Hydrogen Fuel Cell

Overview

The hydrogen fuel cell is a 120 kW proton-exchange-membrane (PEM) power system that converts hydrogen and atmospheric oxygen directly into electricity, heat, and water with no combustion. It serves as a clean prime mover or range extender where battery energy density is insufficient, refuelling in minutes rather than charging for hours.

The heart of the unit is the Fuel Cell Stack: 200 Membrane Electrode Assembly membrane electrode assemblies interleaved with graphite Bipolar Flow-Field Plate flow-field plates, clamped between end plates and copper current collectors under tie-rod compression. Each MEA pairs a Nafion proton-exchange membrane with platinum catalyst layers and gas diffusion layers.

How it works

Hydrogen enters the anode and splits at the catalyst into protons and electrons. Protons cross the membrane to the cathode while electrons are forced through the external circuit, producing current; at the cathode they recombine with oxygen to form water. The 200 cells in series yield a load-dependent 120–200 V, which the Power Electronics boosts to a regulated 650 V DC bus through a DC-DC converter and high-voltage contactors.

Air is filtered, compressed, humidified, and metered into the cathode by the Air Supply Subsystem, whose membrane humidifier recycles product water to keep the membrane conductive. The Hydrogen Supply Subsystem regulates supply pressure and recirculates unreacted hydrogen from the anode outlet back to the inlet, purging periodically to clear nitrogen and water.

The reaction is exothermic, so the Thermal Management Subsystem pumps deionised coolant through the stack to a radiator, using an ion-exchange deioniser to keep the coolant electrically non-conductive across the cell stack. Overseeing everything, the Fuel Cell Control Unit runs stack and balance-of-plant control, monitors temperatures, and watches the ventilated Enclosure for hydrogen leaks, shutting the system down on any unsafe condition.