Design of an Experimental Approach for Characterization and Performance Analysis of High-Frequency Transformer Core Materials

Abstract

High-frequency transformer core materials are used in power converter applications due to high efficiency performance. Their volume and weight can be reduced when higher operating frequencies are used but at the expense of an increase in core material losses. Some studies analyzed transformer core material performance by using finite element method (FEM) analysis, while others used an experimental model. This study proposes an experimental approach to compare the high-frequency transformer efficiency performance of different core material types. In this way, newly produced core material performance can be rapidly analyzed by comparing it against a known core material type, thereby resulting in the fast identification of improved core material design. This empirical approach makes use of a standard half-bridge inverter topology to enable an analysis of high-frequency transformer core material efficiency performance. Actual voltage and current measurements are used to determine the efficiency and output power performance throughout a specified constant current load range at different switching frequencies. Initially commercial standard polycrystalline or ferrite E-core materials were used to validate the characterization jig performance measured curve trends. The usefulness of the jig is then demonstrated by comparatively analyzing and then verifying the expected performance difference between polycrystalline and nanocrystalline toroidal core materials.