Design and analysis of a high-efficiency bi-directional DAB converter for EV charging

The escalating demand for electric vehicles (EVs) arises from apprehensions regarding fossil fuel depletion and the ecological repercussions of conventional combustion engines, propelling the transition towards environmentally sustainable alternatives. EVs are conventionally comprised of a powertrain, battery management system, and communication infrastructure, with the battery playing a pivotal role. Achieving an efficient EV battery charger necessitates the implementation of a proficient charging algorithm and a high-power converter capable of adeptly regulating battery parameters. Among the array of available options, a bi-directional DC/DC converter is often employed for this purpose. This study predominantly focuses on the Bi-Directional Dual Active Bridge Converter with Single-Phase Shift Control. It is renowned for attaining a broad voltage range through transformer turn ratio adjustments. Its controllable parameters, such as phase shift ratio and duty cycle, bolster its versatility. Moreover, due to its input-output isolation and minimal passive elements, this converter exhibits superior efficiency due to its soft-switching capabilities. The analytical framework encompasses steady-state and dynamic assessments, small-signal modeling, and system transfer function analysis, all of which contribute to formulating an optimized controller design. Additionally, the study conducts simulations of various battery charging techniques, including constant current (CC), constant voltage (CV), and CCCV mode, employing a 1.5 kW Dual Active Bridge DAB-based charger through MATLAB/SIMULINK. Furthermore, voltage mode control simulations for a 5 kW DAB converter augment the study's insights into effective EV charging strategies.