High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production

Yu, Qingshuai; Sun, Zhenao; Han, Yetong; Zhang, Tuanlong; Zhang, Rongxing; Lin, Muhua

doi:10.3390/mi16060665

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Open AccessArticle

High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production

by

Qingshuai Yu

,

Zhenao Sun

^*,

Yetong Han

,

Tuanlong Zhang

,

Rongxing Zhang

and

Muhua Lin

College of Information Science and Engineering, Northeastern University, Shenyang 110819, China

^*

Author to whom correspondence should be addressed.

Micromachines 2025, 16(6), 665; https://doi.org/10.3390/mi16060665 (registering DOI)

Submission received: 1 May 2025 / Revised: 26 May 2025 / Accepted: 29 May 2025 / Published: 31 May 2025

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Abstract

While DC/DC converters for water electrolysis systems have been widely investigated, they inherently face a critical compromise between wide voltage regulation capabilities and dynamic response characteristics. This study is based on a two-stage hybrid topology (TSIB-TPLLC) that synergistically combines a two-phase interleaved buck converter with a three-phase LLC resonant converter to resolve this challenge. The first-stage interleaved buck converter enables wide-range voltage regulation while reducing input current ripple and minimizing intermediate bus capacitance through phase-interleaved operation. The subsequent three-phase LLC stage operates at a fixed resonant frequency, achieving inherent output current ripple suppression through multi-phase cancellation while maintaining high conversion efficiency. A dual-loop control architecture incorporating linear active disturbance rejection control (LADRC) with PI compensation is developed to improve transient response compared to conventional PI-based methods. Finally, a 1.2 kW experimental prototype with an input voltage of 250 V and an output voltage of 24 V demonstrates the converter’s operational feasibility and enhanced steady-state/transient performance, confirming its suitability for hydrogen production applications.

Keywords: hydrogen conversion converter; proton exchange membrane (PEM) electrolyzer; LADRC; ripple suppression

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MDPI and ACS Style

Yu, Q.; Sun, Z.; Han, Y.; Zhang, T.; Zhang, R.; Lin, M. High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production. Micromachines 2025, 16, 665. https://doi.org/10.3390/mi16060665

AMA Style

Yu Q, Sun Z, Han Y, Zhang T, Zhang R, Lin M. High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production. Micromachines. 2025; 16(6):665. https://doi.org/10.3390/mi16060665

Chicago/Turabian Style

Yu, Qingshuai, Zhenao Sun, Yetong Han, Tuanlong Zhang, Rongxing Zhang, and Muhua Lin. 2025. "High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production" Micromachines 16, no. 6: 665. https://doi.org/10.3390/mi16060665

APA Style

Yu, Q., Sun, Z., Han, Y., Zhang, T., Zhang, R., & Lin, M. (2025). High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production. Micromachines, 16(6), 665. https://doi.org/10.3390/mi16060665

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High-Performance Two-Stage DC/DC Converter Based on LADRC-PI Hybrid Control for PEM Electrolyzer Hydrogen Production

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