Reference design demonstrates a high-efficiency 60kW isolated DC-DC converter using a dual active bridge topology and fourth-generation SiC power modules.
Wolfspeed has introduced a 60kW isolated DC-DC converter reference design to support the development of high-power conversion systems for renewable energy, energy storage and EV fast-charging applications. Based on a dual active bridge (DAB) topology, the design showcases the use of fourth-generation baseplate-less silicon carbide (SiC) power modules to achieve high efficiency, power density and scalability. Design files are also provided to help engineers speed up product development.
The reference design is built around two CBB011M12GM4T 1200V, 11mΩ WolfPACK full-bridge SiC power modules mounted on a single liquid-cooled coldplate. Operating at a switching frequency of 100kHz, the design enables zero-voltage switching (ZVS) on both sides of the DAB topology.The design uses the leakage inductance of the high-frequency isolation transformer for power transfer of the high-frequency isolation transformer, eliminating the need for an additional magnetic component.
Designed for high-power applications, the converter achieves a peak efficiency of 99.2%, with an efficiency above 98.8% being sustained at power levels above 20kW. The converter achieves a power density of 10.5kW/L inclusive of the transformer, whereas the isolated configuration provides increased safety and a wide output-voltage range. The converter’s inherent bi-directional capability, which makes it applicable for bidirectional energy transfer applications.
The evaluation platform includes isolated gate drivers, an embedded controller with programmable firmware, as well as CAN communication for system control. The Integrated protection features included within the converter include overcurrent protection based on desaturation, Miller clamping and thermistor-based temperature monitoring. The modular design of the converter allows multiple converters to be connected in parallel to achieve higher power levels.
Wolfspeed provides the reference design with schematics, PCB layout files, Gerber files, a bill of Materials, 3D mechanical files, and user’s guide for simplifying evaluation and customisation. The reference design is created by integrating the fourth generation of SiC power modules with an effective DAB configuration that provides a practical foundation for the development of next-generation isolated DC-DC converters for renewable energy systems, energy storage installations and high-capacity EV charging infrastructure.
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