Modeling and thermal management of proton exchange membrane fuel cell for fuel cell/battery hybrid automotive vehicle

The proton exchange membrane fuel cell (PEMFC) stack is a key component in the fuel cell/battery hybrid vehicle. Thermal management and optimized control of the PEMFC under real driving cycle remains a challenging issue. This paper presents a new hybrid vehicle model, including simulations of diver behavior, vehicle dynamic, vehicle control unit, energy control unit, PEMFC stack, cooling system, battery, DC/DC converter, and motor. The stack model had been validated against experimental results. The aim is to model and analyze the characteristics of the 30 kW PEMFC stack regulated by its cooling system under actual driving conditions. Under actual driving cycles (0–65 kW/h), 33%–50% of the total energy becomes stack heat; the heat dissipation requirements of the PEMFC stack are high and increase at high speed and acceleration. A PID control is proposed; the cooling water flow rate is adjusted; the control succeeded in stabilizing the stack temperature at 350 K at actual driving conditions. Constant and relative lower inlet cooling water temperature (340 K) improves the regulation ability of the PID control. The hybrid vehicle model can provide a theoretical basis for the thermal management of the PEMFC stack in complex vehicle driving conditions.     

Parameter optimization for a PEMFC model with a hybrid genetic algorithm

Many steady‐state models of polymer electrolyte membrane fuel cells (PEMFC) have been developed and published in recent years. However, models which are easy to be solved and feasible for engineering applications are few. Moreover, rarely the methods for parameter optimization of PEMFC stack models were discussed. In this paper, an electrochemical‐based fuel cell model suitable for engineering optimization is presented. Parameters of this PEMFC model are determined and optimized by means of a niche hybrid genetic algorithm (HGA) by using stack output‐voltage, stack demand current, anode pressure and cathode pressure as input–output data. This genetic algorithm is a modified method for global optimization. It provides a new architecture of hybrid algorithms, which organically merges the niche techniques and Nelder–Mead's simplex method into genetic algorithms (GAs). Calculation results of this PEMFC model with optimized parameters agreed with experimental data well and show that this model can be used for the study on the PEMFC steady‐state performance, is broader in applicability than the earlier steady‐state models. HGA is an effective and reliable technique for optimizing the model parameters of PEMFC stack. Copyright © 2005 John Wiley & Sons, Ltd.     

Numerical simulation and experimental validation of liquid water behaviors in a proton exchange membrane fuel cell cathode with serpentine channels

The volume-of-fluid (VOF) approach is one of the most promising methods of investigating water transport and water management in proton exchange membrane fuel cells (PEMFCs). A general PEMFC model combined with the VOF method has been developed by our group to simulate the mechanisms of fluid flows, mass and heat transport, and electrochemical reactions in a PEMFC, and it is necessary to validate the numerical model through experiments. In this paper, both the numerical model and an experimental visualization that can simulate the motion and transport behavior of liquid water in a cathode flow channel of a PEMFC are presented. Direct optical visualization is used in this work to capture the droplets’ motions with high spatial and temporal resolutions. The numerical model and experimental setup have similar geometric dimensions and operating conditions, and the results of the experiment are in good agreement with numerical simulations. Moreover, the physics of droplet and liquid water behavior based on certain material and liquid properties and the operating conditions in the fuel cell channel are also addressed. This analysis also offers some basic understanding of the mechanism of liquid droplet dynamics in numerical and experimental studies of micro-fluidics.     

An integrated simulation model for PEM fuel cell power systems with a buck DC-DC converter

Fuel cell powered systems generally have a high current and a low voltage. Therefore, the output voltage of the fuel cell must be stepped-down using a DC-DC buck converter. However, since the fuel cell and converter have different dynamics, they must be suitably coordinated in order to satisfy the demanded load. Accordingly, this study commences by constructing a MATLAB/Simulink model of a proton exchange membrane fuel cell (PEMFC) system comprising a PEMFC stack, an air/fuel supply system, and a temperature control system. The validity of the PEMFC model is demonstrated by comparing the simulation results obtained for the polarzation curves of a single fuel cell with the corresponding experimental curves. A model is then constructed of the DC-DC buck converter used to step-down the PEMFC output voltage. In addition, a sliding mode control (SMC) scheme is proposed for the DC-DC buck converter which guarantees a low and stable output voltage given transient variations in the output voltage of the PEMFC. Finally, a model is constructed of a DC-AC inverter with a pulse width modulated (PWM) control scheme which enables the PEMFC stack to supply the grid or power AC applications directly. Overall, the combined PEMFC/DC-DC buck converter/DC-AC inverter model provides a powerful and versatile tool for the design and development of a wide range of PEMFC power systems.     

