Design of a high-power-density dual-active-bridge converter experimental platform

The dual active bridge (DAB) converter has become widely used in power electronics education and research because of its advantages of low current stress, broad soft-switching range, and bidirectional power transfer. However, traditional teaching platforms often face limitations such as visualization of control strategies, high-frequency operational stability, and attainable power density. To overcome these issues, this study develops a digital signal processor (DSP)–based high-power-density DAB converter experimental platform that provides students with a deeper understanding of the DAB topology and its control principles, thereby improving experimental teaching and practical engineering outcomes in power electronics.

Through theoretical analysis, this study establishes systematic models and waveform derivations for single- and dual-pulse-width modulations (PWMs) combined with phase-shift control strategies. The inductor current expressions under various operating conditions, along with normalized power relationships, are analytically derived. These foundations support the implementation of modulation strategies on the experimental platform. Hardware-wise, the platform integrates the power conversion stage, isolated sensing and gate-drive circuits, and comprehensive protection mechanisms. Silicon carbide (SiC) MOSFETs and a planar transformer are used in the power conversion stage to achieve high-frequency, high-efficiency operation and meet high-power-density requirements. The sensing subsystem employs AMC1302, AMC1311, and Hall-effect sensors to enhance isolation accuracy and noise immunity, while the gate-drive subsystem utilizes the UCC21710QDWQ1 to ensure fast, reliable, and safe switching of SiC devices. The software framework revolves around Texas Instruments’ DSP280039 as the main control unit. The integrated advanced PWM, comparator subsystem, and analog-to-digital converter, along with other peripherals, enable duty-cycle regulation, phase-shift synchronization, overcurrent protection, and real-time system monitoring. Using this setup, a hardware prototype is built and tested under various control strategies to verify voltage and current waveforms. A comparative analysis highlights differences in current stress and energy transfer characteristics across the modulation strategies.

Experimental findings show that PWM plus phase-shift modulation significantly reduces current stress during high-frequency operation. Under traditional single phase-shift control, the measured current stress is about 29.3 A. After applying duty-cycle regulation, the current stress drops to 23.0 A with the single-PWM plus phase-shift technique, and to 23.6 A with the dual-PWM plus phase-shift method. These results confirm that PWM-assisted control effectively optimizes current stress and enhances energy transfer, while also demonstrating the platform’s ability to verify various advanced modulation techniques. The high-power-density DAB platform operates stably at high frequencies, features compact system integration, and shows improved conversion efficiency and thermal performance. Furthermore, its complete sensing, driving, and protection mechanisms provide strong immunity to interference and robust fault response, ensuring reliable operation during laboratory teaching and research.

The DSP280039-based high-power-density DAB converter platform is compact, flexible, well-protected, and capable of stable high-frequency operation. It supports fundamental DAB control strategies and the validation of advanced modulation techniques, offering a solid experimental foundation for understanding energy transfer, modulation principles, and soft-switching characteristics. The platform’s excellent dynamic response and thermal stability make it a valuable platform for future developments in multiloop control, multimode modulation, and high-frequency converter research and education.