Design, Development, and Performance of a 10 kW Polymer Exchange Membrane Fuel Cell Stack as Part of a Hybrid Power Source Designed to Supply a Motor Glider

A 10 kW PEMFC (polymer exchange membrane fuel cell) stack consisting of two 5 kW modules, (A) and (B), connected in series with a multi-function controller unit was constructed and tested. The electrical performance of the V-shaped PEMFC stack was investigated under constant and variable electrical load. It was found that the PEMFC stack was capable of supplying the required 10 kW of electrical power. An optimised purification process via ‘purge’ or humidification, implemented by means of a short-circuit unit (SCU) control strategy, enabled slightly improved performance. Online monitoring of the utilisation of the hydrogen system was developed and tested during the operation of the stack, especially under variable electrical load. The air-cooling subsystem consisting of a common channel connecting two 5 kW PEMFC modules and two cascade axial fans was designed, manufactured using 3D printing technology, and tested with respect to the electrical performance of the device. The dependence of total partial-pressure drop vs. ratio of air volumetric flow for the integrated PEMFC stack with cooling devices was also determined. An algorithm of stack operation involving thermal, humidity, and energy management was elaborated. The safety operation and fault diagnosis of the PEMFC stack was also tested.