Model-based decoupling control for the thermal management system of proton exchange membrane fuel cells

As one of the most promising sustainable energy technologies available today, proton exchange membrane fuel cell (PEMFC) engines are becoming more and more popular in various applications, especially in transportation vehicles. However, the complexity and the severity of the vehicle operating conditions present challenges to control the temperature distribution in single cells and stack, which is an important factor influencing the performance and durability of PEMFC engines. It has been found that regulating the input and output coolant water temperature can improve the temperature distribution. Therefore, the control objective in this paper is regulating the input and output temperature of coolant water at the same time. Firstly, a coupled model of the thermal management system is established based on the physical structure of PEMFC engines. Then, in order to realize the simultaneous control of the inlet and outlet cooling water temperature of the PEMFC stack, a decoupling controller is proposed and its closed-loop stability is proved. Finally, based on the actual PEMFC engine platform, the effectiveness, accuracy and reliability of the proposed decoupling controller are tested. The experimental results show that with the proposed decoupling controller, the inlet and outlet temperatures of the PEMFC stack cooling water can be accurately controlled on-line. The temperature error range is less than 0.2 °C even under the dynamic current load conditions.     

Characterization and experimental results in PEM fuel cell electrical behaviour

A control oriented electrochemical static model of a proton exchange membrane fuel cell (PEMFC) stack is developed in this paper. Even though its validation is performed on a specific 7-cell PEMFC stack fed by humidified air and pure hydrogen, the methodology and fit parameters can be applied to different fuel cell systems with minor changes. The fuel cell model was developed combining theoretical considerations and semi-empirical analysis based on the experimental data. The proposed model can be successfully included into a larger dynamic subsystem to complete the power generation system.     

Control-orientated thermal model for proton-exchange membrane fuel cell systems

A lumped parameter dynamic model is developed for predicting the stack temperature, temperatures of the exit reactant gases and coolant water outlet in a proton-exchange membrane fuel cell (PEMFC) system. A dynamic model for a water pump is also developed and can be used along with the thermal model to control the stack temperature. The thermal and water pump models are integrated with the air flow compressor and PEMFC stack current–voltage models developed by Pukrushpan et al. to study the fuel cell system under open and closed-loop conditions. The results obtained for the aforementioned variables from open-loop simulation studies are found to be similar to the experimental values reported in the literature. Closed-loop simulations using the model are carried out to study the effect of stack temperature on settling times of other variables such as stack voltage, air flow rate, oxygen excess ratio and net power of the stack. Further, interaction studies are performed for selecting appropriate input–output pairs for control purpose. Finally, the developed thermal model can assist the designer in choosing the required number of cooling plates to minimize the difference between the cooling water outlet temperature and stack temperature.     

Analysis of Proton Exchange Membrane Fuel Cell Systems Involving Heat Exchangers

Proton-exchange membrane fuel cells (PEMFCs) have been regarded as the new energy source for portable, stationary, and automotive applications. However, commercial exploitation of PEMFCs is still in an early stage, due to shortage of infrastructure in the society, high cost, and particularly the difficulty of the water/thermal management. One of the objectives of the current work is to analyze the water/thermal balances in a 100-kW class PEMFC system, consisting of PEMFC stack, compressor, intercooler, heater, humidifier, condenser, and radiator. As a first step, the heat and mass balances in the heat exchangers are analyzed for various water recovery schemes, followed by an analysis of the PEMFC stack effects on the system balance concerning the pressure drop and operating current density.     

Collaborative simulation for dynamical PEMFC power systems

In this paper a collaborative simulation platform for proton exchange membrane fuel cell (PEMFC) power systems is presented, where the stack is simulated by a two-phase distributed parameter model and the auxiliary units by lumped parameter models. By exchanging the dynamic data between the external load/auxiliary units and PEMFC stack, dynamic simulation of PEMFC stack has been carried out during the load changes for various states associated with different characteristic variables. The internal states of the stack can be observed due to variation of external load/auxiliary units. Numerical experiments are provided for a special case with multiple cycles of load changes derived from an acceleration mode of a fuel cell vehicle. The numerical results demonstrate that the “undershoot” of output voltage is due to the response lag of the auxiliary units and liquid water accumulation in the fuel cell stack.     

Optimization of fuel cell system operating conditions for fuel cell vehicles

Proton exchange membrane fuel cell (PEMFC) technology for use in fuel cell vehicles and other applications has been intensively developed in recent decades. Besides the fuel cell stack, air and fuel control and thermal and water management are major challenges in the development of the fuel cell for vehicle applications. The air supply system can have a major impact on overall system efficiency. In this paper a fuel cell system model for optimizing system operating conditions was developed which includes the transient dynamics of the air system with varying back pressure. Compared to the conventional fixed back pressure operation, the optimal operation discussed in this paper can achieve higher system efficiency over the full load range. Finally, the model is applied as part of a dynamic forward-looking vehicle model of a load-following direct hydrogen fuel cell vehicle to explore the energy economy optimization potential of fuel cell vehicles.     

