This work presents a downscaled validation of a medium-voltage, medium-frequency transformer (MFT) concept designed for high-current operation on the secondary side using multiple parallel paths. The design is based on a modular winding approach, which simplifies the construction process and conductor placement on the bobbin. A systematic design and optimization procedure is developed, combining analytical calculations and finite-element simulations to explore the mass-efficiency tradeoff and to select a candidate design that meets specified leakage inductance and loss targets. The developed prototype serves as a proof of concept, demonstrating that the electrical, magnetic, and insulation requirements of the full-scale MFT can be effectively verified at reduced power levels. The fabricated prototype is tested under short-circuit and partial discharge conditions. The impedance measurements confirmed the expected resonance behavior, and the partial discharge test results verified sufficient insulation performance under high-voltage stress. The results provide experimental evidence for the scalability and feasibility of the proposed transformer design and offer guidelines for the use of 3D-printed supports, grain-oriented electrical steel cores, and windings in medium-voltage, MFT systems for hydrogen production applications. ... Read more

This paper presents the design and optimization of a Medium Frequency Transformer (MFT) for use in Solid State Transformer (SST) systems supporting green hydrogen production. Operating at 1 kHz and integrated within an LLC resonant converter, the transformer is optimized for minimal weight and high efficiency while ensuring adequate leakage inductance and insulation performance. A core-type configuration with cylindrical windings was selected based on FEM simulations and mass-efficiency trade-offs. The final prototype, using copper conductors, achieves 97.8% efficiency with a mass below 50 kg and meets the required 7 mH leakage inductance. High-voltage testing, including partial discharge and breakdown tests, confirmed the insulation coordination of the design. The results demonstrate a practical and scalable approach for high-performance SST integration in renewable energy applications. ... Read more