This article has been accepted for publication in IEEE Transactions on Industrial Electronics.

This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/TIE.2023.3234135

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A Three-Level Resonant DAB Converter

Featuring Minimised Circulating Losses for EV
Battery Charging
N. J. Merlin Mary, Student Member, IEEE, Shelas Sathyan,Member, IEEE,
and H. M. Suryawanshi, Fellow, IEEE
Abstract—A three-level modified series-parallel bidirec- industrial applications like solid-state transformers, renewable
tional isolated dc−dc resonant converter (TL-MSPBRC) is power generation, uninterrupted power supplies, and electric
proposed for EV battery charging. The converter’s perfor- vehicles [10]. Soft-switching is mandatory in these converters
mance is enhanced for wide load conditions as the mod-
ified series-parallel resonant tank is formed by consider- to minimize switching losses. Various bidirectional converters
ing the parasitics in the transformer. The first-harmonic are proposed in the literature where the soft-switching feature
approximation (FHA) equivalent circuit model is employed is incorporated by including resistor-capacitor-diode snubber
to analyze the converter characteristics for the frequency and active-clamp commutation circuits [11], [12]. But the com-
modulation technique. This converter has high conversion ponent count increases due to additional circuitry. The most
efficiency in charging and discharging operations because
of the soft-switching capability of the power switches in the appropriate isolated converter for large power transfer in both
primary and secondary bridges. In addition, low on-state directions is a dual active bridge (DAB) converter [13]. DAB
resistance switches in the three-level primary bridge mini- is an attractive topology that can operate in buck and boost
mize the conduction losses. A 3.3-kW converter prototype modes with high-power density and soft-switching features
with a battery voltage range of 230−300-V is developed to [14]. In DAB converters, transformer leakage inductance is
validate the design method and the simulation results. The
proposed converter has minimized circulating losses, good the power-transferring element [15]. The stored energy in it
short-circuit protection, and excellent efficiency of 97.7% at may be insufficient to discharge the parasitic switch capac-
the rated power level. itor under light load. It leads to hard-switching, drastically
Index Terms—Dual active bridge (DAB), electric vehicle reducing conversion efficiency and increasing electromagnetic
(EV), three-level (TL), resonant converter, soft-switching, interference [16]. By connecting an auxiliary inductor in
zero-voltage switching (ZVS), zero-current switching (ZCS).
series with the leakage inductance under light load conditions,
I. I NTRODUCTION
energy stored increases, and thus soft switching is attained
he power conversion unit in bidirectional EV charging
T systems consists of converters in the ac−dc stage and
a dc−dc stage that is capable of power flow in both di-
[10], [17]. Traditionally, DAB converters were regulated using
single-phase-shift control. But, the reactive current increases
when there is a voltage imbalance. Thus, conduction losses
rections, i.e., from vehicle-to-grid (V2G) and grid-to-vehicle
increase and reduce the overall efficiency [18], [19]. Different
(G2V) [1], [2]. Onboard EV charging systems with improved
modulation schemes like dual-phase-shift control, extended-
conversion efficiency and high power density are crucial for
phase-shift control, model-based-phase-shift control and hy-
the rapid increase of EVs [3]. Galvanically isolated converters
brid control help to eliminate the reactive losses, minimize the
are generally preferred in the dc−dc stage when the battery
switch current stress and improve the converter performance
output voltage is far higher or lower than the dc-link voltage.
[20], [21]. But these schemes demand complicated control
The isolation breaks the ground loop formed between the
techniques.
input and output power circuits for safety reasons [4], [5].
DAB converters implemented along with the resonant tank
Converters in the dc-dc stage are current-fed or voltage-fed.
achieve soft-switching on both primary and secondary bridges
Current-fed dc−dc converters inherently have high step-up
with high conversion efficiency [22]–[24]. Various resonant
gain, low transformer turns ratio, and less input current ripple
converter topologies with constant current (CC) / constant
[6], [7]. However, due to the mismatch in current between
voltage (CV) battery charging were proposed and studied in
the input boost inductor and transformer leakage inductance,
the literature. Series resonant converters (SRC) under light
voltage spikes across switches occurs during turn-off [8], [9].
load have lower circulating losses as the resonant tank is
In addition, the input boost inductor increases the magnetic
in series with the load and poor voltage regulation. Parallel
components count compared to voltage-fed converters.
resonant converters (PRC) under light load have good voltage
For forward and reverse power flow, bidirectional isolated
regulation, but very high circulating energy as the input current
voltage-fed dc−dc converters are extensively used in various
is independent of the load [25]. Series-parallel resonant con-
This work was funded by the Prime Minister’s Research Fellows verters (SPRC) take the excellent characteristics of SRC and
(PMRF) scheme, Ministry of Education, Government of India. PRC [26], [27]. DAB-LLC resonant converter is a well-known
N. J. Merlin Mary and Shelas Sathyan are with the Electrical and
Electronics Engineering Department, National institute of Technology topology for bidirectional power flow in EV charging systems.
Tiruchirappalli, Trichy, 620015, India. (e-mail: [email protected]; she- Many research works focus on designing an LLC resonant
[email protected]). converter to optimize the dead time, limit the overload current,
H. M. Suryawanshi is with Department of Electrical Engineering,
Visvesvaraya National Institute of Technology, Nagpur, 440010, India. and optimize maximum switching frequency [28]. However,
(e-mail: [email protected]). the methods proposed do not achieve CC/CV charging without

