I am designing a transformer for a traction inverter using the AP method.
1) I have chosen a Metglas core with a saturation flux of 1.56 Tesla. I have chosen a operating flux density of 0.6 Tesla. What is the practical limitation preventing me from running the core at 1 Tesla or more, is it simply core loss?
2) At full output the core loss would be 1.3kW at 0.6 Tesla and 3.2kW at 1 Tesla. Copper loss is another 300W. I can attach to core to the cooling plate shared with the switching devices. Is cooling 1.6kW to 3.5kW reasonable?
3) At full output the MMF will cause a decrease in AL value and hence decrease in inductance. Are there guidelines for acceptable decrease or is the evaluation done using circuit simulation
4) Using 400A/cm^2 current density (good value?) and 30kHz switching frequency I have determined the primary will require three parallel layers of 80mm by 0.508mm copper foil with 7 turns. Is it acceptable to have the parallel layers uninsulated with each turn insulated or must all conductors be insulated from each other.
5) How are the foil ends terminated? Soldered to like thickness copper at a right angle to form a tab?
6) What materials should be used to gap the core, is hard plastic acceptable
Thanks for the help]1