Control Method for Avoiding Transformer Saturation in High-Power Three-Phase Dual-Active Bridge DC-DC Converters

The classic top to down structure of electrical infrastructure is changing due to the extensive spread of renewable energy sources which are connected to medium-voltage and low-voltage grids. Especially for medium-voltage direct-current grids, the three-phase dual-active bridge (DAB) dc-dc converter is one of the most promising converter topologies, as it features bidirectional power flow and galvanic isolation at highest efficiency. Unwanted saturation of the transformer of this converter can occur, particularly for multimegawatt converters with highly efficient, low-loss transformers. The saturation leads to additional core losses, elevated voltage stress at the windings, and increased magnetostriction of the transformer core, which can result in undesired acoustic emissions. The following article presents a feedback control and modulation method that controls the DAB converter such that saturation of the transformer is avoided. The chosen approach evaluates the star-point voltage of the transformer to determine the dc component of the magnetizing current, thereby avoiding the need for expensive high-precision current sensors. The control method is analytically derived and verified by simulation. Experiments carried out using a 5MW medium-voltage three-phase DAB converter prototype verify the presented modulation method.