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 This article has been accepted for publication in IEEE Transactions on Industrial Electronics. This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/TIE.2023.3234135

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Fig. 1. Proposed dual active bridge TL-MSPBRC.

wide frequency variation. For resonant converters operating
away from the resonant frequency, resonant tank impedance
S/2
increases. Thus more energy is circulated in the resonant tank S

leading to increased circulating losses and deterioration of (a)

conversion efficiency [10], [25]. Multilevel resonant topologies
were developed to operate high-input voltage converters with
power devices of low-voltage rating [29], [30]. But not much
attention is given to studying the efficiency of such converters
for wide ranges of battery power.
To overcome the drawbacks mentioned above, a three-level
modified series-parallel bidirectional resonant converter (TL-
MSPBRC) for EV chargers is proposed. The article’s main
contributions and the converter’s merits are given below.
1. FHA equivalent circuits of the proposed TL-MSPBRC
for impedance load and voltage source load methods are
established to analyze the converter frequency characteristics.
2. As a three-level bridge is used on the high input voltage
side, the switch voltage is clamped at half of the dc input
voltage. Thus low on-state resistance switches can be utilized, S/2
S
which minimizes the conduction losses. In addition, the turn-
(b)
off time in lower voltage rating switches is less than in high- Fig. 2. Operational waveforms of TL-MSPBRC for the above resonant
voltage rating switches, thus decreasing turn-off losses [31]. frequency. a) Charging mode (G2V). b) Discharging mode (V2G).
3. As a modified series-parallel resonant tank is used, the signals to avoid damage due to the short-circuiting of the
converter can operate at a narrow frequency range for CC/CV input voltage Vin . There is a phase-shifted time tϕ between
charging with minimized circulating losses and excellent effi- the turn-on instants of primary and secondary bridge switches.
ciency compared to a conventional LLC resonant tank. Similar to a primary bridge, there is a dead time (td ) in
4. The short-circuit protection performance of the proposed gating between S1b , S2b , and S3b , S4b . The proposed converter
converter is excellent compared to the conventional LLC is frequency modulated, and the duty cycle of every single
converter. switch is slightly less than 50%. The principle waveforms
II. P ROPOSED TOPOLOGY AND OPERATING PRINCIPLE for the above resonant frequency in charging and discharging
Fig. 1 shows the proposed DAB TL-MSPBRC. It consists operations are represented in Fig. 2a and Fig. 2b. The charging
of MOSFET switches S1a and S2a in the upper leg, and mode operational circuits of TL-MSPBRC are shown in Fig. 3
S3a and S4a in the lower leg. The voltages across these and elaborated in detail here. The discharging mode circuit
switches are clamped at Vin /2 by the diodes Dx and Dy . operation is similar to that of the charging mode. In this
The two series capacitors, C1 and C2 , have half the input mode, switching pulses to the primary and secondary bridge
voltage Vin /2. The resonant tank elements include Lx and are interchanged, and the battery acts as a source.
Cx in series, Ly and Cy in parallel, and Cp across the high- a) Mode 1 (to - t1 ): This mode begins when the gate
frequency (HF) transformer. This tank contributes to filtering pulse for switches S1a and S2a are given at to . At the start
out the harmonics in the three-level inverter output current. of this mode, the current is is negative as it is lagging by
Lx represents the sum of a resonant inductor and the leakage an angle β w.r.t inverter output voltage VAB for the above
inductance in an HF transformer’s primary and secondary resonant frequency. The energy stored in the filter capacitors
(Lr1 , Lr2 ). The secondary active full-bridge converter has Cx and Cy discharge through the body diodes D1a and D2a .
switches S1b , S2b , S3b , and S4b with capacitive output filter C3a and C4a retain the stored CVin /2 charge as such. Energy
Co . The switches S1a and S2a are gated together, and the is transferred to the battery on the secondary side through the
switches S3a and S4a are gated together with a 180◦ shift. body diodes D3b and D4b . The voltage blocked by S1b and
A dead time of td is introduced between these two gating S2b is Vbat .

