Power electronic converter design for industrial energy systems

DC–DC converters contribute significantly to the efficient functioning of energy conversion devices employed in industries due to their functions such as voltage regulation and power control. Their performance affects conversion efficiency, thermal stress, output voltage quality, and the operating condition of connected components. In industrial applications, these factors must be considered together because a design that performs well in one area may still show limitations in another. This paper presents a simulation-based study of DC–DC converter design with emphasis on the combined effect of component selection, switching losses, thermal conditions, and voltage regulation. Several converter configurations are evaluated under nominal, variable-load, and thermal-stress operating conditions to compare their electrical response and temperature behavior under common design requirements. The analysis examines how semiconductor and passive component choices influence total power loss, device temperature rise, ripple characteristics, and output stability. The results show that converter performance should not be assessed from efficiency alone, since different component combinations produce noticeable differences in loss distribution, thermal response, and regulation quality. Among the tested cases, the preferred configuration achieved lower total loss, moderate temperature rise, and more stable output performance than the alternative designs. The study shows that combined electrical and thermal assessment provides a practical basis for DC–DC converter selection in industrial energy systems.