With the development of active phased array radar systems, the demand for transmit-receive (TR) power supplies has increased significantly. Modern TR modules require power supplies with wide input voltage ranges, high-frequency operation, and high efficiency. dual-active bridge (DAB) converters are widely recognized for their ability to achieve these characteristics, offering diverse control strategies and broad application potential. However, key system parameters such as inductance and switching frequency in DAB converters significantly impact power transmission capabilities and the on-state current of power MOSFETs, posing challenges for optimal design.

This study aims to address these challenges by proposing a parameter optimization design method for DAB converters based on extended phase-shift (EPS) modulation. The goal is to ensure reliable operation under overload conditions while meeting critical design constraints, including maximum power transfer, MOSFET current derating, and output voltage ripple reduction.

The power transfer characteristics and inductor current expressions of the EPS-modulated DAB converter were derived theoretically. A reliability-oriented operating region (ROA) was defined by integrating constraints such as maximum power transfer under overload, MOSFET on-state current derating, and minimum output voltage ripple frequency. The optimization process involved systematic parameter planning to determine optimal inductance values and switching frequencies.

MATLAB simulations of a dual-output DAB converter demonstrated that the proposed method effectively reduced output voltage ripple, minimized MOSFET on-state current, and achieved the desired power output. The simulation results aligned with theoretical predictions, validating the accuracy of the derived equations and the feasibility of the optimization approach.

The EPS-based parameter optimization method provides a systematic framework for designing DAB converters tailored to TR power supply requirements. By addressing key design constraints and leveraging ROA analysis, this approach enhances power transmission efficiency and device reliability. The results highlight the potential of EPS-modulated DAB converters in advanced TR modules, offering a practical solution for high-performance phased array radar systems.