Expected HIL Results are Diferent from Simulation Results in RTBox 1 for Nanostep Model

Hello,

I am currently trying to use the Nanostep Version of the Dual Active Bridge Converter in an RTBox CE order to test an open-loop approach sending high frequency gate signals from outside.

However, as I try to execute the model, I get the following results:

In this picture I am plotting the current flowing through the primary winding, the current flowing through the secondary winding, the magnetizing current and the S1 and S5 signals.

As you can see, the mean value for the magnetizing current is far from zero. I’ve tried changing the DAB parameters and that mean value changes, but remains constant while it should be going to zero.

I also noticed that changing the transformer ratio to 1:1, the winding currents don’t have the same mean value.

I checked the PWMs I’m applying and all have the expected phase. So the problem shouldn’t be on that part.

After all this, I tried making a simulation generating the PWMs by PLECS and I’ve got the following results:

In this scenario, the mean values of the currents are zero as it’s expected.

Right now I’m out of ideas and can’t explain that discrepancy.

The model I’m using is the following one:

DAB_RtBoxHIL.plecs (149.3 KB)

I would greatly appreciate any ideas or suggestions you may have.
Thank you for taking your time and I look forward to your response.

Hi Javier,

A lack of damping in the Nanostep circuit can result in the DC offset phenomena you’re observing. This is a numerical artifact.

If I increase the primary winding resistance parameter from 10 mOhm to 20 mOhm then the DC offset issue is resolved. Note that the winding resistance parameter here can be inclusive not just of the winding DC resistance, but also the \mathrm{R}_\mathrm{ds,on} of the FETs and other losses in the transformer / circuit.

See the attached model for a solution where increased the winding resistance and modified the PWM generation to use the PWM Out block. I assume your current PWM implementation was just for testing.

DAB_RtBoxHIL_BL.plecs (162.9 KB)

Regards,
Bryan