient and compact MFT at the same time. Additionally, the winding configuration. This MFT prototype did not provide
MFT needs to withstand a voltage of ±25 kV of the dc collector sufficient leakage inductance to realize the desired series
grid. These requirements are satisfied by a sectionalized stacked inductance for the converter. Hence, additional inductors were
winding structure, an encapsulated secondary winding with resin used leading to an inevitable extra power loss and mass of the
and by using available nanocrystalline cores. The electrical dc-dc converter submodule. Besides, the insulation level of
and thermal performance of the realized MFT prototypes are
demonstrated. this particular MFT is only ±1 kV. This paper now discusses
Index Terms—Transformer design, dc-dc converter a suitable MFT design for a 10 MW ±1 kV/±25 kV SST dc-
dc converter. The construction of the new MFT together with
size and shape limitations of available nanocrystalline cores is
I. I NTRODUCTION
challenging due to the high-power application and the required
CO2 targets, nuclear as well as coal phase-out require MV static insulation level of ±25 kV on the secondary side
the expansion of renewable energy sources. From technical of the MFT. A design methodology and a construction of the
point of view, the infrastructure of the electric grid system revised single-phase shell-type MFT with enhanced leakage
has to be adapted according to decentralized energy sources inductance are presented avoiding additional inductors and
and large-scale sustainable power generation stations such obtaining the static insulation level of ±25 kV. The paper is
as offshore wind farms. To meet the new requirements in organized as follows. Following the introduction in Section I,
terms of efficiency and flexibility for future electric grid Section II introduces the converter system. Section III explains
infrastructure, medium-voltage (MV) dc collector grids with the MFT design with specifications, geometry and simulations.
power electronic converters are the first step to connect the Finally, section IV highlights the experimental test of both
energy of offshore wind farms [1], [2]. In this work, a solid- MFT prototypes in a DAB3.
state transformer (SST) as a promising technology is uti-
lized in a multiple-submodule converter structure with input- II. S YSTEM C ONFIGURATION
parallel output-series (IPOS) connection to link wind turbines The modular SST is presented in Fig. 1 with parameters
directly to the MVDC grid with ±25 kV voltage level [2]. in Table I. The SST consists of 50 converter submodules to
A multiple-submodule structure is selected due to higher achieve the MV dc collector grid voltage of ±25 kV. The
reliability, modular design, uncomplicated thermal manage- SST submodule consists of a three-phase Dual-Active Bridge
ment and feasible utilization of size-limited low-loss magnetic (DAB3) dc-dc converter. This DAB3 features an input and
components such as medium-frequency transformers (MFT) output bridge with power electronic switches, a MFT and, if

