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Optimizing Transformer RMS Current Using Single Phase Shift Variable Frequency Modulation For Dual Active Bridge DC-DC Converter
Optimizing Transformer RMS Current Using Single Phase Shift Variable Frequency Modulation For Dual Active Bridge DC-DC Converter
Optimizing Transformer RMS Current Using Single Phase Shift Variable Frequency Modulation For Dual Active Bridge DC-DC Converter
Abstract— The dual active bridge dc-dc converter is conduction losses of all the passive and active components of
increasing its acceptance in various applications due to its high the converter, magnetizing loss of the high frequency
efficiency, high power density and the wide range of power transformer, among others. These modulation techniques can
transfer capability with galvanic isolation. All these be categorized as, the phase-shift modulation techniques,
characteristics depend on the modulation techniques used to combinational modulation techniques, PWM modulation
operate the converter. In literature, suitable modulation techniques, and variable frequency-based modulation
techniques and their optimization techniques are proposed for techniques [3]-[20].
2022 IEEE Energy Conversion Congress and Exposition (ECCE) | 978-1-7281-9387-8/22/$31.00 ©2022 IEEE | DOI: 10.1109/ECCE50734.2022.9947681
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Fig. 1: (a) Schematic of a DAB dc-dc converter, (b) Its lossless equivalent circuit, and (c) Typical waveforms for the SPS modulation technique, such as
the transformer winding voltages, transformer current and secondary bridge output current.
[17]. The variable frequency (VFM) based modulation to regulate the output power ( ). This scheme obtains the
techniques further extends the low power region and reduce optimum phase shift ( _ ) to achieve _ . For
the current stress improving the converter efficiency [18]-[20]. fixed output and input voltages, _ will be constant
In this paper, a modulation technique has been proposed, over the full range of . The transformer current ( ) of the
which achieves further improved performance by optimizing converter at steady state condition, which is illustrated in Fig.
the system to achieve minimum rms current using both SPS 1(c), has four switching states similar to the conventional SPS
and VFM. In literature, the optimization techniques are modulation technique. The switching time period ( ) is
discussed using EPS, DPS, TRG, TPS and VFM, where the divided with respect to the voltage polarity of the transformer
modulation techniques utilize a minimum of two degrees of winding voltages ( and ) and the slope of . In this
freedom of the system. Similarly, the proposed modulation section, the principle of operation of SPVFM scheme is
technique in this article uses switching frequency ( ) and discussed considering all the switching states.
phase shift (φ) for the optimization process. It is shown in this A. Switching State I:
article that the optimum phase shift ( _ ) is independent
The time duration refer the waveforms of switching state I
of for achieving the minimum rms current of transformer
as shown in Fig. 1(c). Considering the equivalent circuit
( ). The derived optimization procedure allows to vary
shown in Fig. 1(b), the voltage ( ) across the equivalent
to regulate for a constant _ . This optimized leakage inductance for this state is positive because is
operation reduces the computational effort and increases the equal to and is equal to (− ). Hence, the slope ( )
system robustness. In comparison to the existing optimization of will be positive, as expressed in (2). Here, is the
techniques, the proposed methodology eliminates the need for equivalent leakage inductance referred to the primary side and
current sensor for measuring the inductor/transformer current.
is defined in (1). The duration of this state ( ) is (φ /2π),
The proposed technique combines the modulation schemes of
where φ is the phase shift between and . The current
VFM and SPS; and hence it is named as ‘single phase-shift
magnitude at the end of this state is , as shown at Fig. 1(c).
variable frequency modulation’ (SPVFM) in this article. This
is defined in (3), where (− ) is the initial magnitude of
also achieves full zero-voltage switching (ZVS) operation for
current at time t = 0.
both the input and output active bridges. The minimum rms
current and full ZVS operation lead to reduced conduction and = ! + # (1)
switching losses, thereby improving the system efficiency and =( + )⁄ (2)
reliability. The proposed modulation scheme is most suitable =− +( + )φ ⁄2π (3)
at low load and variable output voltage conditions.
B. Switching State II:
This article is organized as follows. Sec. II discusses the
operating principles of the proposed modulation technique. The waveforms for the time duration of refer the
Sec. III analyzes the steady state condition of the converter. switching state II, as illustrated in Fig. 1(c). During this state,
Sec. IV explains the optimization technique and control is equal to and is equal to . Hence, the polarity
structure of the DAB. Sec. V describes the soft-switching of is defined by ( − ). Therefore, the slope of for
criterion for both the input and output bridges. Sec. VI this state will be , as expressed in (4). The duration of this
provides the experimental and simulation results. Sec. VII state ( ) is ((π − φ) /2π). The current magnitude ( ) at the
concludes this paper with discussion on suitable application end of this time duration is calculated as in (5).
areas.
