Design Optimization and Control System of a Cascaded DAB–Buck Auxiliaries Power Module for EV Powertrains.
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| Title: | Design Optimization and Control System of a Cascaded DAB–Buck Auxiliaries Power Module for EV Powertrains. |
|---|---|
| Authors: | Kotb, Ramy1,2 (AUTHOR), Dalir, Amin1,2 (AUTHOR), Chakraborty, Sajib1,2 (AUTHOR), Hegazy, Omar1,2 (AUTHOR) omar.hegazy@vub.be |
| Source: | Energies (19961073). Jan2026, Vol. 19 Issue 2, p431. 31p. |
| Subjects: | Electric vehicles, Power density, DC-to-DC converters, Electric power conversion, Supervisory control systems, Economic efficiency, Multidisciplinary design optimization |
| Abstract: | Auxiliary power demand in battery electric vehicles continues to increase as manufacturers transition toward multi-low-voltage architectures that combine 48 V and 12 V buses to improve load distribution flexibility and overall system efficiency. This paper evaluates several auxiliary power module (APM) architectures in terms of scalability, efficiency, complexity, size, and cost for supplying two low-voltage buses (e.g., 48 V and 12 V) from the high-voltage battery. Based on this assessment, a cascaded APM configuration is adopted, consisting of an isolated dual active bridge (DAB) converter followed by a non-isolated synchronous buck converter. A multi-objective optimization framework based on the NSGA-II algorithm is developed for the DAB stage to maximize efficiency and power density while minimizing cost. The optimized 13 kW DAB stage achieves a peak efficiency of 95% and a power density of 4.1 kW/L. For the 48 V/12 V buck stage, a 2 kW commercial GaN-based converter with a mass of 0.5 kg is used as the reference design, achieving a peak efficiency of 96.5%. Dedicated PI controllers are designed for both the DAB and buck stages using their respective small-signal models to ensure tight regulation of the two LV buses. The overall system stability is verified through impedance-based analysis. Experimental validation using a DAB prototype integrated with a multi-phase buck converter confirms the accuracy of the DAB loss modeling used in the design optimization framework as well as the control design implemented for the cascaded converters. [ABSTRACT FROM AUTHOR] |
| Copyright of Energies (19961073) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Header | DbId: egs DbLabel: Engineering Source An: 191171872 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Design Optimization and Control System of a Cascaded DAB–Buck Auxiliaries Power Module for EV Powertrains. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Kotb%2C+Ramy%22">Kotb, Ramy</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Dalir%2C+Amin%22">Dalir, Amin</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chakraborty%2C+Sajib%22">Chakraborty, Sajib</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hegazy%2C+Omar%22">Hegazy, Omar</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> omar.hegazy@vub.be</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Energies+%2819961073%29%22">Energies (19961073)</searchLink>. Jan2026, Vol. 19 Issue 2, p431. 31p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Electric+vehicles%22">Electric vehicles</searchLink><br /><searchLink fieldCode="DE" term="%22Power+density%22">Power density</searchLink><br /><searchLink fieldCode="DE" term="%22DC-to-DC+converters%22">DC-to-DC converters</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+power+conversion%22">Electric power conversion</searchLink><br /><searchLink fieldCode="DE" term="%22Supervisory+control+systems%22">Supervisory control systems</searchLink><br /><searchLink fieldCode="DE" term="%22Economic+efficiency%22">Economic efficiency</searchLink><br /><searchLink fieldCode="DE" term="%22Multidisciplinary+design+optimization%22">Multidisciplinary design optimization</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Auxiliary power demand in battery electric vehicles continues to increase as manufacturers transition toward multi-low-voltage architectures that combine 48 V and 12 V buses to improve load distribution flexibility and overall system efficiency. This paper evaluates several auxiliary power module (APM) architectures in terms of scalability, efficiency, complexity, size, and cost for supplying two low-voltage buses (e.g., 48 V and 12 V) from the high-voltage battery. Based on this assessment, a cascaded APM configuration is adopted, consisting of an isolated dual active bridge (DAB) converter followed by a non-isolated synchronous buck converter. A multi-objective optimization framework based on the NSGA-II algorithm is developed for the DAB stage to maximize efficiency and power density while minimizing cost. The optimized 13 kW DAB stage achieves a peak efficiency of 95% and a power density of 4.1 kW/L. For the 48 V/12 V buck stage, a 2 kW commercial GaN-based converter with a mass of 0.5 kg is used as the reference design, achieving a peak efficiency of 96.5%. Dedicated PI controllers are designed for both the DAB and buck stages using their respective small-signal models to ensure tight regulation of the two LV buses. The overall system stability is verified through impedance-based analysis. Experimental validation using a DAB prototype integrated with a multi-phase buck converter confirms the accuracy of the DAB loss modeling used in the design optimization framework as well as the control design implemented for the cascaded converters. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Energies (19961073) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/en19020431 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 31 StartPage: 431 Subjects: – SubjectFull: Electric vehicles Type: general – SubjectFull: Power density Type: general – SubjectFull: DC-to-DC converters Type: general – SubjectFull: Electric power conversion Type: general – SubjectFull: Supervisory control systems Type: general – SubjectFull: Economic efficiency Type: general – SubjectFull: Multidisciplinary design optimization Type: general Titles: – TitleFull: Design Optimization and Control System of a Cascaded DAB–Buck Auxiliaries Power Module for EV Powertrains. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Kotb, Ramy – PersonEntity: Name: NameFull: Dalir, Amin – PersonEntity: Name: NameFull: Chakraborty, Sajib – PersonEntity: Name: NameFull: Hegazy, Omar IsPartOfRelationships: – BibEntity: Dates: – D: 15 M: 01 Text: Jan2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 19961073 Numbering: – Type: volume Value: 19 – Type: issue Value: 2 Titles: – TitleFull: Energies (19961073) Type: main |
| ResultId | 1 |