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 idc,p Lser Lser idc,s TABLE I
2u u 2 S PECIFICATION OF THE SST DC - DC CONVERTER
1p i1p 10p 10s 1s
Udc Np 2p i2p 2s Ns Udc Property Value
Udc,in 3p i3p 3s Real power PN 10 MW
0p 0s SST Input dc-voltage Udc,in = Udc 1 kV
idc,p Lser Lser idc,s converter Output dc-voltage Udc,out ±25 kV
2u u 2
i1p 10p 10s Module count N 50
1p 1s
Udc Np 2p i2p 2s Ns Udc Real power PSM 200 kW
3p i3p 3s Apparent power SSM 243 kVA
0p 0s Udc,out SST Input/output dc-voltage USM,in /USM,out 1 kV/1 kV
submodule Frequency fN 1.55 kHz
Voltage ratio n 1:1
idc,p idc,s Nominal load angle ϕ π/6
Lser Lser
2u u 2
1p i1p 10p 10s 1s
Udc Np 2p i2p 2s Ns Udc
3p i3p 3s Although several degrees of freedom for the modeling of
0p 0s
the MFT are available, the design and construction of the
MFT are limited by system specifications, size constraints and
Fig. 1. The proposed converter structure and DAB3 topology of the MV SST
manufacturing feasibility [2], [3], [5].
A. Transformer Core
necessary, extra inductors in the ac link. The detailed design of
Considering the large number of DAB3 submodules in the
the SST submodule is described in a previous work [2]. The
modular SST, a compromise between low submodule volume,
ac-link representation of the DAB3 comprises an equivalent
weight and high efficiency is desired. Nanocrystalline iron
series inductance Lser and an ideal transformer (see Fig. 1).
material has lower specific losses than ferrite or amorphous
Power PSM is transferred over Lser from primary to secondary
materials. The saturation level of 1.2 T is better applicable for
side by setting a phase-shift ϕ between the input and output
high power applications, thus, benefits like low volume, weight
bridge [7].
and high efficiency of the MFT can be achieved. The authors
2
Udc 2ϕ ϕ2 selected a off-the-shelf high-efficiency nanocrystalline tape-
PSM = ·d·( − ) for 0 ≤ ϕ ≤ π/3 (1)
2πfN Lser 3 2π wound cut core Vitroperm 500F with dimensions of (31.6 mm-
115 mm-198 mm). The geometric and magnetic properties of
Here, Udc is the nominal dc-link voltage of the converter
the single nanocrystalline core element are listed in Table II.
submodule, d is the dc-voltage deviation between input and
For this reason the available winding window area WA and
output bridge and fN is the operating frequency. So, the DAB3
the width of the core area are fixed. However, the length of
requires a minimum value of Lser in the ac-link. Generally,
the core area is a linear parameter of the number of parallel
if the MFT is designed for high-efficiency and low volume
connected core elements. With the help of the datasheet, the
by default, the short-circuit inductance Lps,σ , i.e. leakage
parameters kc , αc and βc of the original Steinmetz equation
inductance, is significantly lower than the required Lser . Con-
(OSE) to calculate the specific core loss density pc are derived.
sequently additional inductors must be installed in series to the
MFT in the ac-link [8]. However, additional components in pc = kh f α B̂ β f (2)
high-power converters usually lead to lower efficiency, higher
mass and lower reliability. For a quantitative comparison, B. Transformer Winding
this work demonstrates both MFT options with and without The medium-frequency operation of the MFT leads to addi-
additional inductors while using the same nanocrystalline core tional ac winding loss due to induced eddy currents by skin and
to realize a sufficient value of Lser . Connecting the SST to proximity effect. Reducing the ac winding loss is possible by
the MV dc collector grid via Udc,out as depicted in Fig. 1, the selecting appropriate winding types such as foil and litz-wire
static voltage of ±25 kV is applied on the secondary side of
the MFT.
TABLE II
III. M EDIUM -F REQUENCY T RANSFORMER D ESIGN T RANSFORMER C ORE E LEMENT

Operating a transformer at higher frequencies with square- Property Value

Nanocrystalline core Vitroperm 500F
wave voltages and non-sinusoidal currents results in an in-
Winding window area WA 44.84 cm2
creased loss density, thermal demand and electrical stress Core cross-cection Afe 11.88 cm2
of the insulation material. Especially in the examined fre- Core stacking factor kf 0.669
quency range between 600 Hz and 5 kHz [2] at a high power Saturation flux density Bsat 1.2 T
Core loss constant kc 10−5
of 200 kW and the static voltage potential of ±25 kV, a Core loss frequency coefficient αc 1.53
suitable choice of core material, core geometry, winding type, Core loss flux density coefficient βc 2.72
winding arrangement and cooling approach is mandatory. Core permeability µc > 10 000

