2016 Eleventh International Conference on Ecological Vehicles and Renewable Energies (EVER)

Research on Loss Reduction of Dual Active Bridge

Converter Over Wide Load Range for Solid State
Transformer Application
Qingshan Wang, Deliang Liang
Xi'an Jiaotong University
Xianning West Street, Xi'an, China
E-mail: dlliang@mail.xjtu.edu.cn

Abstract-This paper presents the design of new high

I. INTRODUCTION
frequency transformer isolated bidirectional dc-dc
converter modules connected in module-cascaded solid
state transformer (SST). A phase-shift dual active bridge
(DAB) converter is employed to achieve high-frequency
galvanic isolation, bidirectional power flow, and zero
voltage switching (ZVS) of all switching devices, which
leads to low switching losses even with high-frequency
operation. Bidirectional DC-DC converter is crucial to the
power transmission in SST. The proposed DAB converter
consists of two three-leg bridges and a high-frequency
transformer with winding shunting taps. Furthermore, the
commutation inductance connected in series with the
transformer in the conventional DAB converter is
integrated into the transformer windings, thus, enjoying
smaller volume and higher power density. By changing the
number of primary winding turns, leakage inductance, Fig.I. The Energy Internet diagram.

which is the key parameter in the energy transfer process

of DAB converter, can be adjusted on a large scale,
enabling the possibility of reducing loss over wide load
range. Additionally, time-sharing circuit topology and
operation mode are adopted to adapt to the output power
by detecting the output current as the feedback. As a
result, the efficiency at both light and heavy load can be
significantly improved compared with the conventional
DAB converter, and, therefore, high efficiency over wide
load range and high power density can be achieved.
Besides, the additional bridge arm structure along with a
flexible control scheme provides possible high-level fault
tolerance. Finally, the simulation results on a 2-kW DAB
converter module switching at 10kHz are presented to
validate the theoretical analysis.
Keywords-solid state transformer (SST); dual active
bridge (DAB); circulating energy; zero voltage
switching (ZVS); high efficiency.
Sustainable energy distributed generation is paid
tremendous attention in the last decade due to energy
shortage and environmental pollution issues. However, the
inherent intermittence and randomness in renewable
energy sources pose stiff challenges for the traditional
power management system. In order to achieve
optimization control of the entire grid, many promising
schemes of the smart grid concept have been put forward
by experts until the present time. The Energy Internet is a
representative one which provides intelligent energy
management (IEM) ports for the plug-and-play integration
of the distributed renewable energy resources (DRER), the
distributed energy storage devices (DESD), and ac/dc
loads, as shown in Fig. l. The intelligent fault management
(IFM) is responsible for fault isolation, used for protecting
the system. In order to enable intelligent management and
remote monitoring, the distributed grid intelligence (DGI)
unit, which integrates both advanced control and
communication functions, is embedded into the IEM and
IFM for fulfilling the needs of the smart grid concept.
What's more, the system implements the stable and
optimal operation of distributed control through reliable
and secured communication (RSC) network.

