Integrated Magnetic Structure to Improve High Power Region Efficiency for Dual Active Bridge Converter

Abstract

In dual active bridge (DAB) converters, series inductor and transformer functionalities are integrated into a single magnetic core structure to improve efficiency or power density. Allowing independent tuning of this integrated series inductance and magnetizing inductance gives higher design flexibility. However, the existing integrated magnetic methods often lower magnetizing inductance, compromise the transformer winding coupling, require complex custom core designs, or cannot effectively decouple transformer and inductor fluxes in the case of separate transformer and inductor windings. To overcome these problems, this article proposes a unified core structure that allows independent tuning of series inductance without the above-mentioned limitations. To demonstrate the performance of the proposed integrated structure, a DAB converter for a dc–dc electric vehicle charging application is built, and the proposed integrated structure is compared with discrete transformer and inductor structures under identical core volume and thermal steady-state conditions. It is experimentally validated that for the proposed structure at a high output voltage and high load conditions of 450 V and 9 kW, the magnetic power loss reduction is 8.8%, whereas, at a low output voltage and high load conditions of 250 V and 7 kW, the magnetic power loss reduction is 13.0%. Furthermore, this article presents an iterative design methodology based on the derived reluctance and analytical models to systematize the design process.