Design_optimization_of_high_frequency_transformer_for_dual_active_bridge_DC-DC_converter
Design_optimization_of_high_frequency_transformer_for_dual_active_bridge_DC-DC_converter
Abstract -- This paper presents a design optimization leakage inductance and the phase-shifted angle between its
procedure for high frequency transformer (HFT) employed in terminal square wave voltages. As a result, there is always
bidirectional dual active bridge (DAB) isolated DC-DC a trade-off between the leakage inductance and the phase-
converter. It is shown that leakage inductance, phase-shifted
shifted angle when maximizing the power conversion.
angle, skin and proximity effects have to be taken into account
together with the HFT voltage-ampere rating to minimize Additionally, at high switching frequency, high AC
total losses. It is also demonstrated that the leakage inductance losses in the HFT windings are inevitable due to the skin-
required for zero voltage switching operation can be realized and proximity-effects [5], [6], and [7]. The leakage
under the proposed design procedure without employing extra inductance and the magnitude of the AC loss are influenced
inductor. The proposed design methodology is experimentally by the transformer geometry and winding layout.
validated by measurements on a prototype HFT. Therefore, the leakage inductance, phase-shifted angle, and
the skin and proximity effects need to be taken into
Index Terms--AC losses, converter losses, design
optimization, dual active bridge DC-DC converter, eddy consideration in the HFT design procedure for minimizing
current effects, high frequency transformer, Litz-wire, electrical losses.
MOSFET, zero voltage switching operation. In [8], [9], [10], [11], and [12], design procedures for
high frequency transformer (HFT) were presented.
I. INTRODUCTION However, all these proposed methods start with the core
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II. PRINCIPLES OF DAB DC-DC CONVERTER OPERATION For (mode 3)
i ( ) B( ) I (7)
A. Operation of DAB DC-DC Converter
1 B 2
3 ( ) ( I B)( )( I B)
2 3 3
I rms (8)
2 3
V1 V1
2 3 1 B 2
vT 1 I av 3 ( 2 ) ( I B)( ) (9)
V1 V1 2 2
I T 1rms 2( I rms
2
1 I rms 2 I rms 3 )
2 2
(10)
V '
V' V1
2 2
I0 [ d (2 )] I (11)
v'
T2
2Llk
V2' V2' V2'
V12
PO d 1 (12)
Llk
V2' V n I
d N 2 ;N 1 ; 0 (13)
iB1 V1 V1 n2 A
where d is the conversion ratio; i(θ) is the instantaneous
HFT current at the angular θ; I0 and Iπ is, respectively, the
HFT current at θ = 0 and θ = π; Iavi and Irmsi is,
respectively, the average and rms values of HFT current
iB' 2 associated with the ith conduction mode; IT1rms is the total
rms value of HFT current; Llk is the leakage inductance; N
is the turn ratio; n1 and n2 is, respectively, the primary turn
number and secondary turn number; PO is the transferred
iT 1
t power; V1 and V2’ is, respectively, the primary voltage
value and secondary voltage referred primary.
Zero voltage switching occurs when an active switch in
. the DAB is turned on while its anti-parallel diode is free-
Fig. 2. Idealized operating waveforms for DAB DC-DC converter [3]; ω wheeling. Thus the condition for ZVS operation is given
is the angular frequency; δ is the current zero-crossing angle; and ϕ is the
phase-shifted angle.
by:
I 0 0 ; I 0 (14)
TABLE I CONDUCTION MODE OF DAB DC-DC CONVERTER
10
Current (A)
Pon Poff
8
vDS
6
iF Qrr iDon Reverse Recovery Effect 100 300 500 700 900
4
0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
Qrr t Conversion Ratio - d
(a) HFT current
t ri trr t fv
400
100 300 500 700 900
Leakage Inductance (H)
8
Core Winding Core Winding Core dT
7
6
0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
Conversion Ratio - d
(a) HFT current a 0.8b a
2 b a b 2
100 Llk 90H 110H 130H 150H 170H Fig. 6. Core dimensions used in HFT design investigation.
80
By defining two factors K1 and K2 as
(degrees)
60 d h
K1 T ; K 2 (28)
40 a b
Substituting (28) into (25) and (26) gives
20
n1 K1a 2 4 Bmax f s V1 (29)
n1 0 K 2 MLT 3Llk
0 2
0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 (30)
Conversion Ratio - d
In addition, the relation between the core window area,
(b) Phase-shifted angle
Aw, and the primary conductor area [9] can be expressed as
Llk 90H 110H 130H 150H 170H 2 I T 1rms
Aw K 2 b 2 n1 (31)
k f J max
ZVS Condtion
1
where kf is the filling factor chosen as 0.3 for Litz-wire and
Jmax is the current density given as 5.5 A.m-2 according to
the thermal dissipation [9].
Equations (29), (30), and (31) can be used to study the
ZVS optimized core dimensions for minimizing both core
0 weight, CW, and winding weight, WW.
0.81.1 0.9 1.2 1 1.3 1.4 1.5
Conversion Ratio - d CW Fe CV Fe aK1[2(a b)(a K 2b) 2 K 2 b 2 ] (32)
(c) ZVS operation range
Fig. 5. Variation HFT current and phase-shifted angle and ZVS range with WW Cu k f AW MLT (33)
leakage inductance and conversion ratio. where ρFe and ρCu is, respectively, the ferrite mass density
C. Step 3: Optimal Core Dimensions and copper mass density; CV is the core volume.
In this step, core dimensions are optimized for minimum 500
CW-K1:0.5
HFT weight and electrical losses with PO = 2.2kW; Llk = 400 WW-K1:0.5
90μH; d = 1.07; and ϕ = 22 degrees.
