DC microgrids are seen as smart solutions to interface DC loads and distributed energy resources (DERs). However, in DC microgrids, the placement of sources and loads as well as the size of cable impact the system’s span, regulation of voltage, and losses. This paper proposes novel algorithms to determine the maximum span and optimal size of cable for the improved performance of a droop-controlled DC microgrid. The proposed algorithms utilize an improved power flow analysis (IPFA) method based on Newton-Raphson technique to determine the maximum span and the optimal size of cable, enhancing the voltage regulation and reducing the cost. Additionally, the impacts of power rating, droop constants, and size of cable on the DC microgrid’s maximum span are investigated and reported. Owing to the intricate nature of the problem concerning the ideal size of cable for the droop-controlled DC microgrid, a heuristic optimization approach is employed. Further to enhance the rate of convergence and computational performance, an improved particle swarm optimization (IPSO) is also proposed. The constraint of keeping the bus voltage variations below the allowable voltage regulation limits is applied to the objective function of the optimization problem. In the case of a droop-controlled, DC microgrid having a specified configuration, the suggested algorithm can determine the ideal size of cable, guaranteeing both the least cost and enhanced voltage regulation. Comprehensive numerical and modelling results have been presented for a droop-controlled DC microgrid with different loads and DERs to verify the effectiveness of the proposed methods. Furthermore, the analysis reveals that configuration III of the DC microgrid with an optimal cable size of 19 mm2 lowers the absolute voltage regulation to as low as 1.06 V. The results of the detailed analysis validate the enhanced performance of the proposed algorithms and are highly useful to both system designers and consumers of the DC microgrids, eventually paving the way for the widespread use of DC microgrids in the future.
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