Design and experimental verification of a cascaded high-power Buck-Boost-DC/DC-Converter for Fuel Cell to Battery Charging

Hydrogen is increasingly recognized as a cornerstone of future energy systems, offering a carbon-free energy carrier with high energy density. Yet the efficiency and reliability of power electronic interfaces remain a bottleneck for large-scale deployment. Fuel cells require highly dynamic and stable DC/DC conversion to bridge high-current characteristics of the stack with the high-voltage levels demanded by batteries or industrial loads. Conventional converters face limitations in efficiency, thermal management, and volumetric power density, particularly under the fluctuating operating conditions of hydrogen-based systems. These shortcomings directly constrain the scalability and economic viability of hydrogen technologies. To address this challenge, the present work explores a next-generation DC/DC converter architecture designed to combine high input/output voltages with high currents. The design leverages wide-bandgap semiconductors and optimized magnetic integration. By systematically integrating prototyping, and experimental validation, this study establishes a technological foundation for DC/DC conversion that aligns with the stringent requirements of hydrogen applications.