Experimental Investigation of an Algorithmic Approach for Optimizing DAB Converter Design

Rossano Mendes Sotoriva; Mateus de Freitas Bueno; Douglas Mendes Sotoriva; Franciéli Lima de Sá; Samir Ahmad Mussa

doi:10.18618/REP.e202444

Authors

Rossano Mendes Sotoriva Universidade Federal de Santa Catarina https://orcid.org/0009-0006-4776-1183
Mateus de Freitas Bueno Universidade Federal de Santa Catarina
Douglas Mendes Sotoriva Universidade Federal de Santa Catarina https://orcid.org/0009-0008-3216-9560
Franciéli Lima de Sá Facvest University Center
Samir Ahmad Mussa Universidade Federal de Santa Catarina https://orcid.org/0000-0003-1102-422X

DOI:

https://doi.org/10.18618/REP.e202444

Keywords:

Dual-Active Bridge, High-frequency magnetic, On-board charger, Optimum design

Abstract

This study endeavors to optimize a dual active bridge (DAB) converter for seamless integration into an electric vehicle's on-board charger (OBC). The optimization process employs an algorithm to ascertain the optimal construction parameters, encompassing factors such as the number of turns in the inductor, gap length, and the number of turns in the primary and secondary windings of the transformer. By considering seven meticulously chosen operating points, the objective is to minimize the total loss sum and pinpoint the optimal frequencies for each point. Subsequently, a lookup table is formulated to ensure efficient OBC operation across varying output power and current levels by optimizing the frequency as a single variable. To validate the optimization process, the power switch losses are compared with theoretical calculations, and simulation results from PLECS 4.7.2 are leveraged. Furthermore, a prototype is meticulously assembled and tested to validate the DAB converter optimization, ultimately achieving an impressive efficiency of over 97 %, thus affirming the efficacy of the optimization algorithm.

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Author Biographies

Rossano Mendes Sotoriva, Universidade Federal de Santa Catarina

Born in Vacaria, Rio Grande do Sul, Brazil, in 1997. He received his Bachelor's degree in Electrical Engineering from the Centro Universitário Facvest (Unifacvest) in 2021 and its master's degree in Power Electronics at the Federal University of Santa Catarina (UFSC) in 2024, currently pursuing a Phd degree in Power Electronics at the Federal University of Santa Catarina (UFSC). His areas of interest are: Power electronics, DC-DC converters and converters optimization.

Mateus de Freitas Bueno, Universidade Federal de Santa Catarina

Graduated in Electrical Engineering from the State University of Santa Catarina - UDESC (2020/2). He was a member and scholarship holder of the PET Electrical Engineering Group at UDESC from March 2016 to July 2019. During this period, he completed scientific initiation for 2 years in the area of statistics and biomedicine. In addition, he also participated in teaching and extension projects aimed at technical, social and administrative development. He completed a supervised internship at WEG Drives and Controls, focused on developing firmware for automatic voltage regulators. Received its master's degree in Power Electronics at the Federal University of Santa Catarina (UFSC) in 2023. Currently working on

Douglas Mendes Sotoriva, Universidade Federal de Santa Catarina

Born in Vacaria, Rio Grande do Sul, Brazil, in 1997. He received his Bachelor's degree in Electrical Engineering from the Centro Universitário Facvest (Unifacvest) in 2020 and is currently pursuing a Master's degree in Power Electronics at the Federal University of Santa Catarina (UFSC).

Franciéli Lima de Sá, Facvest University Center

holds a degree and master's degree in Electrical Engineering from the State University of Santa Catarina - (UDESC, 2008 and 2010) respectively, a PhD in Electrical Engineering from the Federal University of Santa Catarina - (UFSC, 2014). She is currently Coordinator of the Electrical Engineering Course at Centro Universitário Facvest (UNIFACVEST). He has experience in the Power Electronics area, working mainly in the following lines: dc-dc converters, control applied in power electronics, FPGA-based systems. Dr. Franciéli is a member of the Brazilian Society of Power Electronics (SOBRAEP).

Samir Ahmad Mussa, Universidade Federal de Santa Catarina

He received the degree of Electrical Engineer from the Federal University of Santa Maria in 1988, he received the Master's and Doctor's degrees from the Federal University of Santa Catarina in 1994 and 2003 respectively. He currently holds the position of Full Professor in the Department of Electrical and Electronic Engineering (EEL) at the Federal University of Santa Catarina (UFSC) and researcher at the Institute of Power Electronics (INEP). His research interests include PFC rectifiers, digital signal processing and control applied in power electronics, DSP-based systems, FPGA and microprocessors. Dr. Mussa is a member of the Brazilian Society of Power Electronics (SOBRAEP) and the IEEE.

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