Optimized Coil Arrangement for Integrating Leakage Inductance in High-Frequency Transformers of Dual Active Bridge Converters

Optimized Coil Arrangement for Integrating Leakage Inductance in High-Frequency Transformers of Dual Active Bridge Converters | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Optimized Coil Arrangement for Integrating Leakage Inductance in High-Frequency Transformers of Dual Active Bridge Converters Kianoush Yadollahi, Adel Zakipour This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6822293/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 13 Oct, 2025 Read the published version in Scientific Reports → Version 1 posted 10 You are reading this latest preprint version Abstract Dual Active Bridge (DAB) converters offer bidirectional power flow and soft-switching capabilities, making them attractive for high-frequency power conversion applications. However, the presence of a separate series inductor alongside the high-frequency transformer can limit the converter’s power density and efficiency. This paper presents an optimized transformer winding configuration that integrates the required leakage inductance directly within the high-frequency transformer, eliminating the need for an external series inductor. Various coil arrangements are analyzed through finite element simulations using ANSYS Maxwell to evaluate leakage inductance, ohmic losses, and parasitic capacitance. Results show that the vertical coil arrangement achieves the target leakage inductance of 50 μH while minimizing conduction losses and parasitic effects. The optimized transformer winding was experimentally validated on a 150 W DAB converter prototype using a TMS320F28335 DSP for power stage control. Experimental results confirm close agreement with simulations, demonstrating high efficiency (up to 99.1%) and stable soft-switching operation under nominal conditions without current ringing. The proposed winding configuration offers a practical and efficient approach for integrating magnetic components in high-frequency power converters. Physical sciences/Engineering/Electrical and electronic engineering Physical sciences/Energy science and technology/Energy storage Dual Active Bridge (DAB) Power Converter Integrated Leakage Inductance Design Transformer Winding Optimization Coil Arrangement Finite Element Electromagnetic Analysis Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 13 Oct, 2025 Read the published version in Scientific Reports → Version 1 posted Editorial decision: Revision requested 08 Jul, 2025 Reviews received at journal 23 Jun, 2025 Reviews received at journal 18 Jun, 2025 Reviewers agreed at journal 15 Jun, 2025 Reviewers agreed at journal 13 Jun, 2025 Reviewers invited by journal 13 Jun, 2025 Editor assigned by journal 13 Jun, 2025 Editor invited by journal 13 Jun, 2025 Submission checks completed at journal 11 Jun, 2025 First submitted to journal 04 Jun, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6822293","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":471404489,"identity":"d0cc7016-da73-44d8-8e91-de00b41e5d52","order_by":0,"name":"Kianoush Yadollahi","email":"","orcid":"","institution":"Arak University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Kianoush","middleName":"","lastName":"Yadollahi","suffix":""},{"id":471404490,"identity":"871bf51b-6e4a-4a59-9132-66618c15a60a","order_by":1,"name":"Adel Zakipour","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA30lEQVRIie3SsQrCMBCA4SuFTkrXdGlfIRIQxJdpl3TUSTpmahehqz6Gi3PkwC7RuY4udRYnwcG2OlSE2NEhP4RA4IM7CIDJ9Jc5IJvLrY8l3m+yF/FES2g/0kZlh2gLsn2E8wRnrDicr+v0AW4mLUw0xFpyiSuFk62KmbdJKRAVwk5piA2xwGGKdCw5eOeaQAmwE7pN3MuLsLyy7w0JfpEBqQdrCCXcaQejvwghVVjvElNSVs5kdWSDkYqElgQ5Z7d5MqVuzu3TcuH7foF41ZEm+2PSzifoSUwmk8n01RPBJ0+ITxpWgQAAAABJRU5ErkJggg==","orcid":"","institution":"Arak University of Technology","correspondingAuthor":true,"prefix":"","firstName":"Adel","middleName":"","lastName":"Zakipour","suffix":""}],"badges":[],"createdAt":"2025-06-04 16:08:26","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6822293/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6822293/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1038/s41598-025-19533-2","type":"published","date":"2025-10-13T15:58:37+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":93956816,"identity":"af9b7eca-d3a4-4985-be78-6d586d53057f","added_by":"auto","created_at":"2025-10-20 16:12:31","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":704971,"visible":true,"origin":"","legend":"","description":"","filename":"yadolahi2025.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6822293/v1_covered_3f300eed-6fe3-4ec0-9372-427eb964fa91.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Optimized Coil Arrangement for Integrating Leakage Inductance in High-Frequency Transformers of Dual Active Bridge Converters","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"scientific-reports","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"scirep","sideBox":"Learn more about [Scientific Reports](http://www.nature.com/srep/)","snPcode":"","submissionUrl":"","title":"Scientific Reports","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Scientific Reports","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"Dual Active Bridge (DAB) Power Converter, Integrated Leakage Inductance Design, Transformer Winding Optimization, Coil Arrangement, Finite Element Electromagnetic Analysis","lastPublishedDoi":"10.21203/rs.3.rs-6822293/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6822293/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eDual Active Bridge (DAB) converters offer bidirectional power flow and soft-switching capabilities, making them attractive for high-frequency power conversion applications. However, the presence of a separate series inductor alongside the high-frequency transformer can limit the converter’s power density and efficiency. This paper presents an optimized transformer winding configuration that integrates the required leakage inductance directly within the high-frequency transformer, eliminating the need for an external series inductor. Various coil arrangements are analyzed through finite element simulations using ANSYS Maxwell to evaluate leakage inductance, ohmic losses, and parasitic capacitance. Results show that the vertical coil arrangement achieves the target leakage inductance of 50 μH while minimizing conduction losses and parasitic effects. The optimized transformer winding was experimentally validated on a 150 W DAB converter prototype using a TMS320F28335 DSP for power stage control. Experimental results confirm close agreement with simulations, demonstrating high efficiency (up to 99.1%) and stable soft-switching operation under nominal conditions without current ringing. 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