Hardware Design and Decoupled Three-Loop Control for a 10kV/400V ISOP-DAB Converter

In this paper, a 10kV/400V input-series-output-parallel dual-active-bridge (ISOP-DAB) converter has been analyzed and designed to satisfy the demand of high input voltage and high power DC-DC applications. For the high voltage ISOP-DAB converter, there are two main challenges to be addressed, which are the hardware design and isolated control. In this paper, firstly, the hardware design has been developed and presented, which includes the driving circuit design, high frequency transformer design, thermal management design and the modular structure design. Secondly, a decoupled three-loop control (DTLC) based on a master-slave control architecture (MSCA) has been presented, which consists of the input voltage sharing control (IVSC) loop, output voltage control (OVC) loop and output current control (OCC) loop. With the presented control, the power sharing, stable output voltage and current regulation can be realized with fast dynamic response. The effectiveness of the hardware design and the DTLC based on the MSCA has been verified by the simulation and experimental results.