The design is suitable for electric vehicle charging and energy storage, featuring advanced control, robust protection, and significant power output.
The Dual Active Bridge (DAB) converter is a pivotal component in the field of power electronics, renowned for its efficient and versatile handling of power transfers across various voltage levels. Characterized by its ability to facilitate soft switching, thereby minimizing energy losses, and its capability for bidirectional power flow, the DAB converter is indispensable in applications that demand high efficiency, reliability, and safety. This converter is particularly beneficial due to its galvanic isolation feature, which enhances user safety by preventing unwanted current flows, while its modularity allows for scalability in complex systems. From electric vehicle charging stations to renewable energy systems and grid storage, the DAB converter’s broad applicability and superior performance make it a cornerstone technology in modern power management solutions. The reference design from Texas Instruments (TI) presents a detailed overview of a single-phase Dual Active Bridge (DAB) DC/DC converter implementation.
The DAB topology offers benefits such as soft-switching, fewer components, and high efficiency. It is especially advantageous in scenarios where factors such as power density, cost, weight, galvanic isolation, high voltage conversion ratio, and reliability are crucial. This makes the design well-suited for electric vehicle (EV) charging stations and energy storage systems. The modular and symmetrical structure of the DAB enables the stacking of converters to achieve high power throughput and supports a bidirectional operational mode, accommodating both battery charging and discharging applications.
Applications in the field include DC fast charging stations and power modules specifically designed for rapid charging capabilities. Additionally, power conversion systems (PCS) are integral for transforming and regulating electrical power efficiently. The technology also extends to hybrid, electric, and powertrain systems, which are essential for the operation of modern, energy-efficient vehicles.
The system features a bidirectional dual-active-bridge equipped with Single- (SPS) and Extended-phase-shift (EPS) control for versatile power management. It incorporates a Smart Gate driver, the UCC21710, which offers integrated protection for SiC MOSFETs, enhancing system reliability. The TMS320F280039 controller facilitates the implementation of sophisticated digital controls. The design includes isolated voltage and current sensing capabilities, ensuring precise measurement and safety. It boasts a maximum power output of 10 kW and achieves a peak efficiency of 98.7%, with full load efficiency standing at 98%. The primary voltage operates between 700V–800V DC, while the secondary voltage ranges from 350V to 500V DC under SPS and 250V to 500V DC under EPS. The system operates at a PWM switching frequency of 100 kHz, which allows for a reduced transformer size thanks to planar magnetics. Additionally, it features soft switching capabilities without the need for auxiliary components.
TI has tested this reference design. It comes with a bill of materials (BOM), schematics, assembly drawing, printed circuit board (PCB) layout, and more. The company’s website has additional data about the reference design. To read more about this reference design, click here.
