Simulation of a PV-Integrated Dual Active Bridge Converter for EV Charging

Abstract

The increasing use of renewable energy and electric vehicles (EVs) has created a growing need for efficient power-electronic interfaces that can integrate solar energy with high-voltage battery-charging systems. This work presents the design and MATLAB/Simulink analysis of an approximately 11.56 kW photovoltaic (PV)-fed Dual Active Bridge (DAB) DC-DC converter for isolated and controllable power transfer in EV battery-charging applications. The PV array consists of 33 modules rated at approximately 350 W each, configured as 11 series-connected modules per string and three parallel strings, providing approximately 423.5 V and 27.3 A at the maximum power point. The DAB converter employs two active full bridges coupled through an 11 kVA, 50 kHz high-frequency transformer with 419/409 V windings and a 29 µH series transfer inductor. A 220 µF DC-link capacitor is connected at the output. Power transfer is controlled using single-phase-shift (SPS) modulation, where both bridges operate at approximately 50% duty cycle and the relative phase angle between their switching signals determines the transferred power. For closed-loop control, the measured DC output voltage is compared with a predefined reference, and the resulting error is processed by a PI controller to generate the required phase-shift command. A MATLAB Function block dynamically produces the phase-shifted switching references using the controller output and simulation time. These references are converted into complementary gate pulses for the primary and secondary bridges, allowing controlled adjustment of the DAB power flow and output voltage. Initial simulation results confirm the generation of complementary switching pulses, the required phase displacement between the bridges, and controlled power transfer from the PV source to the DC output. The developed model provides a foundation for further battery-charging analysis, efficiency evaluation, transient studies, and experimental implementation.

Introduction

This study focuses on the design and MATLAB/Simulink modelling of a photovoltaic (PV)-fed Dual Active Bridge (DAB) DC-DC converter for electric vehicle (EV) battery charging. The increasing use of solar energy and electric vehicles has created a need for efficient, compact, and electrically isolated power-conversion systems. The DAB converter is suitable for this application because it provides galvanic isolation, controlled power transfer, and bidirectional operation.

The main problem addressed by the study is the challenge of regulating power from a variable solar PV source to a high-voltage battery while maintaining a stable DC output. The proposed system uses single-phase-shift (SPS) modulation and a Proportional-Integral (PI) controller to regulate the output voltage and control the power transferred between the converter's two active bridges.

The system is designed for an approximately 11.56 kW PV-fed converter and a reference 409 V lithium-ion battery-charging application. Its main components include a 33-module PV array arranged in an 11-series, 3-parallel configuration, two active full bridges, a 50 kHz high-frequency transformer, a 29 µH transfer inductor, and an output DC-link capacitor.

The working principle involves six main stages:

1. PV power generation: The solar array generates DC power, with its voltage and current monitored during simulation.

2. Primary-side conversion: The first active full bridge converts the PV-side DC voltage into a high-frequency AC square-wave voltage.

3. Phase-shift generation: SPS modulation introduces a phase difference between the switching signals of the two bridges to regulate power transfer.

4. Isolated power transfer: The high-frequency transformer transfers energy between the two sides while providing galvanic isolation, and the transfer inductor helps control current flow.

5. Secondary-side conversion: The second active full bridge converts the high-frequency waveform back into DC, while the output capacitor helps maintain voltage stability.

6. Closed-loop voltage control: The output voltage is compared with a reference value, and the PI controller adjusts the phase-shift command to regulate the converter's output.

The literature review examines previous research on PV-assisted EV charging, DAB converter control, semiconductor selection, bidirectional power transfer, and constant-current/constant-voltage charging. Previous studies demonstrate the suitability of DAB converters for renewable-energy applications and highlight the importance of control strategies, high-frequency transformer design, and efficient switching devices.

The proposed model is developed in MATLAB/Simulink, with emphasis on selecting suitable switches, generating complementary gate pulses, verifying phase displacement, and evaluating output-voltage regulation and PV-to-DC power transfer. Initially, a DC load is connected to validate converter operation. After stable performance is established, the model can be integrated with a lithium-ion battery for further charging analysis.

The study also identifies zero-voltage switching (ZVS) as an important objective because it can reduce switching losses and improve converter efficiency. However, detailed battery-charging analysis, loss evaluation, and experimental validation are intended for subsequent stages of development.

Conclusion

This paper presents the design and MATLAB/Simulink implementation of an approximately 11.56 kW PV-fed Dual Active Bridge converter for high-voltage EV battery charging. The developed system integrates the PV source, primary and secondary active bridges, high-frequency transformer, transfer inductance, single-phase-shift modulation, PI-based closed-loop control and a lithium-ion battery model. The phase-shift control regulates the power exchanged between the two bridges while the high-frequency transformer provides electrical isolation between the PV source and battery side. The final simulation successfully demonstrates direct battery-charging operation. The battery voltage reaches a stable operating level of approximately 441 V, the charging current settles at approximately 20–24 A in magnitude, and the battery SOC shows a measurable increase from its initial value during the simulation period. These results confirm that power generated by the PV source is transferred through the DAB stage to the lithium-ion battery, thereby validating the proposed converter and control structure for PV-based EV charging.

References

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Copyright

Copyright © 2026 Aditya G. Ghavat, Suhani A. Alone, Sanika G. Umak, Subodh V. Wadaskar, Nilesh R. Dasgupta, Dr. A. A. Deosant. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.