전기자동차용 50 kW 변압기의 설계를 위한 전자기-열 수치해석 파라미터 연구

The transformer is a crucial component in the power conversion circuit of electric vehicles. Given the spatial constraints within electric vehicles, the transformer design must be compact while maintaining the required inductance and thermal stability. In this study, we explore volume reduction strategies for a 50 kW transformer while ensuring an optimal cooling design using an electromagnetic–thermal numerical analysis. The transformer cooling mechanism featured a molding housing that encapsulated the transformer, complemented by convective cooling channels. Our numerical methodologies were validated with experimental results. Through this approach, we achieved a 36.2% volume reduction in the transformer within the desired operating range of inductance. Moreover, our findings revealed that, despite a higher electromagnetic loss, an aluminum housing significantly outperformed bakelite housing in heat dissipation. Based on this investigation, we suggest design guidelines for transformers intended for future electric vehicles.