TW-K1:0.5
Weight (g)
2.5 2 ( ) 5 12 (39)
20
3 2 2 2
2 Cu n1 2 n0 24
10 R AC [ 1 ( ) (16m 2 1 2 ) 2 ( )] (40)
s n0 d 0 24
0
8 14 20 26 32 where dc is the conductor diameter [9] computed from core
a (mm)
(a)
window dimensions, HFT current, and current density; d0 is
the optimized strand diameter; m is the number of winding
10
K1 0.5 layers; n0 is the number of strands per Litz-wire conductor;
1 β is the Litz-wire packing factor; δs is the skin depth.
8
1.5
2 30
6
2.5
K2
0 10
8 14 20 26 32
a (mm)
(b) K1 0.5 1 1.5 2 2.5 3
0
200 8 14 20 26 32
a (mm)
(a) Total HFT losses
150
200
MLT (mm)
K1 1 1.5 2 2.5 3
100
160
Temperature (0C)
50
120
K1 0.5 1 1.5 2 2.5 3
0
8 14 20 26 32 80
a (mm)
(c)
40
150 K1 8 20 14 26 32
0.5 1 1.5 2 2.5 3 a (mm)
(b) Temperature
Fig. 9. Variation of HFT losses and temperature with a and K1.
100
n1 (turns)
2.4128d c2 1.5113d c 0.3535 (34) where ACR is the crossectional area; dvert is the HFT vertical
height; PAC is the winding loss; PC and PV is, respectively,
0.075 b1 b12 12 s4 the core loss and the relative core loss; PHFTΣ is the total
s ; d0 (35)
fs 2 HFT losses; Rθ,conv and Rθ,rad are the thermal resistances due
to convective and radiative heat transfer, respectively; Rθ,sa
2 2 24 is the total thermal resistance; Ta and Ts is the ambient and
b1 (16m 2 1 )d c2 (36)
24 2 surface temperature in 0C, respectively; ∆T = Ts - Ta.
Fig. 9(b) shows the resultant temperature variations with
2200W. For the purpose of illustration, ZVS range at 90V Bmax 0.24848 (T)
(dashed blue line with crosses) and 140V (dashed grey line Primary winding 27 turns, 162 strads-AWG38
with circles) are also shown. As will be seen, the total Secondary winding 8 turns, 300 strands-AWG35
losses decrease with the increases in turn ratio, but ZVS Magnetizing inductance Pri./Sec. 5.231/0.46 (mH)
operation at 140V is lost when the turn ratio is greater than Leakage inductance Pri./Sec. 90/10.5 (μH)
3.4. Thus the optimal turn ratio for minimum total
converter losses and full ZVS operation over the 90V-140V
output voltage range is 3.4. The resultant number of turns
of the secondary winding is n2 = 8. Fig. 11 shows the
variations of minimum leakage inductance for ZVS
operation according to (14) with the output voltage for PO =
2200W and 500W with n2 = 8. It is obvious that ZVS
operation is achieved for full range output voltage at PO =
2200W with Llk = 90μH. At lower output power, modified
modulation techniques should be considered [2] to facilitate (a) (b)
ZVS operation. Fig. 12. HFT design. (a) Winding arrangement. (b) Prototype.
180 160
PO 2200W 1500W 1000W 500W
160 1
90V 120
Total Losses (W)
Total Losses (W)
140
ZVS
120 115V 80
100 140V
40
80 ZVS
60 0 0
2.83.4 3 3.6 3.2
3.8 4 4.2 90 100
110 120 130 140
Turn Ratio Output Voltage (V)
Fig. 10. Variation of total converter losses and ZVS range with turn ratio Fig. 13. Variation of total converter losses with output voltage and power.
and output voltage.
400 V. CONCLUSION
PO=2200W
In this paper, a design optimization procedure for the
Leakage Inductance (H)
PO=500W
300 HFT employed in DAB isolated DC-DC converter has been
described and experimentally validated. It has been shown
ZVS region
200
Non-ZVS region that by considering leakage inductance, phase-shifted angle
together with HFT VA rating, essential design equations
100
ZVS region for minimizing total losses of the DAB isolated DC-DC
Non-ZVS region
converter can be derived. It also has been demonstrated that
0
90
110 120100 130 140 leakage inductance requirement for ZVS operation can be
Output Voltage (V) achieved under the proposed design method without
Fig. 11. Variation of minimum leakage inductance for ZVS with output employing an extra inductor. Comparative study of DAB
voltage for PO = 2200W and 500W with n2 = 8.
HFT design with conventional and the proposed design
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VIII. BIOGRAPHIES
Khoa Dang Hoang (S’10) received the B.Eng. and M.Eng. degrees from
Ho Chi Minh City University of Technology, Ho Chi Minh City, Vietnam,
in 2002 and 2005, respectively, and the Ph.D. degree from the University
of Sheffield, Sheffield, U.K., in 2011, all in electrical and electronics
engineering. He is currently working as a post-doctoral Research Associate
at the University of Sheffield. His key research interests include power
conversion and advanced control techniques for electrical drives.
Jiabin Wang (SM’03) received the B.Eng. and M.Eng. degrees from
Jiangsu University of Science and Technology, Zhengjiang, China, in 1982
and 1986, respectively, and the Ph.D. degree from the University of East
(d) Secondary leakage inductance London, London, U.K., in 1996, all in electrical and electronic
Fig. 14. Measured inductances of prototype HFT. engineering. Currently, he is a Professor in Electrical Engineering at the
University of Sheffield, Sheffield, U.K. His research interests range from
motion control to electromagnetic devices and their associated drives in
VI. ACKNOWLEDGMENT applications ranging from automotive, household appliances to aerospace
sectors.
The authors gratefully acknowledge the European