Hydrogen-powered fuel cell electric vehicles are a promising solution among zero-emission vehicles, offering a viable alternative to fully electric vehicles due to their greater mileage and shorter refuelling times compared to EV battery recharging. To ensure proper operation, the fuel cell powertrain requires several auxiliary systems. Among these, a thermal management system is essential for maintaining the correct operating temperature, while a hydrogen storage and supply system is needed to deliver the appropriate fuel flow rate and pressure. This paper presents an optimization of the architecture of these auxiliary systems through the development of a multiphysics lumped-parameter model. The cooling system is designed to regulate the temperature of multiple electrical components, including the DC-DC converter, inverter, and the PEM fuel cell stack. Additionally, the hydrogen supply system accounts for the impact of time-dependent power demands on the dynamics of a high-pressure fuel storage system. The model also integrates a battery pack, e-drive (motor-inverter), and a control system to simulate a simple ECU. It has been tested under various load conditions, as well as different initial and boundary conditions (e.g., external air temperature, hydrogen storage filling ratio). The results, including fuel cell stack temperature, efficiency, and predicted vehicle autonomy, are analysed and discussed. This simulation work has led to significant design and optimization decisions for the powertrain architecture, enabling the proper selection of components and their operating points.
Design and simulation of a fuel cell electric vehicle powertrain: thermal management and hydrogen supply systems
Frosina, Emma;
2025-01-01
Abstract
Hydrogen-powered fuel cell electric vehicles are a promising solution among zero-emission vehicles, offering a viable alternative to fully electric vehicles due to their greater mileage and shorter refuelling times compared to EV battery recharging. To ensure proper operation, the fuel cell powertrain requires several auxiliary systems. Among these, a thermal management system is essential for maintaining the correct operating temperature, while a hydrogen storage and supply system is needed to deliver the appropriate fuel flow rate and pressure. This paper presents an optimization of the architecture of these auxiliary systems through the development of a multiphysics lumped-parameter model. The cooling system is designed to regulate the temperature of multiple electrical components, including the DC-DC converter, inverter, and the PEM fuel cell stack. Additionally, the hydrogen supply system accounts for the impact of time-dependent power demands on the dynamics of a high-pressure fuel storage system. The model also integrates a battery pack, e-drive (motor-inverter), and a control system to simulate a simple ECU. It has been tested under various load conditions, as well as different initial and boundary conditions (e.g., external air temperature, hydrogen storage filling ratio). The results, including fuel cell stack temperature, efficiency, and predicted vehicle autonomy, are analysed and discussed. This simulation work has led to significant design and optimization decisions for the powertrain architecture, enabling the proper selection of components and their operating points.I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