=( − )⁄ (4)
II. OPERATING PRINCIPLE OF THE SINGLE PHASE-SHIFT = +( − )(' − φ) ⁄2π (5)
VARIABLE FREQUENCY MODULATION (SPVFM) SCHEME C. Switching State III:
The proposed modulation scheme is the combination of The waveforms of different parameters for this switching
SPS and VFM. This hybrid modulation technique uses two state are illustrated in the time duration duration ( , as shown
degrees of freedom to regulate the output power and achieves in Fig. 1(c). The polarity of in this state is negative as
the lowest possible rms current ( _ ) through the is equal to (− ) and is equal to . Therefore, the slope
transformer. Shape of the transformer current and voltage ( ( ) of is negative, as expressed in (6). Note that ( is
waveforms are like those of the SPS modulation technique, equal to (− ). The current magnitude (− ) at the end of this
but the switching frequency ( ) of the converter is modulated
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Fig. 2: Characteristic of vs. for SPS Fig. 3: Existence of minimum NO_ ⁄ ratio at Fig. 4: Trajectory of NO_ under SPS
modulation. different L . and SPVFS at L =1.5.
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converter provides a unique at _ and also provides ℒ( , , _) =
high / at low and high value of . The proposed (
1 12 8
modulation technique SPVFM operates at _ for full F H( − ) + − I (27)
range of , while is regulated by controlling . The 48 ' '(
characteristics of with respect to is illustrated in Fig. 3. (1 − /')
The objectives of SPVFM technique are to find the + _- − #b 0
_ 2'
with respect to L and control to regulate .
The different components of the equations (24) and (25)
IV. COMPUTATION OF _ AND CONTROL ARCHITECTURE are separately mentioned in (28)-(31).
This section discusses two procedures to compute the d ( , )
optimum phase shift angle ( ) and the further =
_ d
utilization of that in the control architecture. The computation √3 (' − )
methods are direct differentiation of iQRST /iU and Lagrangian (28)
optimization technique. Both of these methods converge to a ' (/ e' ( ( − ) + 12' −8 (
unique expression of _ .
A. Method - 1: Direct Differentiation of / ∂ ( , )
=
This method has obtained the minima of / with ∂
respect to . As the slope of / is zero at minima, the e' ( ( − ) + 12' −8 ( (29)
_ value can be computed by solving (19). The −
derivation of expression in (17) with respect to results in 4√3' (/
(20), which is a fourth order polynomial equation defines four
∂ U( , ) (' − 2 )
roots of . Among these four roots, only one root lies in the = (30)
operating range of (0 ≤ ≤ π/2). This root defines the ∂ 2'
optimal phase shift angle ( _ ), as shown in (21), where ∂ U( , ) (' − )
X is defined in (22). Note that, equation (20) and (21) are =− (31)
∂ 2'
independent of .
8( / ) Now, equation (24) and (25) are rewritten as equation (32).
=0 (19) The left-hand side and the right-hand side of this equation are
8 mentioned in (33) and (34), respectively. Incorporating these
8( / ) ) ( expressions in (32), the equation (35) can be obtained.
= 4L − 8'L − 2' ( (1 − L)
8 (20) Equation (35) is a function of only variable . For all values
+ ' ) (1 − L) = 0 of #b , the equation (35) will be independent of
_ = considering L is constant. Solving (35), the _ can be
obtained as expressed in (21).
' (1 + L ) (21)
Y1 + √1 + X − F(2 − X) + [ d ( , ) ∂ ( , )
2 L √1 + X f
/(
d ∂
\2L(1 − L ) ] d U( , ) ∂ U( , ) (32)
X= (22) = f
2L d ∂
B. Method - 2: Lagrangian Optimization Technique d ( , ) ∂ ( , )
f
The method has studied the conventional procedure with d ∂
the formation of Lagrangian (ℒ) as mentioned in (23). Here, 12 (' − ) (33)
( , ) is the objective function and the ( , ) is the =−
' (( − ) + 12' −8 (
constraint function. At minima, the gradient vectors of both of
these functions will be in parallel. _ is the Lagrange multiplier. d U( , ) ∂ U( , ) (' − 2 )
f = (34)
According to this procedure, the slope of Lagrangian (∂ℒ/ ∂ ) d ∂ (' − )
becomes zero at minima. Therefore, the _ value can 12 (' − )
be obtained by solving (24), (25) and (26).
(' − 2 )a' ( ( − ) + 12' −8 (c
ℒ( , , _) = ( , ) + _a ( , ) − (35)
#b c (23) −1 = 0
∂ℒ( , , _) ∂ ( , ) ∂ U( , )
= +_ =0 (24)
C. Control system with the optimization technique
∂ ∂ ∂ The control architecture of the proposed modulation
∂ℒ( , , _) ∂ ( , ) ∂ U( , ) technique fulfills the following two objectives, a) regulation
= +_ =0 (25) of , b) obtain optimum phase shift. The block diagram of
∂ ∂ ∂
the control architecture is illustrated in Fig. 5, which
∂ℒ( , , _) comprises of output voltage controller, optimization block and
= ( , ) − #b = 0 (26)
∂_ modulation block.
