All Case StudiesHydrogen/Fuel Cell
Fuel Cell DC-DC Converter
Power
150kW
Result
97.5% efficiency
Industry
Hydrogen/Fuel Cell
OF
The Challenge
A hydrogen fuel cell company required a 150kW DC-DC converter to interface their fuel cell stack with a 800V vehicle bus. The converter needed to handle the fuel cell's wide voltage range (250-450V) while maintaining high efficiency across all operating points. Thermal management was critical as the converter shared coolant with the fuel cell system, limiting available cooling capacity.
Our Approach
- Designed interleaved boost topology for high efficiency across voltage range
- Selected SiC MOSFETs to minimize switching losses at 100kHz operation
- Optimized magnetic design for minimal core and winding losses
- Integrated converter cooling with fuel cell thermal management system
- Implemented advanced control algorithms for smooth power transitions
- Validated efficiency and thermal performance on fuel cell test bench
Results
97.5%
Peak Efficiency
At nominal operating point
35 kW/L
Power Density
Compact integration achieved
250-450V
Voltage Range
Full fuel cell operating range