Titova T.S., Evstafyev A.M., Kolpakhchyan P.G., Telichenko S.A., Nikitin V.V. Optimization of Pulse Transformer Design for Charge-Discharge Control System at Vehicle On-Board Electric Power Storage Batteries

Abstract

Full Text

The paper is concerned with the development of a charge-discharge system for onboard electric energy storage devices in vehicles. Since galvanic isolation of the circuits is essential, a system with double power conversion and isolation transformers is advisable. The converters in this system are based on IGBT modules with a switching frequency of up to several kilohertz. In this case, it is advisable to use toroidal isolation transformers. The voltage at the output of the charging system converters has a rectangular shape, which leads to a non-sinusoidal change in the magnetic induction in the magnetic cores of the isolation transformers. In this case, the generalized Steinmetz formula is used to more accurately account for magnetic losses. The article describes a methodology for determining the geometric ratios and mass of toroidal isolation transformers, losses in the windings and magnetic system and estimating the surface overheating temperature. An analysis is provided of the conversion frequency and the transformer geometric dimensions influence on the magnitude of losses and its heating. It has been shown that for a 60 kW transformer, it is rational to use electrical steel with a sheet thickness of 0.18 mm and a conversion frequency of 2000 Hz, which ensures the best weight and size parameters.

Keywords

Charge-discharge system of onboard storage devices, toroidal transformer, calculation of magnetic losses, optimization of geometric relationships of a toroidal transformer

Tamila S. Titova D.Sc. (Engineering), Professor, Department Head, Department of Technosphere and Environmental Safety, Emperor Alexander I St. Petersburg State Transport University, Saint Petersburg, Russia, https://orcid.org/0000-0002-9328-0835

Andrey M. Evstafyev D.Sc. (Engineering), Professor, Department Head, Department of Electrical Haulage, Emperor Alexander I St. Petersburg State Transport University, Saint Petersburg, Russia, This email address is being protected from spambots. You need JavaScript enabled to view it., https://orcid.org/0000-0003-1417-977X

Pavel G. Kolpakhchyan D.Sc. (Engineering), Associate Professor, Professor, Department of Electrical Haulage, Emperor Alexander I St. Petersburg State Transport University, Saint Petersburg, Russia, This email address is being protected from spambots. You need JavaScript enabled to view it., https://orcid.org/0000-0003-1669-2075

Stanislav A. Telichenko Senior Lecturer, Department of Electrical Haulage, Emperor Alexander I St. Petersburg State Transport University, Saint Petersburg, Russia, This email address is being protected from spambots. You need JavaScript enabled to view it., https://orcid.org/0009-0002-5271-8949

Viсtor V. Nikitin D.Sc. (Engineering), Associate Professor, Professor, Department of Electrical Haulage, Emperor Alexander I St. Petersburg State Transport University, Saint Petersburg, Russia, This email address is being protected from spambots. You need JavaScript enabled to view it., https://orcid.org/0000-0002-5699-0424

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Titova T.S., Evstafyev A.M., Kolpakhchyan P.G., Telichenko S.A., Nikitin V.V. Optimization of Pulse Transformer Design for Charge-Discharge Control System at Vehicle On-Board Electric Power Storage Batteries. Elektrotekhnicheskie sistemy i kompleksy [Electrotechnical Systems and Complexes], 2025, no. 4(69), pp. 15-22. (In Russian). https://doi.org/10.18503/2311-8318-2025-4(69)-15-22

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