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Primary TABLE IV
S PECIFICATION OF THE SINGLE - PHASE MFT
winding Secondary
winding Property Value
Primary Real Power per phase PMFT 66.67 kW
Waveform coefficient Kν 4.2426
Secondary winding Flux density B̂ 1T
winding Insulation distance dins < 6 mm
Switching frequencies fsw 600 Hz − 5 kHz
(a) Coaxial winding (b) Stacked winding
Power factor λ PMFT/(Urms ·Irms )
√
0.91391
Fig. 2. Shell-type MFT winding configuration with cast resin RMS voltage Urms 2/3Udc 471.41 V
RMS current Irms PMFT/(Urms ·λ·ν) 156.31 A
Apparent power Srms Urms · Irms 73.69 kVA
Total apparent power Stot 2·PMFT/(λ·ν) 73.69 kVA
windings. In the majority of MFTs, the winding configuration Area product method Ap Shell-type MFT Core-type MFT
is in concentric arrangement as depicted in Fig. 2a. Using Current density coefficient Kj 534 468
the same core geometry and shape, an alternative winding Exponential coefficient x 1.14 1.16
Current density Jrms,c 4 A/mm2 4 A/mm2
configuration in sandwich i.e. stacked arrangement is possible,
as shown in Fig. 2b [9]. The winding loss of the transformer
is determined by the formula based on the modified Dowell’s E. MFT Design concept
equation characterizing the ratio between ac and dc winding
resistance [10]. The specifications of one single-phase MFT are listed in
Table IV. Three single-phase MFTs will be connected in
C. Transformer Insulation star point. The shape of the available nanocrystalline tape-
wound cut core provides two possibilities to arrange the
To ensure the minimum insulation level of ±25 kV a transformer core elements and windings: Core-type and shell-
standard windings for 1 kV operating voltage is encapsulated type configuration. With increasing switching frequency fsw ,
by additional insulating material. These insulating materials the transformer size is reduced yielding higher power loss
can be classified into liquids (e.g. oil) and dry-type ma- density, if the flux density B̂ is kept constant and the current
terials (e.g. resin). An easy installation of a compact dry- density Jrms is increased. The design challenge is now to
type transformer is more suitable for an indoor application keep a specified compromise between efficiency, size, thermal
such as a wind turbine cabin. So, double-component (2-K) performance and insulation coordination. The design of the
Epoxy (EP) and Polyurethane (PUR) cast resin are chosen as MFT is realized by two different design approaches. The first
adequate insulating material. In Table III properties of the resin design approach A is made by means of the area product
materials are listed. method with adapted equations out of empirical transformer
data [12]. In Table IV, the parameters of the empirical formula
D. Series Inductance for the dimensional analysis are listed. The second design
Literature already proposes preferred values for the required approach B is composed by standard equations derived out
series inductance Lser [7]. of geometrical constraints, amperes law and general voltage
2
formula of the transformer. The factor kcu describes the
Udc,in 7π supposed copper fill factor of the winding window WA . The
Xser = ωLser = 0.38 · · (3)
PSM 36 exponent x and the constant Kj are taken from the dimensional
Two options exist to realize this Lser . Either the MFT is de- analysis in [12]. Initially the area product Ap is calculated for
signed for high-efficiency with low leakage inductance Lps,σ , both design cases separately.
!x
so an extra inductor Lext is placed in series to the MFT. Or Stot
the MFT is designed with increased leakage inductance Lps,σ Design A : Ap = Ac · WA = (4)
avoiding additional components by integrating Lser into the Kν B̂fsw kcu kf Kj
MFT [11]. The current density Jrms is from the dimensional analysis [12]:
Jrms = Kj · Ap−0.125 · 10−2 [A/mm2 ] (5)
TABLE III
P ROPERTIES OF RESIN MATERIAL In Design B the current density Jrms,c is a constant value.
Sika Axson Wevo Stot
Property Design B : Ap = Ac · WA = (6)
XE2498/1 R&D Wevopur 512 FL Kν B̂fsw kcu kf Jrms,c
Material Epoxy (EP) Polyurethan (PUR)
Temperature range θ -40 ◦C/ + 130 ◦C -40 ◦C/ + 130 ◦C A sufficient number Nc of core elements have to be assembled
Specific weight γ 1.72 g/cm3 1.53 g/cm3
Thermal conductivity λ 1.1 W/mK 0.8 W/mK
according to the needed core cross-section Ac .
Dielectric loss (tan δ) - 0.12 (50 Hz) Ac Ap
Dielectric strength E 22 kV/mm 38 kV/mm Nc = · kf Ac = (7)
Afe WA

