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This paper presents the design and optimization of a bidirectional Dual Active Bridge (DAB) converter for electric vehicle battery charging applications, encompassing both heavy and light electric vehicles. The core of this study is a 5.6 kW DAB converter that can seamlessly transition between 3.7 kW and 11.2 kW power outputs to accommodate different vehicle requirements without the need for circuit component changes. This flexibility is achieved through the novel integration of interleaved and parallel operation capabilities, allowing for efficient operation across a broad power range. Key innovations include the design of a high-frequency transformer with dual secondary outputs to facilitate power transfer at high currents up to 30 A, an optimized thermal design, and minimized stress on the circuit board. The use of next-generation power semiconductors and low-loss magnetic circuit elements has resulted in an optimized single-stage bidirectional converter design that showcases enhanced efficiency and competitiveness in the field. Furthermore, the converter’s design enables easy reconfiguration to meet the desired power output, vehicle type, and application needs, making it adaptable for future applications such as Vehicle-to-Grid (V2G) systems. The combination of these features—versatility in power output, efficient high-current transfer, innovative use of power semiconductors, and adaptability for future technologies—positions this DAB converter as a significant advancement in electric vehicle charging technology, offering a scalable solution to meet the evolving demands of electric mobility and renewable energy integration.
Muhammetoglu et al. (Mon,) studied this question.