Real-time digital twin implementation of power electronics-based hydrogen production system

This article implements a real-time digital twin (RTDT) of a 10 kW Dual Active Bridge (DAB)-electrolyzer system. The electrical model of a 10 kW alkaline electrolyzer is presented to understand its I–V characteristics. A sensitivity analysis is performed to assess the impact of various parameters on the electrolyzer’s electrical characteristics. The series inductance, crucial for power transfer within a DAB converter, is examined using PLECS software to study the impact of the electrolyzer load on the peak and RMS currents. Based on this, the value of series inductance is optimized, resulting in a minimum overall RMS current throughout the operating power range. RTDT of the DAB electrolyzer system is developed using an OP4610XG real-time simulator to validate the presented model and simulation parameters. A comparison with the PLECS simulation results shows that the developed RTDT accurately operates within the 10 kW alkaline electrolyzer’s electrical characteristics. Thus, this setup exhibits the potential to evaluate power electronics converter designs without a physical electrolyzer system. • This study models a 10 kW alkaline electrolyzer to analyze I–V and parameter sensitivity. • Series inductance influences DAB power flow and must suit electrolysis dynamics. • A real-time digital twin helps test converters safely without a physical electrolyzer.