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 400 160
Loss MethodA
350 Loss MethodB
140
Power loss in W

300 Mass MethodA 120

Mass in kg
Mass MethodB
250 100
200 80
150 60
100 40
50 20
0 0
0 1 2 3 4 5 0 1 2 3 4 5 0 1 2 3 4 5 0 1 2 3 4 5
Frequency in kHz Frequency in kHz Frequency in kHz Frequency in kHz
(a) Core-type MFT 1 (b) Shell-type MFT 1 (c) Core-type MFT 2 (d) Shell-type MFT 2
Fig. 3. Design results of MFT 1 and MFT 2 with litz-wire winding

Typical litz-wire copper windings with defined strand diameter of MFT 2 are a bit increased compared to MFT 1, this one
dis are utilized. The number of turns Nw and the conductor needs an additional inductor in series due to its insufficient
cross section area Acu is calculated with the voltage equation: Lps,σ as shown in Fig. 4. With selected design method A, the
Urms Irms Lps,σ of MFT 2 is still lower than the required Lser due to the
Nw = Acu = (8) fixed core shape, but is sufficient enough for smooth control
Kν B̂fsw kf Ac Jrms
of the submodule power flow by adjusting the load angle ϕ in
Hence, with the winding loss Pw,ps the total transformer loss Equation (1). So, in the next step the inductor is designed to
PMFT is given as follows: check MFT 2 in relation to the magnetic component system
MFT 1 + Inductor.
PMFT = Pw,ps + Pc = Pw,ps + Nc Vc pc (9)
All design computations were executed automatically by a F. Design results
recursive program considering further geometrical restrictions. In Fig. 5c and Fig. 5d, the combined power loss and mass
The effect of the defined frequency range fsw on the power of MFT 1 with series inductor are presented. Compared to
loss and mass of the MFT 1 (coaxial winding) and MFT 2 MFT 2, the total mass and the power losses are essentially
(stacked winding) with litz-wire windings are documented in higher. Hence, from design and reliability point of view, the
Fig. 3. Especially in case of MFT 2, the power losses of design single magnetic component solution (MFT 2) is beneficial in
method B are considerably higher compared to design method comparison to the MFT 1 with extra series inductor. Table V
A due to the higher current density Jrms,c . But, the mass shows the Design results with most of the relevant parameters
differences between both design methods are lower. So, design for MFT 1, the extra inductor and MFT 2 at the selected
method A is considered for high-efficient MFT realization. switching frequency fN .
In most frequency cases, the shell-type MFT offers slightly
decreased power loss and mass, because the resulting cuboid G. Simulation results
shape of the MFT provides shorter winding length in contrast The detailed geometries of the selected MFTs and inductor
to the core-type MFT [2]. Although the power loss and mass are simulated in magnetic domain with 2D FEM software
to check the winding power losses and achieved leakage
inductances Lps,σ in short-circuit test condition. Considering
250
Leakage inductance in µH

