Efficiency and Cost Optimization of Dual Active Bridge Converter for 350kW DC Fast Chargers

TL;DR

This paper presents an optimization framework for a Dual Active Bridge converter in 350 kW DC fast chargers, balancing efficiency and cost, and identifies an optimal configuration achieving over 95% efficiency.

Contribution

It introduces a novel optimization approach for high-power DAB converters, considering multiple design parameters for improved efficiency and cost-effectiveness.

Findings

Achieves over 95% efficiency at rated power

Optimal configuration: seven 50 kW modules, 30 kHz switching frequency

Transformer turns ratio of 0.9

Abstract

This study focuses on optimizing the design parameters of a Dual Active Bridge (DAB) converter for use in 350 kW DC fast chargers, emphasizing the balance between efficiency and cost. Addressing the observed gaps in existing high-power application research, it introduces an optimization framework to evaluate critical design parameters,number of converter modules, switching frequency, and transformer turns ratio,within a broad operational voltage range. The analysis identifies an optimal configuration that achieves over 95% efficiency at rated power across a wide output voltage range, comprising seven 50 kW DAB converters with a switching frequency of 30 kHz, and a transformer turns ratio of 0.9.