Medium-Frequency Transformer for SST Applications: Design and Optimization

This work presents a downscaled validation of a medium-voltage, medium-frequency transformer (MFT) concept designed for high-current operation on the secondary side using multiple parallel paths. The design is based on a modular winding approach, which simplifies the construction process and conductor placement on the bobbin. A systematic design and optimization procedure is developed, combining analytical calculations and finite-element simulations to explore the mass–efficiency tradeoff and to select a candidate design that meets specified leakage inductance and loss targets. The developed prototype serves as a proof of concept, demonstrating that the electrical, magnetic, and insulation requirements of the full-scale MFT can be effectively verified at reduced power levels. The fabricated prototype is tested under short-circuit and partial discharge conditions. The impedance measurements confirmed the expected resonance behavior, and the partial discharge test results verified sufficient insulation performance under high-voltage stress. The results provide experimental evidence for the scalability and feasibility of the proposed transformer design and offer guidelines for the use of 3D-printed supports, grain-oriented electrical steel cores, and windings in medium-voltage, MFT systems for hydrogen production applications.