225 MFT 1 MethodA

MFT 1 MethodB
200
175
MFT 2 MethodA TABLE V
MFT 2 MethodB D ESIGN RESULTS WITH LITZ - WIRE WINDING AT fN = 1.55 kHz
150 Required Lser
125 Parameter MFT 1 MFT 2 Inductor
100 Core configuration Shell-type Shell-type Core-type
75 Winding configuration Coaxial Stacked Coaxial
50 Number of core elements Nc 12 12 4
25 Number of winding turns Nw 8 7 14
0 Flux density B̂ in T 0.94 1.07 0.44
0 1 2 3 4 5 Current density Jrms in A/mm2 1.79 1.77 1.81
Copper area Acu in mm2 86.95 88.31 86.4
Frequency in kHz Winding diameter dcu in mm 14.17 14.28 14.13
Strand diameter dis in mm 0.2 0.2 0.2
Fig. 4. Leakage inductance Lps,σ of MFT 1 and MFT 2 Number of strands k 2715 2757 2698

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 400 160
Loss MethodA
350 Loss MethodB
140
Power loss in W

300 Mass MethodA 120

Mass in kg
Mass MethodB
250 100
200 80
150 60
100 40
50 20
0 0
0 1 2 3 4 5 0 1 2 3 4 5 0 1 2 3 4 5 0 1 2 3 4 5
Frequency in kHz Frequency in kHz Frequency in kHz Frequency in kHz
(a) Core-type inductor (b) Shell-type inductor (c) Core-type MFT 1 + inductor (d) Shell-type MFT 1 + inductor
Fig. 5. Design results of Inductor and MFT 1 + Inductor with litz-wire winding

the 3D structure with winding end turns and axial transformer As visualized in Fig. 6f and Fig. 8b, MFT 2 and the induc-
symmetry, the magnetic field simulation within centrical cross tor produce the highest worst-case hot-spot temperatures of
section is performed by a planar front view model and an about 350 K in the windings. The simulated maximum electri-
axially symmetric side view model as shown in Fig. 6a, 6b, 6e cal field strengths in Fig. 6d and Fig. 6h are around 15 kV/mm
and 6f. By simulations in electrical and thermal domain, at the smallest radius of the winding corners with grounded
the maximum electrical field strength in the resin material core. The design and FEM simulation results of power loss,
with 6 mm insulation distance and the thermal performance mass and achieved leakage or series inductance are presented
i.e. hot-spot temperatures of the magnetic components are in Table VI. The FEM results match the analytical calculations
analyzed. The isotropic thermal simulations are performed within reasonable deviations.
with constant heat convection coefficient of 10 W/m2 K at free
convection air cooling and an ambient temperature of 313.5 K.

A
18 mm A
15 mm 325 K kV
15 mm
A A
14 mm 12 mm 323 K kV
11 mm

A 320 K kV
A
10 mm 8 mm 8 mm

A A 316 K kV
6 mm 4 mm 4 mm

A A kV
0 mm 0 mm 313 K 0 mm
~
(a) Magnetic field H: ~
(b) Magnetic field H: (c) Thermal flow: ~ MFT 1 (front view)
(d) Electrostatic field E:
MFT 1 (front view) MFT 1 (side view) MFT 1 (front view)
A
51 mm A
28 mm 341 K kV
12 mm

A
40 mm A
22 mm 334 K
kV
9 mm

A kV
26 mm A
16 mm 328 K 6 mm

A kV
15 mm A
8 mm 320 K 3 mm

A A kV
0 mm 0 mm 313 K 0 mm
~
(e) Magnetic field H: ~
(f) Magnetic field H: (g) Thermal flow: ~ MFT 2 (front view)
(h) Electrostatic field E:
MFT 2 (front view) MFT 2 (side view) MFT 2 (front view)
Fig. 6. FEM simulations of MFT 1 and MFT 2 in magnetic, thermal and electrostatic domain

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 1.1 T 352 K TABLE VII
S PECIFICATION OF THE MFT AND I NDUCTOR WINDINGS

0.9 T 342 K Property Litz-wire (Type 1) Litz-wire (Type 2)

Manufacturer Sofilec Sofilec
Material Copper Copper
0.6 T 332 K Copper area Acu 33 mm2 89.54 mm2
Height hcu 8 mm 11.8 mm
Width wcu 8 mm 14 mm
Strand diameter dis 0.2 mm 0.2 mm
0.3 T 324 K Number of strands k 1051 2850
Specific weight mw,sp 0.29 0.29 kg/m 0.86 0.86 kg/m

