Design Methodology Based on Dual Control of a Resonant Dual Active Bridge Converter for Electric Vehicle Battery Charging

In this paper, a detailed design methodology of a Resonant Dual Active Bridge (R-DAB) converter is proposed for battery charging applications. The converter design methodology is tailored to the charging profile of a Li-ion battery and is based on unique operating points (UOPs) that derive from a dual control method analysis. Specifically, both Pulse Frequency Modulation (PFM) and Phase-Shift Modulation (PSM) are adopted, to minimize the switching losses and the reactive power at the resonant tank. A detailed flowchart is presented, considering multiple design parameters and the UOPs, so that the resonant tank parameters are not overestimated. Simulation results of a conventional charger are presented, that validate the control method and design procedure. Finally, a 1kW|30A laboratory prototype charger is designed and evaluated, using a closed loop control system. The analysis of the experimental results proves the significance of the dual control method and verifies the proposed design methodology.