High-frequency-link (HFL) power conversion systems (PCSs) are attracting more and more attentions in academia and industry for high power density, reduced weight, and low noise without compromising efficiency, cost, and reliability. In HFL PCSs, dual-active-bridge (DAB) isolated bidirectional dc-dc converter (IBDC) serves as the core circuit. This paper gives an overview of DAB-IBDC for HFL PCSs. First, the research necessity and development history are introduced. Second, the research subjects about basic characterization, control strategy, soft-switching solution and variant, as well as hardware design and optimization are reviewed and analyzed. On this basis, several typical application schemes of DAB-IBDC for HPL PCSs are presented in a worldwide scope. Finally, design recommendations and future trends are presented. As the core circuit of HFL PCSs, DAB-IBDC has wide prospects. The large-scale practical application of DAB-IBDC for HFL PCSs is expected with the recent advances in solid-state semiconductors, magnetic and capacitive materials, and microelectronic technologies.

Overview of Dual-Active-Bridge Isolated Bidirectional DC–DC Converter for High-Frequency-Link Power-Conversion System

An efficiency-optimized modulation scheme and design method are developed for an existing hardware prototype of a bidirectional dual active bridge (DAB) dc/dc converter. The DAB being considered is used for an automotive application and is made up of a high-voltage port with port voltage V1, 240 V ≤ V1 ≤ 450 V, and a low-voltage port with port voltage V2, 11 V ≤ V2 ≤ 16 V; the rated output power is 2 kW. A much increased converter efficiency is achieved with the methods detailed in this paper: The average efficiency, calculated for different voltages V1 and V2, different power levels, and both directions of power transfer, rises from 89.6% (conventional phase shift modulation) to 93.5% (proposed modulation scheme). Measured efficiency values, obtained from the DAB hardware prototype, are used to verify the theoretical results.

Efficiency-Optimized High-Current Dual Active Bridge Converter for Automotive Applications

An optimal modulation scheme that enables minimum conduction and copper losses is presented for a bidirectional dual active bridge (DAB) dc-dc converter. The considered converter system is employed for an automotive application and comprises of a high voltage (HV) port with port voltage V1, 240V ≤ V1 ≤ 450 V, and a low voltage (LV) port with port voltage V2, 11 V ≤ V2 ≤ 16 V; the rated output power is 2 kW. The closed-form expressions for the optimal control parameters are derived and implementation details are presented in order to facilitate the direct application to a given DAB converter. The paper further details the properties of the presented modulation scheme with respect to switching losses. Experimental results confirm a considerable increase of the converter efficiency achieved with the proposed optimal modulation scheme, compared to the efficiency obtained with conventional phase shift modulation. The efficiency increase is most distinct at V1=450V and V2 = 11V with an increase from 78.6% to 90.6% at 1 kW output power and from 85.9% to 90.7% at rated output power as compared to conventional phase shift modulation.

Closed Form Solution for Minimum Conduction Loss Modulation of DAB Converters

Two of the main challenges for electric vehicle (EV) adoption include limited range and long recharge times. Ultrafast charging can help to mitigate both these concerns. However, for typical 400-V battery EVs (BEVs), the charging rate is limited by the practical cable size required to carry the charging current. To reach ultrahigh charge rates of 350 or 400 kW, 800-V BEVs are a promising alternative. However, the design of an 800-V EV requires careful new considerations for all electrical systems. This article reviews the current state of 800-V vehicle powertrain electrical design and performs an analysis of benefits, challenges, and future trends regarding multiple vehicle powertrain components. Specifically, detailed benefits and challenges related to the battery, propulsion motor, inverter, auxiliary power unit, and on- and off-board chargers are discussed.

800-V Electric Vehicle Powertrains: Review and Analysis of Benefits, Challenges, and Future Trends