The expressions of and U , mentioned in (14) and The optimization block calculates the optimum phase shift
(16), are substituted in (23) and found the equation (27). Here, _ with respect to the and the output reference
#b is the desired output power of the converter. voltage ( #b ). Here, L is considered as ratio ( #b / ),
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Fig. 5: Block diagram for control system. Fig. 6: Soft switching criterion of optimized Fig. 7: Efficiency for SPS and SPVFS at
trajectory. L =0.875.
which used to obtain _ from equation (21). The For the proposed SPVFM scheme, the trajectory of the
output voltage controller receives the instantaneous value of optimal phase shift _ with respect to L is plotted with
and #b to compute the switching frequency of the the black line as illustrated in Fig. 6. This indicates that the
converter. A conventional PI controller is used in the voltage switching operation characteristics for input and output
controller, which response with respect to the voltage bridges lie entirely within the soft switching zone. This
difference ( #b − ). eliminates the switching loss during turn-on. However, at low
load condition, the turn OFF loss increases with operating
According to (21), the computation of optimum phase shift frequency .
does not depend on . The voltage controller output will
vary with respect to the output power following the equation VI. SIMULATION AND HARDWARE RESULTS
(16). The optimization block will be unaffected for this The proposed SPVFM technique is verified using
variation of . This ensures the decoupling between the simulation study as well as tested with the help of a hardware
control variables ( and ). Furthermore, at the transient state
setup. PLECS is used to avail the actual model of the
due to the change of load, the instantaneous variation of
semiconductors. The copper loss of the inductor and
does not effect the the optimization block, as #b remains
transformer is modeled using a lumped resistance. For
constant at output voltage reference value. So, the optimum
SPVFM technique, is varied from 10 kHz to 100 kHz for
phase shift _ will be constant for full range of output
the power variation from 1.0 pu to 0.1 pu, as shown in Fig. 3.
power at constant #b / .
For wide range of frequency, SiC-MOSFET is considered.
The optimization technique used in the proposed SPVFM However, this leads to higher cost compared to Si-MOSFET.
scheme ensures the operation at minimum rms current for the Nonetheless, higher efficiency is achieved using SiC-
full range of output power. According to Fig. 4, the blue curve MOSFET with SPVFM technique, as shown in Fig. 7. This
represents the gh X/ i ratio for SPVFM technique. This reduces the operating cost of the system with respect to Si-
MOSFET with SPS modulation technique. This comparative
signifies that the rms current always attend the minimum
gh X study is performed where L is maintained at 0.875.
value for full range of i
. Whereas, the SPS modulation
The details of the parameters used in the hardware setup
technique exhibits very high gh X at very low and high power is listed in Table I. The hardware is tested using both SPS and
region. Following the rms current, the reactive power flow in SPVFM techniques for 0.75 pu, 0.5 pu and 0.33 pu of the
the system also reduces, but this optimization technique does rated output power, as shown in Fig. 8. For SPS modulation
not measure the transformer current or winding voltages to technique, = 10 kHz irrespective of the output power;
obtain the reactive power. Therefore, the proposed SPVFM however, changes with respect to . On the other hand,
technique can be implemented using only one sensing input under SPVFM scheme, inversely changes with , whereas
(output voltage) as shown in Fig. 5.
and L are constant at 41.89° and 1.5 respectively. These
V. SOFT SWITCHING CRITERION OF SPVFM TECHNIQUE experimental results validate that the is lower for the
The typical SPS modulation technique works in zero
voltage switching (ZVS) condition following the constrains
mentioned in (36). The system crosses the boundary of soft
TABLE I. PARAMETERS USED IN HARDWARE PROTOTYPE.
switching criterion for wide variation of L and/or low power
condition. The boundary of the soft switching zone for SPS Parameters Details
modulation technique is illustrated in Fig. 6. The shaded area Input voltage 48V
indicates the zero voltage switching region and this is Output voltage 72V
independent of the operating frequency . Rated power 160 W
Primary Leakage inductance 90 µH
' 1
.1 − / , L ≥ 1 Secondary Leakage inductance 90 µH
2
> k' L (36) Turns ratio of transformer 1:1
(1 − L), L ≤ 1 Input capacitance 940 µC
2 Output capacitance 940 µC
Switches SCT3030
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Fig. 8: Waveforms of hardware result. (a), (b) and (c) are the waveforms of SPS modulation technique at 0.75 pu, 0.5 pu and 0.33 pu of the rated load,
respectively. (d), (e) and (f) are the waveforms for SPVFM technique at 0.75 pu, 0.5 pu and 0.33 pu of the rated load, respectively.
Fig. 9: Experimental results of efficiency vs. output power for SPS and
SPVFM. Fig. 10: Experiential setup.
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