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The Challenge
A grid modernization startup was developing a 1MW solid-state transformer for medium voltage applications (4.16kV to 480V). The extreme power density target of 30 kW/L required innovative thermal solutions for SiC devices operating at 20kHz switching frequency. The design needed to meet IEEE C57.12 transformer standards while handling fault currents and maintaining galvanic isolation.
Our Approach
- Developed multi-physics simulation model coupling thermal, electrical, and magnetic domains
- Designed custom direct-cooled power module with integrated cold plate
- Implemented dielectric fluid cooling for medium voltage isolation
- Optimized magnetic component cooling with forced oil circulation
- Created thermal management system with redundant cooling paths
- Validated design through accelerated life testing protocols
Results
30 kW/L
Power Density
10x improvement over LF transformer
98.2%
Efficiency
Full load efficiency achieved
85%
Weight Reduction
Compared to conventional transformer