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محول عزل عالي الجهد ثنائي النواة من طراز EE65 بقدرة 3 كيلوواط و800 فولت تيار مستمر
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This 3kW high-frequency isolation transformer is engineered around a dual-set EE65 ferrite core platform, purpose-built for 800V DC high-voltage input power conversion systems. Utilizing a Phase-Shift Full Bridge (PSFB) topology operating at 40–60 kHz, it delivers reliable galvanic isolation and efficient step-down conversion from an 800V DC bus to a regulated 27.5V DC / 110A output — making it an ideal magnetic solution for next-generation EV fast-charging power modules, energy storage DC-DC stages, industrial high-voltage DC power supplies, and telecom rectifier systems.
With an absolute maximum input voltage rating of 800V DC and a wide operating range of 400V–750V DC, this transformer accommodates the demanding voltage excursions found in 800V-class EV architectures and high-voltage battery cascades. The dual EE65 core configuration maximizes the effective cross-sectional area, minimizing core flux density and ensuring ultra-low core loss even at sustained 3kW continuous operation. The design supports a 130A / 60-second overload capability, providing robust transient headroom for real-world load profiles.
المواصفات الكهربائية الرئيسية
| المعلمة | المواصفات | ملاحظات / شروط الاختبار |
|---|---|---|
| Core Type | 2 × EE65 (Dual Set) | Stacked dual-core configuration for doubled effective cross-sectional area |
| Topology | PSFB | Phase-Shift Full Bridge — ZVS soft-switching capable |
| Rated Output Power | 3 kW | Continuous full-load operation |
| الجهد الكهربائي الاسمي للدخل | 650V DC | Normal operating input bus voltage |
| Operating Input Voltage Range | 400V – 750V DC | Full operating range with regulated output |
| Absolute Max Input Voltage | 800V DC | Maximum withstand voltage — 800V-class architecture ready |
| Peak Input DC Current | 16A | Transient peak current handling capability |
| Nominal Input DC Current | 7A | Continuous rated input current at nominal voltage |
| Rated Output Voltage (Vdc_avg) | 27.5V ± 0.3V | Tight regulation at full load |
| Output Voltage Range | 27V – 28V DC | Min to max output voltage envelope |
| Rated Output Current | 110A | Continuous DC output current |
| Max Output Current | 130A / 60 sec | Overload capacity for transient demand surges |
| Switching Frequency | 40 – 60 kHz | Optimized for ZVS soft-switching and high efficiency |
| PWM Duty Range | 10% – 90% | Wide duty cycle range for flexible control |
أبرز الميزات التقنية والحرفية المتميزة
Dual-Core Architecture for Enhanced Power Density
By employing two sets of EE65 Mn-Zn ferrite cores in a stacked configuration, the effective cross-sectional area (Ae) is effectively doubled compared to a single core. This reduces operating flux density, minimizes core loss, and dramatically improves thermal performance under sustained 3kW loading — all within a compact footprint suitable for high-density power module integration.
800V-Class Voltage Withstand Capability
Designed from the ground up for 800V DC architecture, this transformer safely handles absolute maximum input voltages up to 800V while maintaining full functionality across a wide 400V–750V operating range. Premium-grade insulation materials and reinforced winding techniques ensure exceptional dielectric strength, partial discharge resistance, and long-term reliability in high-voltage DC bus environments.
Phase-Shift Full Bridge (PSFB) Optimization
The transformer is specifically optimized for Phase-Shift Full Bridge resonant soft-switching topology. Engineered leakage inductance values enable Zero-Voltage Switching (ZVS) across the load range, dramatically reducing switching losses at 40–60 kHz. The 10%–90% PWM duty range provides wide control authority for precise output regulation under varying input conditions.
110A Continuous / 130A Overload Current Handling
Delivering 27.5V at 110A continuous with a 130A / 60-second surge capacity, the secondary winding is constructed with precision multi-strand Litz wire or copper foil technology. This minimizes high-frequency skin and proximity effect losses, ensuring ultra-low AC resistance (ACR) and stable thermal performance even under aggressive transient load profiles typical of EV charging and industrial processes.
Superior Thermal Design with Low Temperature Rise
The dual-core geometry distributes magnetic flux across a larger effective area, inherently reducing flux density and core losses. Combined with optimized winding window utilization and premium Mn-Zn ferrite materials (e.g., DMR95 / PC95 class), the transformer maintains low temperature rise at full load — critical for enclosed power modules where thermal headroom is limited.
Reinforced Insulation System
Given the 800V DC high-voltage input, the transformer features a reinforced insulation system with multi-layer margin-wound construction and high-grade epoxy impregnation. This ensures compliance with industry standards for hi-pot dielectric withstand, partial discharge extinction, and long-term insulation endurance under thermal cycling — providing a safety margin essential for automotive and industrial certifications.
التطبيقات النموذجية
- EV Fast-Charging Power Modules800V-class electric vehicle DC fast-charging stations — high-voltage bus to low-voltage auxiliary/isolated DC-DC conversion stages.
- Energy Storage Systems (ESS/PCS)Bidirectional DC-DC conversion in battery energy storage and power conversion systems — 800V DC bus isolation and voltage step-down.
- Industrial High-Voltage DC Power SuppliesProcess power supplies, plasma systems, and electrochemical applications requiring isolated high-voltage to low-voltage conversion at 3kW class.
- Telecom & Data Center RectifiersHigh-voltage DC distribution architectures (HVDC) in data centers — 800V DC bus to 27V/28V regulated output for server rack power delivery.
- Renewable Energy Power ConversionSolar string inverter DC-DC stages and microgrid power conditioning units operating at elevated DC bus voltages.
- Battery Test & Formation EquipmentBattery cell/module formation and test systems requiring precise high-current, low-voltage isolated output from a high-voltage DC source.
خدمات الهندسة والتخصيص
Backed by an experienced electromagnetic simulation team and automotive-grade production lines, we provide rapid prototyping and full customization services for this EE65 platform. Our engineering capabilities include:
- Turns Ratio & Winding CustomizationFine-tune turns count, wire gauge, and winding topology to match your specific voltage conversion ratio and current requirements.
- Core Material SelectionPremium Mn-Zn ferrite grades (DMR95, PC95, 3C95, N97, etc.) selected based on your operating frequency, temperature range, and loss budget.
- Mechanical & Mounting AdaptationCustom bobbin designs, mounting configurations, and mechanical interfaces tailored to your PCB layout and enclosure constraints.
- Compliance & Certification SupportUL, CE, RoHS, and automotive-grade (IATF 16949) documentation and testing support for your certification requirements.
Ready to Power Your 800V DC Application?
Contact our engineering team today to discuss your specific requirements, request samples, or schedule a technical consultation. We deliver custom magnetic solutions with rapid prototyping turnaround and automotive-grade quality assurance.