A comparative study of single and dual ejector concepts for anodic recirculation system in high-performance vehicular proton exchange membrane fuel cells

The fuel supply system is a critical element in Proton Exchange Membrane Fuel Cell (PEMFC). In vehicular applications, an anode recirculation system (ARS) is required to return residual hydrogen to the fuel line. A 1D model of an ejector-based ARS was created and integrated with a vehicular PEMFC in this study. Therefore, two configurations, single-ejector-based and dual-ejector-based ARS, were developed to regulate the fuel supply and, thus, utilized to examine and conduct a comparative study of their advantages and disadvantages to the dynamic behavior of the stack. The use of ARS was found to improve stack performance and fuel utilization by delivering high stoichiometry, recirculation rate, and relative humidity. Contrary to a single-ejector-based ARS, whose use is restricted due to its limited working range, dual-ejectors can cover all fuel cell stack operating ranges. Sensitivity analysis revealed that primary pressure was the most significant parameter affecting ejector performance and flow characteristics.     

A study of operation strategy of cooling module with dynamic fuel cell system model for transportation application

A fuel cell system model with detailed cooling module model was developed to evaluate the control algorithms of cooling module which is used for the thermal management of a proton exchange membrane fuel cell (PEMFC) system. The system model is composed of a dynamic fuel cell stack model and a detailed dynamic cooling module model. To extend modeling flexibility, the fuel cell stack model utilizes analytic approach to capture the transient behavior of the stack temperature corresponding to the change of the coolant temperature and the flow rate during load follow-up. The cooling module model integrated model of fan, water pump, coolant passage, and electric motors so that the model is capable of investigation of operating strategy of pump and fan.The fuel cell system model is applied to the investigation of the control logics of the cooling module. Since, it is necessary for the control of cooling module to define the reference conditions such as coolant temperature and fuel cell stack temperature, this study presents such thermal management criteria. Finally, two control algorithms were compared, a conventional control algorithm and a feedback control algorithm. As a consequence, the feedback control algorithm was found to be more suitable for the cooling module of the PEMFC stack, as they consume less parasitic power while producing more stack power compared to a conventionally controlled cooling module.     

Identification of the Hammerstein model of a PEMFC stack based on least squares support vector machines

This paper reports a Hammerstein modeling study of a proton exchange membrane fuel cell (PEMFC) stack using least squares support vector machines (LS-SVM). PEMFC is a complex nonlinear, multi-input and multi-output (MIMO) system that is hard to model by traditional methodologies. Due to the generalization performance of LS-SVM being independent of the dimensionality of the input data and the particularly simple structure of the Hammerstein model, a MIMO SVM-ARX (linear autoregression model with exogenous input) Hammerstein model is used to represent the PEMFC stack in this paper. The linear model parameters and the static nonlinearity can be obtained simultaneously by solving a set of linear equations followed by the singular value decomposition (SVD). The simulation tests demonstrate the obtained SVM-ARX Hammerstein model can efficiently approximate the dynamic behavior of a PEMFC stack. Furthermore, based on the proposed SVM-ARX Hammerstein model, valid control strategy studies such as predictive control, robust control can be developed.     

Thermal analysis and management of proton exchange membrane fuel cell stacks for automotive vehicle

The thermal management of a proton exchange membrane fuel cell (PEMFC) is crucial for fuel cell vehicles. This paper presents a new simulation model for the water-cooled PEMFC stacks for automotive vehicles and cooling systems. The cooling system model considers both the cooling of the stack and cooling of the compressed air through the intercooler. Theoretical analysis was carried out to calculate the heat dissipation requirements for the cooling system. The case study results show that more than 99.0% of heat dissipation requirement is for thermal management of the PEMFC stack; more than 98.5% of cooling water will be distributed to the stack cooling loop. It is also demonstrated that controlling cooling water flow rate and stack inlet cooling water temperature could effectively satisfy thermal management constraints. These thermal management constraints are differences in stack inlet and outlet cooling water temperature, stack temperature, fan power consumption, and pump power consumption.     

Adaptive thermal control for PEMFC systems with guaranteed performance

Proton exchange membrane fuel cell (PEMFC) s are faced with dynamical load scenario in practical applications, and the resulting temperature variation will decrease the performance and consequently shorten the fuel cell lifetime. To address this problem, a control strategy for regulating the stack temperature is proposed in this paper. Firstly, a thermal management-oriented dynamic model of a water-cooled PEMFC system is built to facilitate the control design. Secondly, considering that the stack temperature should be maintained in a certain range regardless of the dynamical changing current demand, a Barrier Lyapunov function is employed to construct a feedback error of the stack temperature. Thirdly, a set of adaptation laws is designed to estimate the unknown parameters related to the gas flow rates in the flow fields. Particularly, a dynamic inversion tracking methodology is applied to design the non-affine input. A Lyapunov method based analysis demonstrates the stability and convergence of the closed-loop properties. Simulation results are provided to show that the proposed control strategy can satisfy all the control objectives and enhance the control performance compared to the proportional-integral controlled case.     

