For this converter a power transformer was developed which is a physical part of the power
stage. It also uses surface mount assemble (SMA) with a maximum constant current of
300ADC. [5] Full integration of a power transformer into the power stage has very strong
benefits when we have a current of 100A and more. Fig.6 shows this power transformer with
SMA power stage for prototype. We made a comparison of our transformer with a planar
transformer with the same conditions (110kHz 280A output). Fig.7 The planar transformer has a
price which is 20% higher than our transformer and 2% lower efficiency. Efficiency is reduced
because the planar transformer has not enough contact area for 280A. If the contact of the area
increases, the cost will increase too. The converter works fine under current mode when it has
over load conditions. It provides 300A current continuously and when over load is disconnected
overshoot is minimal compared with an alternator. That allows many customers use this mode
for running heavy load for 2-3 min. The converter will provide energy along with a 24V battery.
When the heavy load is disconnected the battery gets charged without damage and without
stress to the electrical system, which would not be the case if an alternator was used. With an
alternator system the customer would need to use a more powerful alternator or two alternators,
which of course significantly increases the cost.