Design optimisation of a high-power DC-DC power converter with a high-frequency rotary transformer for aerospace applications

This thesis presents the design, optimization, and testing of a high-power density DC-DC converter incorporating a high-frequency radial-type rotary transformer (RT) for contactless power transfer (CPT) in aerospace applications. Aimed at transferring up to 800 V, 40 kW of power within the confined space and operating at ambient temperatures up to 120°C, the research addresses the challenges of integrating CPT systems in high-power, high-temperature environments. The study investigates two converter topologies—Dual Active Bridge (DAB) and Phase-Shifted Full-Bridge with Capacitor Filter (PSFB-C)—to determine their suitability for integration with the RT. Comprehensive methodologies were employed, including the development of high-fidelity finite element models (FEM) for the proposed RT topologies, exploration of key design parameters such as frequency on weight, size, and efficiency, and the creation of equivalent circuit and thermal models for the RT. The research encompasses analytical, simulation-based, and experimental approaches to ensure thorough validation of the models and designs.