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(a) Mode 1 (to - t1 ) (b) Mode 2 (t1 - t2 ) (c) Mode 3 (t2 - t3 )

(d) Mode 4 (t3 - t4 ) (e) Mode 5 (t4 - t5 ) (f) Mode 6 (t5 - t6 )

Fig. 3. Operational mode circuits of dual active bridge TL-MSPBRC.
b) Mode 2 (t1 - t2 ): This mode begins when the gate A. Impedance load method
pulse for switches S1b and S2b are given at t1 . The transformer 1) AC equivalent impedance: The fundamental rms com-
secondary voltage VCD rises from −Vbat to +Vbat . Current ponent of secondary side transformer voltage VCD , referred
′
through S1b and S2b increases while the energy stored in C1b to primary as shown in Fig. 4c, is expressed as VCD,f rms =
′ √ ′
and C2b decreases, and thus it is a hard turn-on. Meanwhile, 4Vbat /π 2. The current peaks of filter current is , and io are
′
C3b and C4b charges to +Vbat . equal. The primary referred average output current io avg equal
′
c) Mode 3 (t2 - t3 ): This mode begins when C1b and to Ibat is given
C2b discharges its energy entirely, and the voltage across it √ by    
′ 2 2is rms Ts ws
becomes zero. At t3 , the current is naturally crosses zero and Ibat = −cos − θ + cos (−θ) (1)
ws Ts 2
becomes positive. It is sinusoidal due to harmonic filtering by The filter rms current is rms is deduced as is rms =
the resonant tank. Thus S1a and S2a are turned on with ZVS, ′ √
πIbat / 8 cos θ. The AC equivalent impedance Zac is
whereas S1b and S2b are turned off with ZCS. ′ ′
VCD,f rms ∠0 8V cos θ∠θ
d) Mode 4 (t3 - t4 ): In the primary bridge, the current Zac = = bat 2 ′ = |Zac | ∠θ (2)
through D1a and D2a are taken over by S1a and S2a . Whereas, is rms ∠ − θ π Ibat
′ ′
in the secondary bridge, the current through S1b and S2b are where Vbat / Ibat = n2 RO . The AC equivalent resistance Rac =
′ ′
taken over by D1b and D2b . The energy stored in Cx and Cy 8Vbat / π 2 Ibat . The value of θ varies with switching frequency;
′
increases. This mode ends when the gate pulses to S1a and thus, it is not a constant. It is the angle by which is lags VCD .
S2a are turned off. From Fig. 2, it is seen that θ = β − ψ. The time tψ is the
e) Mode 5 (t4 - t5 ): Current through S1a and S2a addition of dead time (td ) and phase-shift time (tϕ ), which are
decreases while C1a and C2a energy increases. Thus it is a fixed for frequency control. ψ is expressed as 2πfn fr tψ , and
hard turn-off. Meanwhile, C3a and C4a discharge their energy. β is given by 
f) Mode 6 (t5 - t6 ): Once C1a and C2a charge to Vin /2, −1 Img   ′


β = tan jXs− pu + Zac ∥(−j/ωCp )/Rac
the diode Dx conducts and clamps the voltage. C3a and C4a Real
discharge their energy entirely. Thus, the body diodes D3a (3)
and D4a start conducting. In the next mode, S3a and S4a are 2) Open-circuit impedance and short-circuit impedance:
turned on with ZVS. The short-circuited input impedance Zin SC and the open
circuited input impedance Zin OC are obtained by shorting
III. S TEADY - STATE ANALYSIS OF TL-MSPBRC and open circuiting the equivalent impedance Zac . Zin OC is
FHA technique is incorporated for modeling the converter expressed as Zin SC − jn2 /wCp , and Zin SC is given by
proposed. The gain of TL-MSPBRC is obtained by multiply- j jwLy
ing the individual gains of the three-level inverter, resonant Zin SC = jwLx − − 2 (4)
wCx w Ly C y − 1
filter, transformer, and active full-bridge rectifier. It is given
by Vbat /Vin = Mf /2n [32]. The transformer’s primary to At resonance the equations become
4 2 2 2
secondary turns ratio n is obtained by fixing the filter gain −wr
SC 100Lx Cx + wr SC 111Lx Cx − 1 = 0 (5)
Mf as one and designing the converter at 305 V, which is 10wr OC 4 Lx 2 Cx 2 − wr OC 2 65.52Lx Cx + 0.6442 = 0 (6)
slightly higher than the rated output voltage. Fig. 4a and
By solving these forth order equations, resonant frequencies
Fig. 4b show the equivalent circuits for the impedance load and
obtained are 1.04925 0.09531
voltage source load methods to obtain the design equations.
wr SC1,2 = ± √ , wr SC3,4 = ± √ (7)
Though both methods are advantageous in analyzing different Lx Cx Lx Cx
parameters of frequency modulated converter, voltage source 2.5577 0.09923
load method equations become indeterminate at the resonant wr OC1,2 = ± √ , wr OC3,4 = ± √ (8)
Lx Cx Lx Cx
frequency.
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Ly Xs_pu Ly i0 Ibat
is is_pu
A VCD
+ Lx C is
Vin/2 Z Cx + nVbat Lx is
Cy Zac Cx VCD R0
in Cy Vbat
Cp’ - VAB,f_pu Cp’ VCD,f_pu Zac = 0, Diode rectifier
- > 0, Controlled rectifer
B D
(a) (b) (c)
Fig. 4. FHA equivalent circuit for charging operation. (a) Impedance load method. (b) Voltage source load method. (c) Circuit to determine Zac .
obtained as desired. As load increases, peak current increases,
Rac decreases, and thus Q increases. Whereas for other
combinations of x, y, and z, the peak current decreases as Q
increases which is not a desired feature. The kVA/kW rating
for other combinations of x,y, and z increases drastically for
the above resonant frequency and is thus not favorable.
5) Voltage gain: The filter gain by applying the voltage
divider rule to the circuit in Fig. 4a is given by
4
fn3 m zn2 − fn n2 m2 xyz
Mf =  v 2
u −fn5 m6 + fn4 Qm4 zn2 tan θ + Qn2 xyz tan θ
u
−Qfn2 n2 m2 z tan θ
(xy + 1 + y) +
u 
u

