Algorithmic Approach for Optimal Design of DAB Converters in On-Board Chargers

This study aims to optimize a dual active bridge (DAB) converter for integration into an electric vehicle's onboard charger (OBC). The optimization process utilizes an algorithm to determine the optimal construction parameters, including the number of turns in the inductor, gap length, and the number of turns in the primary and secondary windings of the transformer. By considering seven selected operating points, the objective is to minimize the total loss sum and identify the optimal frequencies for each point. Subsequently, a lookup table is created to ensure efficient OBC operation across various output power and current levels by optimizing the frequency as a single variable. The power switch losses are compared with theoretical calculations and simulation results were obtained from PLECS 4.7.2 to validate the optimization process.