This thesis investigates different bidirectional and isolated DC–DC converters with a high voltage port (ranging from 240 V to 450 V), a low voltage port (11V to 16 V), and a rated power of 2 kW. The work starts with an overview on different bidirectional DC–DC converter topologies and investigates their applicability with respect to the given specifications (Chapter 2). Based on the findings of Chapter 2, the singlephase Dual Active Bridge (DAB) converter topology is considered most promising regarding the achievable converter efficiency and the achievable power density. Moreover, due to the wide input and output voltage ranges, two-stage DC–DC converters, i.e. the series connection of an isolated DC–DC converter and a DC–DC converter without galvanic isolation, are expected to facilitate an improved converter efficiency. The subsequent Chapters discuss the single-phase DAB converter in detail. • Chapter 3 explains the working principle of the DAB converter based on 3 different simplified converter models. This includes a lossless model of the DAB, which facilitates basic analytical investigations and allows for a simplified synthesis of optimal modulation schemes (calculated with respect to minimum transformer RMS current). Moreover, two different refinements of the electric DAB converter model are included in order to consider the impacts of the conduction losses and the magnetizing current on the transformer currents. • Chapter 4 discusses a detailed loss model of the DAB, needed in order to parameterize the models developed in Chapter 3 and to develop the efficiency optimized modulation presented in Chapter 5. This loss model is used to calculate the losses in the most relevant converter components. • Chapter 5 presents a systematic investigation of efficiency improvements achievable for the given DAB converter, obtained with the use of optimized modulation schemes. Finally, with the suboptimal modulation schemes discussed in Section 5.2.2, converter operation close to its maximum possible efficiency is achieved (Figure 5.28).

Modeling and optimization of bidirectional dual active bridge DC-DC converter topologies

The dual active bridge (DAB) converter attracts more and more attentions thanks to its advantages over the other isolated dc-dc converters, such as soft-switching, immunity to parasitic inductance, less circuit components and less component stress. Rectangular (also named as phase-shifted) modulation method on DAB has been widely studied and but other two proposed modulations (trapezoidal and triangular methods) have much less applications. Due to the characteristics of the modulation principles, one of these three methods outperforms the other two in certain operating ranges from system efficiency point of view. This paper summarizes the properties of three modulation methods and optimizes the combined use of three modulations on a DAB converter (12V/360V, 1 kW and 25 kHz) in order to obtain the best system efficiencies over full converter operating range. A validated loss model is utilized as the analyzing platform, based on which the optimal operating ranges of three modulations are determined.

Optimal operating ranges of three modulation methods in dual active bridge converters

High power density power electronics converters are increasingly demanded. Generally speaking, raised switching frequency improves the power density. However, dramatically increasing frequency on the present level still depends on the advance of power electronic components in material property, packaging technique, thermal management technique and etc. This paper surveys the recent material development of key components in the PWM power converters and then try to quantify the potential of improving the system power density by using advanced components. For illustrating this potential, power densities of air-cooled dual active bridge DC-DC converters (12V-360V, 1 kW) with three categories of components are analyzed and compared, namely state-of-art components, available advanced components and future components. The future components assume ten times better loss-related properties than those of the advanced components currently available.

Potential of improving PWM converter power density with advanced components

The demand on high power density tends to limit the area of printed circuit boards (PCB) and increase current density in PCB traces. A thermal design guideline which is able to reliably predict the current carrying capacity (CCC) of PCB traces will be valuable to PCB designers. This paper describes several design guidelines for trace CCC. They cannot be properly applied to today's PCB design characterized with high component density and high current density. The influence of effects, such as multilayers, corners and high frequency current undermines their use. These limitations are evidenced with experiments. Methods for developing a new design guideline which are practical for today's PCB design are introduced. Methods for temperature measurement and high frequency current generation are proposed as well.

Thermal design guideline of PCB traces under DC and AC current

In the high-current phase-shifted DC-DC converter, the high-frequency transformer is a key component. Its conduction loss needs to be reduced and the leakage inductance needs to be specifically tuned. This paper investigates the design of low-profile nanocrystalline transformer for high-current phase-shifted DC-DC converters. The core dimension optimization to minimize the transformer loss is proposed. A lossless method of tuning the leakage inductance of the transformer, suitable for low-profile nanocrystalline transformer, is discussed. Designed for a dual active bridge (DAB) converter with high current transients, the planar transformers with both ferrite (3C90) and nanocrystalline (FT-3M) materials are compared. From these comparisons, the benefits and drawbacks of the low-profile nanocrystalline cores are identified.

Design of low-profile nanocrystalline transformer in high-current phase-shifted DC-DC converter

This paper introduces a novel loss model concept for performance evaluation and design optimization of power electronics converters based on MathCAD sheet. A dual active bridge (DAB) converter (12 V/360 V, 1 kW and 25 kHz) is used as the test platform. The practical methods for extracting useful component parameters used in loss model and for experimentally assessing losses to verify the loss model are elaborated. With the verified loss model, design optimizations of the DAB converter are done theoretically.

Methods for experimental assessment of component losses to validate the converter loss model

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