Design Optimization of Modular High-Frequency Transformer for Fast EV Charger Using Ansys Software Tools

In this paper, the design of a modular high-power transformer for constant gain LLC converter used in 2-stage Fast EV charger is investigated. Two modular approaches are compared, input-parallel-output-parallel (IPOP) and input-series-output-parallel (ISOP) transformers with stacked cores. The Pareto optimization of total power losses and volume is applied to evaluate different modular designs. The design method based on Ansys PExprt software tool is developed and explained. Finally, the selected design is validated by 3D FEA thermal simulation in ICEPAK.