Optimal Design of a Dual-Active-Bridge DC-DC Converter

This article presents a systematic design procedure for a dual-active-bridge (DAB) dc-dc converter. Design of a DAB converter involves determination of two key parameters, i.e., transformer turns ratio and the series inductance value. Existing literature addresses this problem through numerical optimization, which is computation intensive and does not provide much insight. In general, loss is minimized by applying equal weightage to all operating conditions, which may not be practical. Given an operating power range, terminal voltage range, and switching frequency, this article presents a way to optimally select the design variables through analytical solution of a constrained optimization problem. Analysis is carried out in the time domain, and an optimal triple-phase-shift modulation strategy is considered that ensures minimum inductor rms current and soft switching. The choice of the design parameters results in minimization of the worst-case inductor rms current over the entire operating range of the converter, which leads to both efficiency and size optimization. A procedure for selection of devices and filter capacitors and design of magnetics is given. A 2.6-kW experimental prototype is designed to validate the theoretical analysis.