High-Frequency Design and Implementation of a 1 MHz Dual Active Bridge Converter Using Planar Magnetics
Implementing Organization
National Institute of Technology Calicut
Principal Investigator
Dr. Ashiq Muhammed PE
National Institute Of Technology Calicut
ashiqmuhammed@nitc.ac.in
Project Overview
Power electronics plays a pivotal role in enabling efficient, reliable energy conversion across various industries, from data centres and renewable energy systems to electric vehicles. This proposal aims on developing a 48V/12V, 125W Dual Active Bridge (DAB) module, a topology commonly used in server power supplies, renewable energy, and automotive sectors due to its flexibility and efficiency at high frequencies. The project aims to design a converter that achieves high efficiency and power density, addressing the increasingly tight space constraints of modern applications. The converter will incorporate integrated planar magnetics, which offer significant benefits in terms of compactness and improved thermal performance. However, key challenges in this design include minimizing core and copper losses, reducing the effects of parasitic capacitance, and ensuring robust electromagnetic interference (EMI) and electromagnetic compatibility (EMC) performance. Addressing these factors is essential to optimizing high-frequency operation and maintaining efficiency within a compact, cost-effective form factor. This proposal adopts a multi-pronged approach to meet these objectives. To reduce core losses, low-loss ferrite core materials will be selected, while planar litzing techniques will be applied to reduce copper losses by minimizing skin and proximity effects at high frequencies. Additionally, novel winding techniques will be explored to reduce parasitic capacitance, thereby enhancing converter performance and reliability in high-speed switching environments. For effective thermal management, cold plates will be integrated into the design, promoting efficient heat dissipation and stable operation under high load conditions. To share the knowledge gained and design insights with the broader scientific community, a hands-on workshop will be organized upon project completion, facilitating knowledge transfer and fostering collaboration in the field of advanced power electronics. This research will drive advancements in high-density power conversion for medium-voltage applications, supporting the development of compact, reliable, and efficient power solutions for demanding applications like server power supplies and electric vehicles.
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