Lightweight Power Transformer for Shipboard Electrical Power Distribution Systems

The objective is to develop lightweight voltage step-down equipment to be used in vehicle power distribution systems, with particular emphasis on the DD(X) and CVN(X) programs. Conventional 60Hz power distribution transformers are large and heavy. The Navy seeks a smaller and lighter replacement technology. The voltage level and operating frequency drive the physical size of a power transformer. High voltage and low frequency yield high magnetic flux and necessitate a large transformer core. Engineering Matters proposes to design, simulate, fabricate and build a transformer-isolated high-frequency switch-mode power supply to replace existing low-frequency transformers. Engineering Matters has already developed a high voltage, high frequency solid-state switch. This switch will enable the power supply to operate directly from primary shipboard distribution voltage (13.8kV) at frequencies above 5kHz. At high frequency, the size of the transformer will be greatly reduced. The core design will be optimized for volume savings, with material to be selected from ferrite, amorphous metal, and advanced iron-based magnetic alloys. The switching power supply will also feature voltage regulation and a high power factor.