u 3 4
(a) (b) t fn m 1 + zn2 + y + xy − fn m2 xy 1 + zn2
Fig. 5. (a) Gain versus frequency characteristics for wr SC3 . (b) Gain  2
versus frequency characteristics for wr SC1 . + Qn2 z(xy + fn4 m4 ) − Qfn2 n2 m2 z (xy + 1 + y)
(10)
After neglecting all the negative frequencies (wr SC2,4 and
wr OC2,4 ), it is seen that wr SC3 < wr OC3 < wr SC1 < The expression for angle θ is a transcendental equation
wr OC1 . At short-circuit impedance resonant frequencies and hence getting a theoretical solution is impossible. So,
(wr SC1 , wr SC3 ), the converter’s gain equals one. By plotting θ for the operating range of frequencies is expressed as
the gain frequency characteristics for different Q factors, as π(fn 2 − 1)/2fn 2 . This assumption is based on the fact that
shown in Fig. 5, it is seen that for wr SC3 , selectivity is very at the resonant frequency, θ is zero, and as the switching
high. Thus, controlling the frequency to obtain the required frequency increases, θ increases up to π/2.
converter gain becomes very difficult. Whereas for wr SC1 , 6) kVA / kW rating: The kVA/kW rating is the ratio of
selectivity is moderate for flexible frequency control. There- reactive power in the filter tank circuit to the active power
fore the proposed converter is designed at wr SC1 , denoted delivered to the equivalent load resistance (Rac ) at full-load
as wr . Fig. 6a and Fig. 6b show the variation of Zin SC and conditions. This ratio indicates the required reactive compo-
Zin OC with respect to frequency. The frequency at which nents size per kW output active power. The per unit kVA of
the positive and the negative imaginary terms of Zin SC and the resonant tank is given
" by
#
2 2
Zin OC equations meet is the resonant frequency. R is the f n m + 1 Q f n Qy fn m2
kV A− pu = i2s purms + +
characteristic impedance at which Zin SC is zero. In Fig. 6c, fn m2 fn2 m2 − xy 4zQn2
Rac at rated power is indicated. (11)
3) Quality factor: Quality factor (Q) is the dimensionless The filter rms current (is rms ) is given by
parameter, which varies dramatically with the load resistance. Vin
The Zin versus fn plot in Fig. 7a indicates that the Zin curve is rms = 4 3 2 4 3 2 2 2 2
(12)
n Q z R−jn Q z R tanθ−jQ zfn m Rn
moves from Zin SC to Zin OC as Rac increases. As the Zin Q4 n4 z 2 R−jQ4 n4 z 2 R tan θ+fn 2 m4 Q3
2R 2
jf 4 m4 −jf 2 m (y+1+xy)+jxy
curve traces the dominating inductive reactance slope for f > + n m2 (fn 3 m2 −f xy)
n n
fr , ZVS is achieved. For f < fr , a slope similar to capacitive
reactance dominates, thus achieving ZCS. Under light load
conditions (Q significantly less), the Zin plot in Fig. 7b has B. Voltage source load method
different characteristics than higher Q values. This is due to To plot the curves, the design equations of this method are
the effect of parasitic capacitance that is in parallel with the derived in p.u. The base values for normalizing the design
load impedance. For a wider range of frequencies, the curve’s equations are Vbase = Vin , Zbase = Rac , and fbase = fr . The
slope is zero, indicating neither
 ZVS nor ZCS.  normalized switching frequency fn = fs /fr .
R wr Lx 1 1 Ly wr
Q= = = + 2 (9) 1) Per-unit filter current: The fundamental normalized
Rac Rac Rac wr Cx w r Ly C y − 1 components of inverter output voltage (VAB ) and VCD′ lag-
4) Selection of resonant parameters: The resonant pa- ging VAB by ψ are given by
rameters are selected by ensuring the filter tank’s minimum 2
VAB,f pu (t) = sin ws t (13)
kVA/kW rating, reduced peak current, and narrow frequency π
control range [26]. The ratios Lx /Ly , Cx /Cy , and Cx /Cp ′ 2Mf
VCD,f pu (t) = sin(ws t − ψ) (14)
are denoted as x, y, and z. The plots of peak filter current π
−−→
and kVA/kW rating for x=0.1, y=0.1, and z=10 are shown The phasor representation of the current Is pu can be easily
in Fig. 8. The filter peak current at different Q factors is obtained since the equivalent circuit has two sources separated