978-1-5090-2464-3/16/$31.00 2016 IEEE

 Composed of power electronics and high-frequency
transformer, the solid state transformer (SST), which is
called the Energy Router, is the key enabling elements in
the Energy Internet system. Besides serving as a regular
distribution transformer, the SST makes use of state-of
the-art control techniques that allows it to provide
advantages such as small volume, low weight, load
disturbance rejection, intelligent energy management, and
high power density.
A variety of SST implementation schemes have been
proposed from different perspectives by researchers in [1]
[11]. The circuit topologies raised to date can be divided
roughly into two categories according to the existence of
intermediate dc link in the power conversion process.
Relatively fewer switching devices used, simpler structure,
and lower volume are gained through adopting the direct
ac-ac configuration. However, the voltage and current
waveforms on the secondary side are basically the
revivification of that on the primary side, contributing little
to the improvement of power quality. Increased link stages
and number of switching devices of the ac-dc-ac
configuration bring about much more flexible control
features of voltage, current and power by employing the
pulse width modulation (PWM) method and appropriate
control strategies, thus representing the future
development trend.
Two measures can be taken in order to accommodate
the high voltage level in distribution network. One is to
develop new switching devices with high withstanding
voltage level, e.g., SiC- and GaN-based devices. In this
way, small number of devices connected in series can meet
the voltage level requirement and mature control strategies
are apt to be transplanted to continue working. However,
fact that new types of switching devices are much more
expensive (I 0-20 times) than conventional Si-based
devices indicates that large-scale application is unrealistic
at this moment. The other implementation roadmap is to
exploit the multi-level converters and module-cascaded
converters using current available switching devices. The
multi-level converters are relatively sophisticated in
working manners and their reliabilities deteriorate with the
increase of flying capacitors and clamping diodes. The
module-cascaded topologies show superiorities in system
reliability, modular feature consistency, and redundant
protection, thus improving the system compactness and
operating efficiency. Several module-cascaded SSTs have
been reported in [12]-[18], and much of previous work has
focused on developing control techniques to achieve input
voltage and output current sharing, stable operation, and
better dynamic performance.
Besides realizing electrical power conversion and
galvanic isolation, the middle-stage bidirectional dc-dc
converter has decisive impact on the operating efficiency
and power density of the whole system, therefore, is one of
the main challenges for the SST design. A 750-V 100-kW
20-kHz bidirectional isolated dual active bridge (DAB) dc
dc converter is constructed in [19], and its overall power
loss is divided into conduction and switching losses
produced by the SiC modules, the iron and copper losses
due to magnetic devices, and the other unknown loss. An
adaptive inductor is proposed in [20] as the main energy
transfer element of a phase-shift dual half bridge (DRB)
converter so that the circulating energy can be optimized
to maintain ZVS at light load and minimize the conduction
losses at heavy load as well. Reference [21] presented a
comprehensive theoretical analysis and experimental
verification of dead-time effect in the isolated bidirectional
full-bridge dc-dc converter (IBDC).
However, the phase-shift dual-bridge dc-dc converters
such as DAB and DHB converters have been reported in
[19] - [25] can operate in the ZVS mode only within a
limited region restricted by the converter voltage ratio of
input to output and the load condition, and suffer
additional conduction losses due to the circulating energy
at heavy load. Consequently, high efficiency can be
achieved only within a limited load range.
This paper proposes an module-cascaded DAB
converter as the high-frequency transformer isolated
bidirectional dc-dc converter stage of the SST. The
proposed converter employs phase-shift DAB topology for
the individual modules to achieve high-frequency galvanic
isolation, bidirectional power flow, and ZVS operation of
all the switching devices. The ZVS technique leads to low
switching and conduction losses even under high
frequency operation. Furthermore, the commutation
inductance connected in series with the transformer in the
conventional DAB converter is integrated into the
transformer windings, thus, enjoying smaller volume and
higher power density. By changing the number of primary
winding turns, leakage inductance, which is the key
parameter in the energy transfer process of DAB
converter, can be adjusted on a large scale, enabling the
possibility of reducing loss over wide load range.
Additionally, time-sharing circuit topology and operation
mode are adopted to adapt to the output power by
detecting the output current as the feedback. As a result,
the efficiency at both light and heavy load can be
significantly improved compared with the conventional
DAB converter, and, therefore, high efficiency over wide
load range and high power density can be achieved.
Besides, the additional bridge arm structure along with a
flexible control scheme provides possible high-level fault
tolerance. Finally, the simulation results on a 2-kW DAB
converter module switching at 10kRz are presented to
validate the theoretical analysis.
 Cascaded Ii-bridge rectifier Dual active bridge converter dc-ac inverter

H igh-voU nge de bus Low-voltage dc bus

Fig.2. Main circuit configuration of the single-phase module-cascaded ac-dc-ac SST.