0T 313 K
~ Inductor
(a) Magnetic field H: (b) Thermal flow: Inductor
Fig. 8. FEM simulations of inductor in magnetic and thermal domain results in the DAB3 at rated frequency fN . Now, principle
construction steps of the new shell-type MFT 2 with stacked
TABLE VI winding configuration and cast resin insulation on the HV
S IMULATION RESULTS FOR MFT AND I NDUCTOR AT fN = 1.55 kHz
secondary side are described. Due to the small winding area
of the core, the construction of high-efficient windings with
Parameter MFT 1 Ind MFT 1+Ind MFT 2
large copper cross-section and required insulation distance dins
Winding loss Calc. 51.16 30.27 81.43 67.31 is challenging. In accordance with the design requirements,
Pw in W FEM 50.75 24.24 74.99 56.89
Core loss Pc in W 23.01 7.67 30.68 23.01 suitable litz-wire winding (Type 2) for MFT 2 are custom-built
Total loss Calc. 74.17 37.94 112.11 90.31 by a wire manufacturer (Table VII). Due to availability rea-
Pac in W FEM 73.76 31.91 105.67 79.90 sons, first prototype MFT 1 and inductor were built with three
Core mass mc in kg 30.24 10.08 40.32 30.24
Total mass mt in kg 39.21 15.12 41.11 54.33 litz-wire windings (Type 1) connected vertically in parallel as
Inductance Lσ Calc. 7.03 119.18 126.21 69.37 single layer winding. First, the litz-wire windings are manually
in µH FEM 5.78 108.26 114.04 55.28 built with a self-made appliance and auxiliary coil former
to keep the geometrical design and restrictions (Fig. 7a).
Next, the windings are immersed in 1-K impregnating agent
H. MFT Construction (Fig. 7b) and tempered for mechanical stability and improved
In [6] the MFT 1 prototype with coaxial winding configu- dielectric strength. Afterwards, the HV windings are wrapped
ration and extra inductor was initially presented with first test with black semi-conductive tape for smooth electrical fields

(a) Auxiliary coil former and winding shape (b) HV winding after 1-K impregnation (c) HV winding with semi-conductive tape

(d) HV winding in 2-K resin (e) Primary winding in MFT (f) Finished MFT 2
Fig. 7. Main construction steps of MFT 2 (Prototype 2)