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IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

1 Ly n2
 2 
C x  LyC y  1 C p
Z
in_SC
 Lx 1 Ly
1 Ly  2
 Z in_OC C x  LyC y  1
C x  2 LyC y  1

 Lx  Lx Rac

f r _ SC 3 f r _ SC1 f r _ OC3
f r _ OC1
(a) (b) (c)
Fig. 6. (a) Zin SC versus fr . (b) Zin OC versus fr . (c) Determining Q factor by plotting R and Rac .

primary bridge operates in lagging power factor mode or ZVS

if is− pu (0) is negative. For below resonant frequency at Mf
= 1, Xs pu and Mf cos ψ − 1 becomes negative, and thus
ZCS is achieved in the primary bridge. For the above resonant
frequency at Mf = 1, Xs pu and Mf − cos ψ become positive,
and thus ZCS is attained in the secondary bridge. For the
below resonant frequency, is− pu (ψ/ωs ) is negative, and the
secondary side works in ZVS. The first derivative of (15) is
f r _ SC1 f r _ OC1 set to zero at t = tp to find the peak filter current. ωs tp is
f r _ SC1 f r _ OC1 tan−1 (Mf sin ψ / Mf cos ψ − 1). The p.u. peak filter current
as a function of fn represented in Fig. 9c is given by
(a) (b)
2
ispk− pu (t) = [− cos (ωs tp ) + Mf cos (ωs tp − ψ)]
πXs pu
Fig. 7. Input impedance versus fn (a) High Q. (b) Low Q.
(19)
2) Average per-unit power: The transfer of instantaneous
power from the primary to the secondary can be evaluated
from either side. Here it is calculated on the output side. The
′
instantaneous power P−pu (t) is the product of VCD,f − pu
(t)
and is− pu (t). " n o #
Mf
4Mf 2 sin 2 (ωs t − ψ)
P−pu (t) = 2 (20)
π Xs− pu − {cos (ωs t) sin (ωs t − ψ)}
The per-unit active output power (Po− pu ) transmitted can
be deduced by finding
Z 2π the average of instantaneous power.
1 2Mf sin ψ
Po− pu = P−pu (t)d (ωs t) = 2 (21)
(a) (b) 2π 0 π Xs− pu
Fig. 8. (a) Filter peak current versus fn . (b) kVA/kW rating versus fn . The plot of Po− pu is given in Fig. 9d. For the above resonant
by an impedance [33]. By converting the phasor current back frequency, VAB leading VCD indicates ψ is positive, and the
to the time domain, one can obtain net flow of power is positive (charging mode or forward power
sin (ωs t − 90◦ ) −

2 flow). VAB lagging VCD indicates ψ is negative, and the
is− pu (t) = (15)
πXs pu Mf sin (ωs t − ψ − 90◦ ) net flow of power is negative (discharging mode or reverse
where the normalized reactance Xs pu is given by [23]. power flow). As fs increases, Xs pu increases, and thus
power delivered is reduced. It is seen from the graphs that
Qfn4 m4 + Qxy − Qfn2 m2 (xy + 1 + y)
Xs pu = (16) at the resonant frequency, we don’t get the correct value as
m4 fn3 − m2 fn xy Xs pu becomes zero, and (17), (18), (19), and (21) become
By evaluating (15) at t = 0 and t = ψ/ωs , two current indeterminate. So this method is unsuitable for obtaining exact
values are obtained, which are used to determine the type of resonant frequency values. In contrast, we get a graphical
soft-switching for frequency variation, as shown in Fig. 9a and representation with correct values at all frequencies in the
Fig. 9b. 2 impedance load method.
is− pu (0) = [Mf cos ψ − 1] (17) IV. E XPERIMENTAL RESULTS
πXs pu
  Experimental verification is carried out with a 3.3-kW
ψ 2
is− pu = [Mf − cos ψ] (18) hardware prototype shown in Fig. 10 to validate the theoretical
ωs πXs pu analysis. The input voltage is 450 V, and the output voltage
is− pu (0) is the initial current when VAB goes positive, and is 230−300 V. The resonant frequency is 100 kHz. The
is− pu (ψ/ωs ) is the current when VCD goes positive. The converter design specifications are given in Table I. At the

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 This article has been accepted for publication in IEEE Transactions on Industrial Electronics. This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/TIE.2023.3234135

IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

s
 - ve, P + ve  + ve, P + ve

 + ve, P - ve  - ve, P - ve

(a) (b) (c) (d)

Fig. 9. Charging mode plots for different Q factors. (a) is− pu (0) versus fn . (b) is− pu (ψ/ωs ) versus fn . (c) Per-unit filter peak current versus fn .
(d) Per-unit average output power versus fn .