II. MODELING AND CONTROL ANALYSIS

A . Analysis a/ Cascaded H-Bridge Rectifier

As can be seen in Fig.2, the first stage of the proposed
SST is a cascaded H-bridge rectifier interfacing with the
electric utility grid which is used to provide power factor
correction function while converting input ac voltage to
high-voltage dc bus. The average differential equations of Fig. 3. The double-closed-loop d-q vector control block.
cascaded H-bridge rectifier can be expressed as following
In order to realize the decoupling control of active
power and reactive power, voltage and current ac variables
are converted into dc variables through coordinate
transformation, in which at least two phases are needed.
Thus, a mirror image phase M, lagging the actual phase A
by 90, is hypothesized. Then, the dq-axis equation of the
(1)
single-phase module-cascaded H-bridge rectifier is given
in (2)
dV3 1 (d . . )
-=--
C a3 1a -Ib3
dt HJ

where, ia is the input current, ea is the input ac voltage, L is

the input inductor, Vi is the high-voltage dc bus voltage,
CHi is the rectifier dc capacitor, and dai is the rectifier
where id, iq are the d-q axis component of rectifier ac side
PWM duty cycle, ibi is the input current of the DAB
input currents, ed, eq are the d-q axis component of grid
converter, i= I, 2, 3.
input voltage, ddl, dd2, dd3 are the d axis component of the
rectifier PWM duty cycle, dql, dq2, dq3 are the q axis
component of the rectifier PWM duty cycle.
 It is known from (2) that d-axis current and q-axis
current are still coupled together after coordinate
transformation. To independently control the d-axis
current and q-axis current, add wLiq item in the d-axis
current control loop and wLid item in the q-axis current
control loop. Moreover, employ the grid input voltage as
the feed forward compensation to improve the ability to
resist interference and dynamic performance of the system.
The double-closed-Ioop control is applied in the
rectifier controller together with the d-q vector control
depicted above, as shown in Fig.3. The outer voltage loop
is to ensure a constant output dc voltage while the inner
current loop is to achieve unity input power factor. The
sum of three rectifier dc capacitor voltages is input into the
voltage loop regulator, obtaining the set value of d-axis
current, which represents the active power component.
The desired quantity of q-axis current is set to zero to
offset the reactive power. The three sinusoidal pulse width
modulation (SPWM) carriers for the cascaded H-bridge
are phase shifted so that the rectifier has seven voltage
levels to reduce the voltage stress and harmonics.
B. Analysis 0/DAB Converter
The DAB converter, which is the key stage of SST,
consists of a high-voltage H-bridge converter, a low
voltage H-bridge converter and a high-frequency
transformer, as shown in FigA, providing high-frequency
galvanic isolation and converting high-voltage dc bus to
low-voltage dc bus as well.
L,
u,
Fig.4. The simplification of the transformer T-circuit equivalent model.
Phase-shift technique is adopted in DAB converter to
realize ZVS operation for all switching devices in either
direction of power flow [7]-[9], and, therefore, enables the
high-frequency operation while keeping low switching
losses. Real power flows from the bridge with leading
phase angle to the bridge with lagging phase angle, the
amount of transferred power is controlled by the phase
angle difference and magnitudes of the dc voltages at two
ends as given by (3).
p
= nV,Xout d(l- d)
2JL,
where n is the turns ratio of the high-frequency
transformer, Vin is input side high dc-link voltage, VOll! is
output side low dc bus voltage referred to input side, Ls is
the sum of the leakage inductance of the transformer and
the external auxiliary inductance, /is switching frequency,
and d is the ratio of the phase-shift angle between the
primary bridge and secondary bridge to one half of
switching cycle, usually ranging from -1/2 to 112.
Fig. 5. The DAB voltage controller.
Generating the primary and secondary side 50%-duty
ratio square wave drive signals with the same frequency,
acquire the secondary side voltage as the feedback
quantity to form a closed-loop control to adjust the phase
bias between the two signals, as can be seen in Fig.5. First
the difference between the low dc voltage VdcL and the
reference voltage is compared. Then, the phase-shift angle
is adjusted by the proportional-integral-differentiation
(PID) controller to regulate VdcL to the reference value
according to this voltage error.
C. Analysis a/Output dc-ac Inverter
Low-voltage dc bus can be converted to output ac
voltage for end-use application through a dc-ac inverter. A
modulation method based on SPWM and a control
strategy for external voltage RMS loop and instant voltage
internal loop is adopted. The output unit generates
constant single-phase 50Hz sinusoidal ac voltage
regardless of the load conditions.
Fig. 6. The output dc-ac inverter controller.
III. LOSS ANALYSIS OF THE CONVENTIONAL DAB
CONVERTER
Figs.6 shows the circuit diagram of the conventional
DAB converter. The key ideal steady-state waveforms are
shown in Fig.7. The operation of the conventional DAB
converter is fully described in [20]-[23].
.\'1,4 > I
S2,3 1
S5,8
.\'6,7
----i---- >t
v,
(3)
> I
>t
> I
h 04 4
Fig.7. The key ideal steady-state waveforms of the conventional DAB
converter.
 To simplify the analysis, the converter voltage ratio of
the input voltage V;n to output voltage Vout is assumed to be
I (i.e. Vout=NsV;nINp, where Np and Ns are the number of
primary and secondary turns in the transformer,
respectively.) The output power can be given by
Ec 'C. E'h (11)
where Eth is the energy of ZVS threshold and insufficient
energy Ec will result in the loss of ZVS of the switching
devices. On the other hand, large circulating energy will
cause large additional conduction losses. In order to

