Design and Optimization of Three-Phase Dual-Active-Bridge Converters for Electric Vehicle Charging Stations

In this paper, design and optimization method of a three-phase dual-active-bridge DC/DC converter is discussed. Three single phase transformers connected in star-star configuration were designed with large leakage inductance aiming to eliminate the need for external inductors. Switching frequency, peak flux density, number of turns, number of layers, etc., were optimized using non-linear programming technique for minimizing the overall converter loss. Experimental results on a 10 kW prototype show that the optimized converter can operate efficiently an efficacy of up to 98.65% and a low-temperature rise of less than 70 degrees Celsius on both transformers and semiconductor devices.