A New 12-Phase Toroidal Transformer Design to Improve Efficiency and Power Quality in Electric Vehicle Fast Charging Systems

Partaonan Harahap; Muhammad Imran Hamid; Ariadi Hazmi

doi:10.33019/jurnalecotipe.v12i2.4568

Authors

Partaonan Harahap Andalas University , Universitas Muhammadiyah Sumatera Utara
Muhammad Imran Hamid Andalas University
Ariadi Hazmi Universitas Muhammadiyah Sumatera Utara

DOI:

https://doi.org/10.33019/jurnalecotipe.v12i2.4568

Keywords:

12-Phase Configuration, Electric Vehicle, Energy Efficiency, Fast Charging, Toroidal Transformer

Abstract

Transformers are essential components in electric vehicle (EV) fast charging systems, particularly in ensuring high efficiency and maintaining power quality. This study introduces a new design and implementation of a 12-phase toroidal transformer integrated into a 50 kW fast charging system. The main contribution of this research lies in improving energy efficiency, thermal stability, and harmonic suppression, which are critical challenges in conventional transformer configurations. The proposed transformer was modeled and simulated using MATLAB/Simulink, followed by prototype fabrication and experimental validation. Simulation and test results demonstrated that the 12-phase toroidal transformer achieved an efficiency of 98.3%, representing a 2.2% improvement over a conventional 6-phase configuration. Furthermore, steady-state coil temperature decreased by 10°C, while DC voltage ripple was reduced from 6.7% to 3.2%. Harmonic performance also improved significantly, with Total Harmonic Distortion (THD) dropping from 7.8% to 4.5% at the AC side and from 4.2% to 2.1% after rectification. In terms of charging performance, the system successfully shortened the charging time for an 80% state of charge (SoC) battery from 32 minutes to 27 minutes, a reduction of 15.6%. These findings confirm that the 12-phase toroidal transformer provides a technically reliable and novel solution for next-generation EV fast charging infrastructure, delivering both high efficiency and improved power quality.

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