POOl =
_1_ f.16
t6 - t0 10
v i
ae L =
V;d(1-ldl)
(4)
achieve high efficiency over a wide load range, Ec is
expected to be large enough to maintain ZVS to reduce
2fL .
switching losses at light load, but to be minimized to
where iL is the instantaneous current of commutation
reduce additional conduction losses at heavy load.
inductor L. The output power of the proposed converter
In the conventional phase-shift DAB converter,
can be controlled by d and L as well, while the output commutation inductance L is fixed and the output power is
power of the conventional DAB converter can only be controlled only by d. According to (3), phase shift d, if
controlled by d. ranging from -112 to 112, is proportional to the output
The instantaneous current of commutation inductor at to power Pout. Combined with (8), it can be seen that the
can be given by circulating energy Ec is proportional to Pout, and therefore,
U;nd Ec at heavy load is always much larger than that at light
1
. =- (5)
L(lo) load due to larger d and Pout. Consequently, L can only be
-
2fL optimized for a limited load range, and so does the high
By combing (3) and (4), the current stress of switching efficiency.
tubes can be given by
IV.
liT('O)1 = V;n
THE PROPOSED PHASE-SHIFT DAB CONVERTER
(6)
(o:ldl) A . Leakage Inductance Variation with Winding Turns
The delivered power during (to-t2) and (t3-t5) can be
obtained by Leakage inductance is an inductive element in a

f'2 v
transformer that results from the flux linking only one
{I winding and closing mainly by air or oil. Primary winding
PdOZ = 10aeiL
t2 - to magnetic flux c[>11 and the secondary winding magnetic
I 'f s (7) flux c[>22 of a transformer can be expressed as
V .
Pd3, = t -- aelL
. S- t3 13 <PII =<Pll +<P =<Pll +<P ZI+<PIZ
{ (12)
Combining (6) and the boundary conditions iL(t2)=-iL(to) <Pzz =<P'2 +<P = <p/z +<PIZ +<P21
and iL(t3)=- iL(t5) yields where" c[>11 is the magnetic flux linking only the primary
PdOZ = PdJS = 0 (8) winding and generated by iI, c[>12 is the magnetic flux
which means that the average power during both (to-t2) linking only the secondary winding and generated by i2,
c[>21 is the magnetic flux linking both the primary winding
and (t3-t5) are equal to zero, but the energy stored in the
and secondary winding and generated by iI, c[>12 is the
commutation inductor will circulate in the circuit and
magnetic flux linking both the primary winding and
generate additional conduction losses, the total circulating
secondary winding and generated by i2.
energy during one switching period (to-t6) can be given by
-4 f2 i
I
Z 2
V d dP001 The voltage equations of the primary and secondary
T.
m_

