Partaonan Harahap, Muhammad Imran Hamid, Ariadi Hazmi

A New 12-Phase Toroidal Transformer Design to Improve Efficiency and Power Quality in Electric Vehicle Fast Charging Systems

Introduction

A new 12-phase toroidal transformer design to improve efficiency and power quality in electric vehicle fast charging systems. Discover a new 12-phase toroidal transformer improving EV fast charging efficiency to 98.3%, reducing harmonics & thermal issues, and cutting charging time by 15.6%.

Abstract

Transformers are essential components in electric vehicle (EV) fast charging systems, particularly in ensuring high efficiency and maintaining power quality. This study introduces a new design and implementation of a 12-phase toroidal transformer integrated into a 50 kW fast charging system. The main contribution of this research lies in improving energy efficiency, thermal stability, and harmonic suppression, which are critical challenges in conventional transformer configurations. The proposed transformer was modeled and simulated using MATLAB/Simulink, followed by prototype fabrication and experimental validation. Simulation and test results demonstrated that the 12-phase toroidal transformer achieved an efficiency of 98.3%, representing a 2.2% improvement over a conventional 6-phase configuration. Furthermore, steady-state coil temperature decreased by 10°C, while DC voltage ripple was reduced from 6.7% to 3.2%. Harmonic performance also improved significantly, with Total Harmonic Distortion (THD) dropping from 7.8% to 4.5% at the AC side and from 4.2% to 2.1% after rectification. In terms of charging performance, the system successfully shortened the charging time for an 80% state of charge (SoC) battery from 32 minutes to 27 minutes, a reduction of 15.6%. These findings confirm that the 12-phase toroidal transformer provides a technically reliable and novel solution for next-generation EV fast charging infrastructure, delivering both high efficiency and improved power quality.

Review

This paper presents a compelling new design for a 12-phase toroidal transformer, specifically aimed at enhancing the performance of electric vehicle (EV) fast charging systems. The authors clearly identify critical challenges in conventional transformer configurations, particularly concerning energy efficiency, thermal stability, and the suppression of harmonics, all of which are paramount for robust and reliable EV charging infrastructure. The proposed 12-phase toroidal design is positioned as a novel solution to these issues, promising significant improvements in system efficiency and overall power quality, a timely contribution given the rapid expansion of EV adoption and the increasing demand for faster charging solutions. The research meticulously details a robust methodology, commencing with comprehensive modeling and simulation using MATLAB/Simulink, followed by the crucial step of prototype fabrication and experimental validation. The results are quantitative and highly impressive: the 12-phase transformer achieved a remarkable 98.3% efficiency, representing a 2.2% improvement over conventional 6-phase systems. Furthermore, thermal management was notably enhanced, with a 10°C reduction in steady-state coil temperature. Power quality metrics also saw substantial gains, including a significant reduction in DC voltage ripple from 6.7% to 3.2%, and a notable decrease in Total Harmonic Distortion (THD) on both the AC (7.8% to 4.5%) and rectified DC (4.2% to 2.1%) sides. Crucially, these technical improvements translated directly into practical benefits, with charging time for an 80% state of charge battery shortened by 15.6%, from 32 minutes to 27 minutes. Overall, this study provides strong evidence that the newly designed 12-phase toroidal transformer offers a technically reliable and superior solution for EV fast charging systems. The significant improvements across multiple performance indicators – efficiency, thermal stability, harmonic suppression, and charging speed – underscore its potential to address key limitations of current charging technologies. This research is a valuable contribution to the field, offering a practical and innovative step forward for the development of next-generation EV fast charging infrastructure that can deliver both high efficiency and improved power quality, ultimately enhancing the user experience and grid stability.

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