IS12.6 - Challenges in Design and Validation of High-Power High-Frequency Magnetics for Power Electronics in Commercial Vehicles and Distributed Generation

System architectures of commercial vehicles (CVs) and distributed generation (DG) range from hybrids to battery-based to fuel-cell-based enabling paths to decarbonization. Power electronics for such systems are typically rated in 10 kW–500 kW range and are often required to fit in space-limited applications without compromises in performance. High-frequency (HF) magnetics significantly impact the size, weight, and cost in such high-power (HP) power electronics. This talk will present the challenges in designing, sourcing, and validating HF inductors and transformers for power electronics in CVs and DG. Gaps identified in the design process, integration, cooling, tools, testing equipments, validation practices, and supplier technologies will be presented. A few ways to overcome these challenges will be briefly discussed. The goal of this presentation is to share an industry view to help practicing engineers and applied researchers understand the real-world problems of HF magnetics design and discuss techniques to achieve efficient, compact, and robust design of HP power electronics for CVs and DG.