Fig. 12. Control loop algorithm.

Fig. 10. Hardware prototype of the proposed converter
TABLE I
K EY PARAMETERS OF 3.3- K W PROTOTYPE
Parameter Value/Model Vendor

Primary MOSFETs IRFP4868PBF Infineon

Secondary MOSFETs SIHG018N60E-GE3 Vishay
Ultrafast diodes RHRG75120 Onsemi
HF transformer Ungapped PM 62/49 core (5:7 turns) Epcos
Series inductor (Lx ) EE 55/28/21 core (13 turns) Epcos
Parallel inductor (Ly ) ETD 44/22/15 core (33 turns) Ferroxcube
Series capacitor (Cx ) PHE450SD6100JR06L2 Kemet
Parallel capacitor (Cy ) PHE450PR7100JR02R06L2 Kemet Fig. 13. Gate pulses for switches.
Transformer secondary
B32529C8103J189 TDK
capacitor (Cp ) measured parasitic capacitor across the transformer secondary
Constant
is 2.698 nF. Though in theoretical design, Cp of 10 nF is
Constant current voltage chosen, including an extra capacitor does not have any visible
End point
330 W
change in the plots of voltage gain, kVA/kW rating, and peak
Output battery current (A)
Output battery voltage (V)

Current Turning point

Voltage
inverter output current.
3.3 kW
The charging profile of the lithium-ion battery pack is
plotted in Fig. 11. The algorithm for the control loop is
Nominal point implemented using the TMS320F28335 DSP kit, as shown in
2.750kW
Fig. 12. The main aim is to charge the battery with a nominal
voltage of 250 V from a depleted condition (230 V) to a
Begin point
2.530kW fully charged state (300 V) during G2V mode and discharge
the battery during V2G mode. The switch gate pulses for the
charging mode are shown in Fig. 13.
1) Constant-current (CC) charging mode operation: The
Fig. 11. Charging profile of lithium-ion battery.
proposed converter main waveforms for G2V mode at the be-
resonant frequency, it is designed for 305 V. The area-product ginning point when Vbat is 230 V (P=2.530kW) are illustrated
method calculates the core size required for filter inductors in Fig. 14. For this power level, fs is regulated at 113.49 kHz
and transformers. The measured primary leakage inductor plus to get the rated current of 11 A. The negative portion of the
primary referred secondary leakage inductor is 6.985 µH. The current indicates that the MOSFET body diode is conducting

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(a) (b) (c)

Fig. 14. TL-MSPBRC operating at begin point in charging mode (2 µs/div).(a) Gate-source voltage, drain-source voltage, and current of switch S1a .
(b) Gate-source voltage, drain-source voltage, and current of switch S2b . (c) Filter inductor current ILx and filter capacitor voltages VCx and VCy .

(a) (b) (c) (d)

