Experimental Characterization and Validation of a PLECS-Based Hardware-in-the-Loop (HIL) Model of a Dual Active Bridge (DAB) Converter

Hardware-in-the-loop (HIL) simulation is an essential tool for rapid and cost-effective development and validation of power-electronic systems. The primary objective of this work is to validate and fine-tune a PLECS-based HIL model of a single dual active bridge (DAB) DC-DC converter, thereby laying the foundation for building more complex models (e.g., multiple converters connected in series or parallel). To this end, the converter is experimentally characterized, and the HIL model is validated across a wide range of operating conditions by varying the PWM phase-shift angle, voltage gain, switching frequency, and leakage inductance. Power transfer and efficiency are analyzed to quantify the influence of these parameters on converter performance. These experimental trends provide insight into the optimal modulation range and the dominant loss mechanisms of the DAB under single phase shift (SPS) control. A detailed comparison between HIL simulations and hardware measurements, based on transferred power and efficiency, shows close agreement across all the tested operating points. These results confirm the accuracy and robustness of the proposed HIL model, demonstrate the suitability of the PLECS platform for DAB development and control validation, and support its use as a scalable basis for more complex multi-converter studies, reducing design time and prototyping risk.