E - V - _
(9)
C
II
ae 4{ z windings of the transformer are as following
L 2/(1-ldl)
Ec is the sum of the energy stored in the commutation { ( ) dli d2 i
1-';= LII+Lzl -+MI2-
inductor during (to-t2) and (t3-tS ) , and the energy stored in dt dt
dil ( ) di2
(13)
the commutation inductor during each transition period is
half of Ec, and can be expressed as Vz =M 21 -+ L,z +LIZ -
dt dt
Ec d'11 The self-inductances of the primary and secondary
EL = = (10) windings of the transformer are as following
2 4/(1-ldl)
ZVS operation of the switching devices is achieved by {Lp =L/l +Lzi
(14)
utilizing the circulating energy Ec to discharge the output L, =L,z +L12
capacitance Co of the switching devices, and the
It is approximately considered that the magnetic core of
circulating energy Ec should be no less than the total
the transformer is uniform, then
capacitor energy to maintain ZVS operation, i.e.,
 {
L 21 : ( N" / N, M 21
)
(15)
B. Transformer Core Loss Reduction
The high-frequency transformer flux density swing, as
LI2 - ( N. , / Np ) M12 seen in (20), becomes smaller when NI is enlarged and
where, M21=MI2=M is the mutual inductance between the other parameters remain unchanged, [30]-[33].
primary winding and secondary winding of the
transformer, so the leakage inductances can be (20)
calculated as
{
LII :L " - ( N" ) / N, M
(16)
The core loss can be calculated by the following
empirical formula:
LI 2 - L, - ( N, / Np ) M
1 = VeemF B:c (21)
The engineering calculation formula of self-inductance where Ve is the effective core volume of transformer, Cm,
are adopted as in [26]-[29]: x, and yare the coefficient related to the core material, Bac
is the maximum flux density and can be expressed as

(22)

(17)
It is obvious from (22) that the maximum flux density
is inversely proportional to the primary winding turns M
M=K"fLi: LpL
S
when the same switching frequency and effective cross
sectional area of the transformer core are employed. Thus
Substituting (15), (16), (17) into (14), then the leakage it can been seen that increasing the transformer winding
expressions are gained turns is an effective way to the core loss reduction,
2 improving the overall efficiency at wide load range.

I
N" Ae
L11 = (I _ K) f.1of.1e
Ie C. Circuit Structure and Operation Principle of the
(18)
2 Proposed DAB Converter
f.1of.1e NA
LI 2 = (1- K) s e As observed from Fig.8, the proposed DAB converter
Ze
in this paper consists of two three-leg bridges and a high
where, Np is winding turns of transformer primary
frequency transformer with winding shunting taps. Loose
winding, Ns is winding turns of transformer secondary coupled structure is employed when designing the primary
winding, K is the coupling coefficient of the primary and and secondary windings of the transformer, gaining
secondary winding, Uo is the core permeability in a
relatively large winding leakage inductance. In this way,
vacuum, Ue is the core effective permeability, Ae is the
the commutation inductance connected in series with the
core effective cross-sectional area, and Ie is the core
transformer in the conventional DAB converter is
effective length of the magnetic path. integrated into the transformer windings, thus, enjoying
Ignoring the winding resistances, magnetizing smaller volume and higher power density.
resistance, and magnetizing inductance, meanwhile,
converting the leakage inductance of the secondary
winding to the primary winding, the equivalent model of
the high-frequency transformer is achieved, as Fig.4
shown.
2f.1of.1e NI'2Ae
L., = L11 +L12 ' = ( l-K ) (19)
Ie
As (19) demonstrates, leakage inductance Ls is Fig.8. The proposed DAB converter.

proportional to the square of primary winding turns Np So
by changing the number of primary winding turns, leakage
inductance Ls, the key parameter in the energy transfer
process of DAB converter, can be adjusted on a large scale,
enabling the possibility of reducing loss over wide load
range.
Assume that the shunting tap divides the primary
winding of the transformer into two segments, winding
turns of which are Nl and N2 respectively. Similarly, the
secondary winding of the transformer is segmented into
two parts with N3 and N4 winding turns. Define the
external turns ratio n and the internal turns ratios nl, m as
shown in (23), (24), (25). In order to output constant
voltage Vout, the internal winding turns ratios nl and mare are: f=IO-kHz, rated power Pouuatect=2-kW, ViI1=400-V,
expected to be kept consistent. and Vout=200-V. For the comparison purpose, an
optimized fixed l-mH inductor Ls is chosen for the
N] +N2
n = --------=-
-' (23) conventional phase-shift DAB converter, while the
N3+N4 adaptive inductance as shown in Fig.15 is adopted for the
N] proposed DAB converter.
n =- (24)
I N2 500

43
450

n2 = (25) 400

350

> 300 -Vgsl

-Vdsl
-Vgs2
The proposed converter employs phase-shift DAB
-Vds2
2S0

topology for the individual modules to achieve high 200

<0
;;> 150
Hflrd swilching
frequency galvanic isolation, bidirectional power flow, and 100

ZVS operation of all the switching devices. The ZVS 50

technique leads to low switching and conduction losses

-100 2850 2900 2950 3000 3050 3100 3150 3200
even under high-frequency operation. Number of sampling points

Fig.II. Key waveforms of the conventional DAB converter at IIOOW.