Fig. 15. TL-MSPBRC operating at turning point in charging mode (2 µs/div). (a) Gate-source voltage, drain-source voltage, and current of switch
S3a . (b) Gate-source voltage, drain-source voltage, and current of switch S4b . (c) Inverter output voltage VAB , transformer secondary voltage VCD ,
and filter inductor current ILx . (d) Input DC voltage and output battery voltage.
The operating switching frequency at the end point is 121.53
kHz.
3) Discharging mode operation: The main waveforms of
V2G mode while discharging a battery that is charged to a
rated value of 300 V are shown in Fig. 17. The frequency
of operation is 109.68 kHz. ZCS occurs on the primary side
(rectifying stage), and ZVS occurs on the secondary side
(inverting stage).
Fig. 16. Input ripple current by setting AC coupling in DSO and output
current at turning point in charging mode (5 µs/div). V. P ERFORMANCE ANALYSIS AND COMPARISON
before switch S1a turns on. This indicates that ZVS is obtained
in the primary bridge switch S1a . In the secondary bridge A. Comparison of the proposed converter with bidirec-
(rectifying stage), switch S2b current becomes zero before the tional LLC resonant converter [24].
switch turns off, thus achieving ZCS. The filter currents and A comparative analysis is made with a bidirectional LLC
voltages ILx , ILy , VCx , and VCy are sinusoidal as the tank resonant converter [24], as shown in Table II, to validate the
circuit filters out the harmonics. ILx lags VAB by β. VCx proposed converter advantages. For a reasonable comparison,
lags ILx by 90◦ . Though ILx divides between shunt branch [24] is designed for the same power, voltage, and current
elements, the angle of ILx remains as such. So, VCy is in ratings as the proposed converter with variable-frequency
phase with VCx . The voltage across the clamping diodes VDx operation.
and VDy are out of phase. fs is regulated at 110.92 kHz when 1) Circulating losses: Circulating loss or reactive power
the battery is charged to a nominal power level of 2.750 kW. loss is the figure-of-merit to estimate the conduction losses
On the primary side, ZVS turn-on, and on the secondary side, in the circuit. It is the energy sent back to the source in
ZCS turn-off is attained. each switching cycle. Fig. 18 shows the resonant circuit’s
2) Constant-voltage (CV) charging mode operation: Once circulating currents at the end of the charging process. In [24],
the battery reaches the turning point voltage of 300 V, the the current flowing in the resonant tank lags the resonant tank
transition from CC charging to CV charging occurs. The input voltage. Thus, more current is circulated in the resonant
turning point waveforms at the rated power of 3.3 kW are tank instead of transferred to the output. In the proposed TL-
illustrated in Fig. 15 and Fig. 16. The frequency is regulated MSPBRC, the resonant tank current is almost in phase with
at 109.01 kHz to get the rated voltage of 300 V. The primary the resonant tank input voltage. Thus, the circulating current
side (inverting stage) switches attain ZVS. In contrast, the is minimal, reducing the circulating losses. The reactive power
secondary bridge (rectifying stage) switches attain neither ZVS (Qreactive ) in the resonant tank is given by
nor ZCS. ILx slightly lags VAB as it operates near the resonant q q
2 2 2 2
frequency. Due to the phase shift between the gate pulses in Qreactive = Sapparent − Preal = (Vin Iin rms ) − (Vbat Ibat )
the primary and secondary bridge, VAB leads VCD by 80 ns. (22)
From the turning point to the ending point, the battery current Sapparent is the apparent power from the DC input, and Preal
decreases from the rated current to 10 % of the rated current. is the real power delivered to the battery.

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 This article has been accepted for publication in IEEE Transactions on Industrial Electronics. This is the author's version which has not been fully edited and
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IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

(a) (b) (c) (d)

Fig. 17. TL-MSPBRC operating in discharging mode (2 µs/div). (a) Gate drive voltage, drain-source voltage and current of switch S1a . (b) Gate drive
voltage, drain-source voltage, and current of switch S4b . (c) Inverter output voltage VAB , transformer secondary voltage VCD , and filter inductor
current ILx . (d) Diode voltages VDx and VDy .

critical issues to be solved for the reliability of the resonant

converters. One of the simple methods to reduce the current
stress under the short-circuited condition in the output load ter-
minals of the converter is to increase the switching frequency.
As the switching frequency increases, the impedance of the
(a) (b) resonant tank increases, and thus the short-circuit current is
Fig. 18. Circulating current at end point. (a) LLC resonant converter [24] reduced effectively. The frequency of operation under short-
at 117.35kHz. (b) Proposed TL-MSPBRC at 116.01kHz. circuited conditions to maintain the output current less than the
rated current (11 A) for the proposed converter is 124.66 kHz,
and for LLC [24], it is 151.9 kHz. As the operating frequency
for the proposed converter is less, losses are minimum. The
waveforms while short-circuiting the output load terminals of
the converter are shown in Fig. 19. The short-circuit output
current Io waveshape changes for different wire lengths used
for short-circuiting since the wire resistance varies.
B. Comparison of the proposed converter with other bidi-
rectional resonant converters.
(a) (b)
Fig. 19. TL-MSPBRC operating in short-circuited condition at Table III presents a comparison of six different bidirectional
124.66kHz (2 µs/div). (a) Output current Io for different wire lengths resonant converters. The three-level topologies in [22], [24],
used for short circuiting. (b) Filter inductor current ILx and filter capaci- and the proposed converter have 0.5Vin voltage stress across
tor voltages VCx and VCy while using short wire for shorting.
primary switches. Thus switches of low on-state resistance
TABLE II can be utilized. But the number of switches in [22] and [24]
P ROPOSED AND LLC [24] SIMULATION RESULTS COMPARISON . is high compared to the proposed converter. Thus switching
Converter
Begin Nominal Turning
End point
losses increases in [22] and [24]. In the frequency-modulated
point point point converters [22], [27], and [30], the frequency range of opera-
Reactive Proposed 1161.6 1000.3 403.81 77 tion is very high to obtain the required voltage gain compared
losses (VA) LLC [24] 1762 1679 1229 825.2 to the proposed converter, and thus, the circulating losses
Operating Proposed 104.3 104.01 103.8 116.01
increase. Compared to the full-bridge topologies [27], [30],
frequency (kHz) LLC [24] 130.5 128.3 103.8 117.35
Soft Proposed ZVS ZVS ZVS In phase and [33], there are two additional diodes in the proposed
switching (PB) LLC [24] ZVS ZVS ZVS ZVS converter for voltage clamping. But due to lesser current stress,
Soft Proposed ZCS ZCS ZCS In phase the diode current rating is significantly reduced. Compared to
switching (SB) LLC [24] ZCS ZCS ZCS ZCS the most popular LLC in [30], the proposed converter requires
Calculated Proposed 95.90 96.98 98.61 95.55
LLC [24] 94.48 95.78 97.64 94.85
an additional isolated gate driver and two extra film capacitors
efficiency (%)
in the resonant tank, which adds to the extra cost. The area
PB − Primary bridge, SB − Secondary bridge. occupied by the film capacitors is very less, and thus the power
density of the proposed converter is not significantly affected.
    The peak efficiency of the proposed converter in forward and
 (iLxrms )2 jwLx − j 2
+ (iLyrms ) (jwLy ) 
wC x reverse power flow mode is higher when compared to all other
Qreactive =    
− (iCy rms )2 j
− (iCp rms )
2 j  topologies.
wCy wCp
(23) VI. L OSS ANALYSIS OF THE PROPOSED CONVERTER
2) Short-circuit protection: Under the short-circuited con- For different operating points of the converter, theoretical
dition, i.e., when the Q factor is infinity, the current flowing loss analysis for charging operation is shown in Fig. 20. Fig. 21
in the converter is very high and damages the converter. depicts the measured efficiency for various processed power
Short-circuit protection or over-current protection is one of the levels in G2V and V2G modes. As the converter operates close

