Generalized Multiport, Multilevel NPC Dual-Active-Bridge Converter for EV Auxiliary Power Modules

Among other uses, DC-DC converters are employed in the auxiliary power modules (APMs) of electric vehicles (EVs), connecting the high-voltage traction battery to the low-voltage auxiliary system (AS). Traditionally, the APM is an isolated two-port, two-level (2L) DC-DC converter, and the auxiliary loads are fed at a fixed voltage level, e.g., 12 V in passenger cars. Dual-active-bridge (DAB) converters are commonly used for this application, as they provide galvanic isolation, high power density and efficiency, and bidirectional power flow capability. However, the auxiliary loads do not present a uniform optimum supply voltage, hindering overall efficiency. Thus, a more flexible approach, providing multiple supply voltages, would be more suitable for this application. Multiport DC-DC converters capable of feeding auxiliary loads at different voltage levels are a promising alternative. Multilevel neutral-point-clamped (NPC) DAB converters offer several advantages compared to conventional two-level (2L) ones, such as greater efficiency, reduced voltage stress, and enhanced scalability. The series connection of the NPC DC-link capacitors enables a multiport configuration without additional conversion stages. Moreover, the modular nature of the ML NPC DAB converter enables scalability while using semiconductors with the same voltage rating and without requiring additional passive components, thereby enhancing the converter’s power density and efficiency. This paper proposes a modulation strategy and decoupled closed-loop control strategy for the generalized multiport 2L-NL NPC DAB converter interfacing the EV traction battery with the AS, and its performance is validated through hardware-in-the-loop testing and simulations. The proposed modulation strategy minimizes conduction losses in the converter, and the control strategy effectively regulates the LV battery modules’ states of charge (SoC) by varying the required SoC and the power sunk by the LV loads, with the system stabilizing in less than 0.5 s in both scenarios.