Novel dynamic semiempirical proton exchange membrane fuel cell model incorporating component voltages

This paper introduces a novel dynamic semiempirical model for the proton exchange membrane fuel cell (PEMFC). The proposed model not only considers the stack output voltage but also provides valid waveforms of component voltages, such as the no‐load, activation, ohmic, and concentration voltages of the PEMFC stack system. Experiments under no‐load, ramping load, and dynamic load conditions are performed to obtain various voltage components. According to experimental results, model parameters are optimised using the lightning search algorithm by providing valid theoretical ranges of parameters to the lightning search algorithm code. In addition, the correlation between the vapour and water pressures of the PEMFC is obtained to model the component voltages. Finally, all component voltages and the stack output voltage are validated by using the experimental/theoretical waveforms mentioned in previous research. The proposed model is also compared with a recently developed semiempirical model of PEMFC through particle swarm optimisation. The proposed dynamic model may be used in future in‐depth studies on PEMFC behaviour and in dynamic applications for health monitoring and fault diagnosis.     

Fuel cell power conditioning unit for standalone application with real time validation

In recent era, fuel cells are emerging as better alternative to wind and solar based energy sources due to its reliability and high efficiency. Polymer Electrolyte Membrane Fuel Cell (PEMFC) is widely used in various applications due to low operating temperature and high energy density. On the other side low and unregulated stack voltage demands PEMFC integration with suitable power conditioning unit. However, the use of actual fuel cell power conditioning unit in design and testing for research is expensive. Any failure may lead to damage of source or power circuit. In this regard, the present work aims at developing a soft-computing model of PEMFC. Also, a DC-DC converter is designed to step-up the stack voltage. A classical PI controller is implemented to regulate the PEMFC fed power conditioning units for resistive loads. The proposed system is implemented is Hardware-In-the-Loop (HIL) using OPAL-RT's OP5600 Real Time Digital Simulator (RTDS).     

Behaviour modelling of a PEMFC operating on diluted hydrogen feed

The polymer electrolyte membrane fuel cell (PEMFC) using reformate gas as fuel is regarded as an attractive solution for the near‐term introduction of fuel cells in stationary or mobile power generation market. With respect to hydrogen feeding, the reformate gas fuelling involves additional polarization losses because of the hydrogen dilution and the impurities contained in the gas. In this paper a one‐dimensional model has been developed to investigate the behaviour of a PEMFC operating with reformate gas mixture. The model, based on a semi‐empirical approach, considers the kinetic reactions in the anode side taking into account the effect of reverse water–gas shift (RWGS) due to the presence of CO₂ in the fuel. As it is well known, the exhaust stream from fuel reformers can contain a high carbon dioxide concentration (>20%) that can have a detrimental effect on the fuel cell performance because of the combination of the dilution and the formation of CO by the RWGS reaction. The numerical simulation results have been compared with the experimental data, obtained in the test room of Industrial Engineering Department of Cassino University, and a good match has been observed. The model has been developed by using a simplified approach that, nevertheless, can allow to obtain a good numerical prediction of the fuel cell performance reducing the simulation time and computational efforts. Copyright © 2008 John Wiley & Sons, Ltd.     

A comparison of temperature distribution in PEMFC with single-phase water cooling and two-phase HFE-7100 cooling methods by numerical study

Thermal management has been considered as one of the critical issues in proton exchange membrane fuel cell (PEMFC). Key roles of thermal management system are maintaining optimal operating temperature of PEMFC and diminishing temperature difference over a single fuel cell and stack. Severe temperature difference causes degradation of performance and deterioration of durability, so understanding temperature distribution inside a single fuel cell and stack is crucial. In this paper, two-phase HFE-7100 cooling method is suggested for PEMFC thermal management and investigated regarding temperature change inside a fuel cell. Also, the results are compared to single-phase water cooling method. Numerical study of temperature distribution inside a single PEMFC is conducted under various conditions for the two different cooling methods. Fuel cell model considering mass transfer, electrochemical reaction and heat transfer is developed.The result indicates that two-phase HFE-7100 cooling method has an advantage in temperature maintenance and temperature uniformity than single-phase water cooling method, especially in high current density region. It is also revealed that the cell temperature is less dependent on system load change with two-phase cooling method. It indicates that the fuel cell system with two-phase cooling method has high thermal stability. In addition, the effect of coolant flow rate and coolant inlet pressure in two-phase HFE-7100 cooling method are discussed. As a result, two-phase cooling method showed reliable cooling performance even with low coolant flow rate and the system temperature increased as coolant pressure rose.