Broadband Simulation-Based EMC Modeling and EMI Assessment of a GaN-Based Phase-Shift Full-Bridge Converter for EV DC Powertrains

Nowadays, numerical simulation methods are advanced and widely used in industry, enabling the modeling of complex systems from printed circuit boards (PCBs) to full power converters. Among many isolated topologies, the phase-shift full-bridge (PSFB) topology is a well-established solution for isolated DC–DC conversion in electric vehicles. Therefore, this paper proposes a broadband electromagnetic compatibility (EMC) modeling methodology for a custom-designed 1 kW gallium nitride (GaN)-based PSFB converter intended for an electric vehicle (EV) DC powertrain. Moreover, the approach combines full-wave electromagnetic simulation with circuit-level simulation, including parasitic effects from PCB layout, power harnesses, and discrete components. Thus, the virtual prototype is assessed within a complete virtual test bench compliant with the standard Comité International Spécial des Perturbations Radioélectriques (CISPR) 25 over the 150 kHz–108 MHz range to capture common-mode (CM) and differential-mode (DM) conducted electromagnetic interference (EMI). Results show that the converter achieves efficiencies of 97.26% in standalone mode and 97.03% when integrated into the full DC powertrain. However, the conducted EMI assessment reveals that both CM and DM emissions exceed CISPR 25 Class 2 limits across the entire spectrum, with excess levels reaching up to 72 dBµV. Therefore, power harnesses significantly increase EMI levels at low frequencies due to the distributed inductance and stray capacitance. Finally, this study demonstrates the value of virtual prototyping for simulation-based EMI prediction in early-stage power converter design.