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TABLE III
COMPARISON OF THE PROPOSED CONVERTER WITH OTHER BIDIRECTIONAL RESONANT CONVERTERS
Parameters Converter in [22] Converter in [30] Converter in [33] Converter in [27] Converter in [24] Proposed

Topology (PB + SB) TL-CLLC + TL FB-LLC + FB FB-SRC + FB FB-CLLC + FB TL-LLC + FB TL-MSPRC + FB

Primary switches 8 4 4 4 8 4
Secondary switches 8 4 4 4 4 4
Input voltage Vin (V) 750 75 - 130 110 - 130 200 - 400 30 - 60 450
Output voltage Vout (V) 200 - 700 400 75 - 100 48 240 - 480 230 - 300
Power (W) 3500 1000 200 480 1000 3300
Resonant frequency (kHz) 70 100 100 100 100 100
Modulation technique Frequency Frequency Phase-shift Frequency PWAM Frequency
Switching frequency(kHz) 31 - 70 69 - 92 100 65.2 - 163.7 100 103.8 - 116.01
Resonant inductors 2 2 1 2 2 2
Resonant capacitors 2 1 1 2 1 3
Isolated gate drivers 12 4 4 4 8 5
Non-isolated gate drivers 4 4 4 4 4 3
Number of Diodes 8 0 0 0 0 2
Switch voltage stress (PB) 0.5Vin Vin Vin Vin 0.5Vin 0.5Vin
Switch voltage stress (SB) 0.5Vout Vout Vout Vout Vout Vout
Peak forward efficiency 96.8% 97% 95% >96% 96.5% 97.78%
Peak reverse efficiency 96.5% 96.45% 95% >96% 96.5% 97.78%

FB − Full-bridge, TL − Three-level, PWAM − Pulse-width + amplitude-modulation, PB − Primary bridge, SB − Secondary bridge.

to the resonant frequency, maximum efficiency is obtained at forward and reverse power flow modes, ZVS is attained in the
the rated power level. Efficiency is always higher than 93.4% inverting stage, and ZCS is attained in the rectifying stage.
in both power directions. The converter is suitable for a wide Compared with conventional LLC, the proposed topology’s
range of load power as the minimum and maximum efficiency performance is excellent in CC/CV charging modes and short-
difference is less than 5%. circuited conditions. Experimental data obtained using a 3.3-
kW prototype verifies the validity of the converter design. The
30 results show that the converter has excellent efficiency and
Loss (Watts)

25
20
changes a little for a wide power range of 330 W to 3.3 kW.
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Smart Technologies for Power, Energy and Control (STPEC), DOI gineering from Walchand College of Engineer-
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three-level llc resonant converter with pwam control,” IEEE Transactions Science, Bangalore, India, in 1994 and the Ph.D.
on Power Electronics, vol. 31, DOI 10.1109/TPEL.2015.2438072, no. 3, degree in electrical engineering from Nagpur
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isolated resonant converters in pev battery charging applications,” in Engineering, Visvesvaraya National Institute of
2013 IEEE Transportation Electrification Conference and Expo (ITEC), Technology, Nagpur, India. His research inter-
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verter with new cllc resonant tank featuring minimized switching

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