500

450

400

350

;;- 300
-Vgsl
-Vdsl

'ar' 250
..
-Vgs2

200
-Vds2

<0
>
ZVS switching
150

100

Fig.9. The full-winding operation mode of the proposed DAB 50

converter.
-'ioo 2850 2900 2950 3000 3050 3100 3150 3200
Number of sampling points
-I
s, Fig.I2. Key waveforms of the proposed DAB converter at IlOOW.

500

450

400

-I
35U

$' 300
-Vgsl
-Vgs2

250 -Vgs5

ZOO -Vds 2
-Vtlsi
Fig. 10. The partial-winding operation mode of the proposed DAB <0
>- ISO
converter.
100

1---- ----/
Additionally, the time-sharing circuit topology and 5U 17us

operation mode are adopted to adapt to the output power -1oo

Number of sampling points
2850 2900 2950 3000 3050 3100 3150 32:00

by detecting the output current lout as the feedback, as

shown in Fig.9 and Fig.IO. The DAB converter works in Fig.I3. Key waveforms of the conventional DAB converter at I700W.
full-winding mode at light load, reducing the core loss and
500
enlarging the leakage inductance to maintain ZVS 450
400-------,
operation. The DAB converter works in partial-winding
350
mode at heavy load, decreasing the leakage inductance to JOO -Vgsl

250
-Vgs2

alleviate the conduction loss, promoting efficiency further. -Vgs5

200
-Vdsl

As a result, the efficiency at both light and heavy load can ;;> 150
-Vtls2

be significantly improved compared with the conventional IOU-------,

50
DAB converter, and, therefore, high efficiency over wide
load range and high power density can be achieved. 2850 2900 2950 3150 32 00
Number of sampling points
3000 3050 3100

v. SIMULATION RESULTS Fig.14. Key waveforms of the proposed DAB converter at 1700W.

On the foundation of topologies and control strategies The conventional DAB converter with fixed inductor
discussed above, simulation model of bidirectional dc-dc was also tested and compared with the proposed new DAB
converter applied in SST middle stage is built in converter to validate the extended high-efficiency range of
MA TLAB/SIMULINK environment. The specifications the latter. Fig.11 and Fig.12 show the key switching
waveforms of two DAB converters under light load adjusted on a large scale, enabling the possibility of
condition. ZVS of S1 of the proposed DAB converter can reducing loss over wide load range. Additionally, time
be maintained in Fig.12, while S1 of the conventional DAB sharing circuit topology and operation mode are adopted
converter loses ZVS in Fig. l l. Fig.13 and Fig.14 show the to adapt to the output power by detecting the output
switching waveforms of the two DAB converters under current as the feedback. As a result, the efficiency at both
heavy load conditions. The proposed DAB converter can light and heavy load can be significantly improved
achieve smaller phase shift which means smaller compared with the conventional DAB converter, and,
circulating energy and resulted additional conduction therefore, high efficiency over wide load range and high
losses. Fig. lS shows comparison of the measured power density can be achieved. Besides, the additional
efficiency of two DAB converters. Both DAB converters bridge arm structure along with a flexible control scheme
can realize high efficiency during mid-range load provides possible high-level fault tolerance. Finally, the
conditions. However, the proposed DAB converter can simulation results on a 2-kW DAB converter module
achieve higher efficiency under both light and heavy load switching at lOkHz are presented to validate the
conditions. theoretical analysis.
100
90 ACKNOWLEDGMENT

Supports to this research work from State Key

://
/
50
Laboratory of Electrical Insulation and Power Equipment
are gratefully acknowledged.
- Conn'ntionnl DAR con\'('rtt'r
-I'rollOSCtl DAH conwrler
40
'"
105m II
30
20 1'--- __
ImH ---+-O
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1-
---
--+- --- .51111 -------I
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