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avoiding partial discharges and corona (Fig. 7c). Fig. 7d served from secondary side is 26 % higher compared to the
depicts the finished secondary HV winding molded with PUR primary side. Additionally, the series inductors are installed
resin (Table III) by using a 2-K casting system with mixers on the primary side of the ac-link yielding an unsymmetrical
in a vacuum chamber. The primary winding is inserted into ac-link. Both factors together produce a residual flux in the
the winding area (Fig. 7e), the HV winding is mounted and MFT core, a voltage drop over Lps,σ and modified no-load
finally the parallel core elements are fixed together (Fig. 7f). voltage ratio n generating a high no-load reactive current
to the secondary side together with undesired active power
IV. E XPERIMENTAL R ESULTS flow in the dc-link (Fig. 9b). The expected no-load reactive
The experimental setup and performance of the DAB3 dc-dc current is calculated to be ≈ 100 times lower. Furthermore,
converter with three-phase star connected single-phase MFT dc-voltage components at the MFT winding terminals push
prototypes are presented in Fig. 9. Fig. 9a shows the first the magnetic core into the highly non-linear region of its
prototype of the DAB3 ac-link (Prototype 1) with MFT 1 and hysteresis curve. Depending on the different switching states
modified series inductors [6]. The inductors are designed with of the DAB3, an alternating core saturation between the three
plastic fixtures and less core elements yielding a peak flux MFTs occurs, first mentioned and analyzed in [13]. This effect
density B̂L close to 1 T [6]. The new prototype of the DAB3 is visible in the no-load MFT terminal voltages in Fig. 9b
ac-link (Prototype 2) with MFT 2 is depicted in Fig. 9d. The and Fig. 9e as distorted waveform in contrast to the ideal
dielectric strength capability of the secondary HV winding is step-wise DAB3 voltage waveform. As a consequence, the
proved with the high insulation tester Megger MIT30 operated star-to-neutral point voltages of primary and secondary side
up to 30 kV between winding terminal to ground. In Fig. 9, the shift reflecting a superimposed second harmonic on the MFT
MFT terminal phase-to-star point voltages u10p at the primary terminal voltages. Depending on the sign of the current gradi-
side, u10s at the secondary side as well as the phase currents ent, this reduces or increases the voltage over the magnetizing
i1p and u1s at the primary side are shown at rated Udc,in . First, inductance of the equivalent electrical circuit (EEC), shifting
Fig. 9b and Fig. 9e details the no-load behavior of MFT 1 and the magnetizing current on the hysteresis trajectory into the
MFT 2 at zero phase-shift angle ϕ. Comparing both voltage linear or deeper into the saturation region in the adjacent phase.
waveforms, in case of Prototype 1, higher voltage oscillations Hence, corresponding magnetizing inductances of the phases
and corresponding higher peak voltages are produced due to are changed in opposite direction consequently augmenting the
the increased stray capacitances of the tight winding structure saturation effect. So, by reason of the star-connected phases,
with litz-wire winding (Type 1). Due to the coaxial winding the applied three-phase switching state terminal voltages differ
configuration of Prototype 1, the magnetizing inductance ob- from the ideal condition and produce the distorted MFT

800
u10p ,u10s

400
in V

0 u10p u10p
-400 u10s u10s
-800
300
150
i1p ,i2p
in A

0 i1p i1p
-150 i2p i2p

-300
-200 0 200 400 600 800 -200 0 200 400 600 800
Time t in µs Time t in µs
(a) Prototype 1 with MFT 1 + Inductor (b) Prototype 1: No-load test (c) Prototype 1: Full-load test

800
u10p ,u10s

400
in V

0 u10p u10p
-400 u10s u10s
-800
300
150
i1p ,i2p
in A

0 i1p i1p
-150 i2p i2p

-300
-200 0 200 400 600 800 -200 0 200 400 600 800
Time t in µs Time t in µs
(d) Prototype 2 with MFT 2 (e) Prototype 2: No-load test (f) Prototype 2: Full-load test
Fig. 9. Experimental DAB3 setup and measurement results of Prototype 1 with MFT 1 + inductor and Prototype 2 with MFT 2

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 MFT (MFT 1) prototype with coaxial winding configuration
requires extra inductors to achieve the required series induc-
tance of the ac-link. To avoid these extra inductors, a second
MFT (MFT 2) prototype with integrated series inductance by
using a stacked winding configuration in the same core is built.
Impregnated and cast resin-filled secondary windings of the
MFT 2 guarantee the static MV capability of ±25 kV. The
design and FEM simulations of the prototypes are described
in detail. The construction of MFT 2 is presented. Electrical
(a) Temperatures of MFT 1 + inductor (b) Temperatures of MFT 2
and thermal measurements are performed at no-load and full-
Fig. 10. Thermal infrared image of Prototype 1 and 2 at full-load test load operation. The MFT 2 features superior performance by
achieving sufficient integrated inductance, lower peak voltages
and the desired voltage ratio with ideal current waveforms in
voltage waveforms. In comparison to Prototype 1, the absence
contrast to MFT 1 with extra series inductors.
of the inductor and the stacked winding configuration of MFT
2 in Prototype 2 make an ideal symmetric ac-link with ideal R EFERENCES
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