Intelligent optimization of clamping design of PEM fuel cell stack for high consistency and uniformity of contact pressure

Aiming to accurately predict the leakage rate of the sealing interface, this work proposes a two-dimensional finite element model of a proton exchange membrane fuel cell, which includes the microscopic surface morphology and the asperity contact process of the components. First of all, we constructed the surface morphology of the seal by the two-dimensional W-M (Weierstrass–Mandelbrot) fractal function and explored the influence of fractal dimension (D) and scale parameter (G) on the surface profile. Furthermore, the finite element method and Poiseuille fluid theory were adopted to obtain the deformation variables of the asperity under different clamping pressures and leakage rates. Moreover, we quantitatively analyzed the impact of surface roughness on the clamping pressure and leakage rate. It was found that both the surface amplitude and surface roughness are positively correlated with G and negatively correlated with D. Surface morphology is proportional to D but has no relationship with G. Additionally, the deformation asperity decreases exponentially with growing clamping pressure, and the leakage rate is consistent with the experimental values at a clamping pressure of 0.54 MPa. With the same leakage rate, when the seal surface roughness value is less than 1 μm, a doubled roughness value leads to an increase of 31% in the clamping pressure. In contrast, when the surface roughness of the seal is greater than 1 μm, a doubled roughness value induces an increase of 50% in the corresponding clamping pressure.

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“…For the sake of simplification, the following reasonable assumptions were made for the finite element modeling [39]:…”

Section: Model Assumptionsmentioning

confidence: 99%

Analysis and Experimental Verification of the Sealing Performance of PEM Fuel Cell Based on Fractal Theory

Han

Wang

et al. 2023

Fractal Fract

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“…In PEMFC, the non-uniform distribution of contact pressures on the GDL leads to an increase in contact resistances, which increases ohmic losses, reduces porosity, and leads to the reaction gas concentration [13]. Therefore, it is essential to optimize the consistency and uniformity of the contact pressure of the GDL [14]. By optimizing the geometric parameters of the fuel cell assembly deign, the uniformity of the contact pressure distribution on the GDL can be increased [15].…”

Section: The Effect Of Assembly Force Temperature and Humidity On Fue...mentioning

confidence: 99%

A Multi-Field Coupled PEMFC Model with Force-Temperature-Humidity and Experimental Validation for High Electrochemical Performance Design

Zhang

Chen

et al. 2023

Sustainability

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PEMFCs (Proton Exchange Membrane Fuel Cells) are commonly used in fuel cell vehicles, which facilitates energy conversation and environmental protection. The fuel cell electrochemical performance is significantly affected by the contact resistance and the GDL (Gas Diffusion Layer) porosity due to ohmic and concentration losses. However, it is difficult to obtain the exact performance prediction of the electrochemical reaction for a fuel cell design, resulting from the complex operating conditions of fuel cells coupled with the assembly force, operating temperature, relative humidity, etc. Considering the compression behavior of porosity and the contact pressure in GDLs, a force-temperature-humidity multi-field coupled model is established based on FEA (Finite Element Analysis) and CFD (Computational Fluid Dynamics) for the fuel cell electrochemical performance. Aside from that, the characteristics between the contact resistance and the contact pressure are measured and fitted through the experiments in this study. Finally, the numerical model is validated by the experiment of the fuel cell stack, and the error rate between the presented model and the experimentation of the full-dimensional stack being a maximum of 3.37%. This work provides important insight into the force-temperature-humidity coupled action as less empirical testing is required to identify the high fuel cell performance and optimize the fuel cell parameters in a full-dimensional fuel cell stack.

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Section: Introductionmentioning

confidence: 99%

“…[9,10] In comparison to BEVs, [11] FCVs get rid of range anxiety and long charging time concerns [12] and have the advantage of subzero environment adaptability. [13] However, their commercial application is still largely hindered by the unsatisfactory fuel cell power density, [14] cost, [15] and durability [16] and undeveloped hydrogen infrastructure.As shown in Figure 1, the proton exchange membrane (PEM) fuel cell stack is the core of FCVs, which consists of several hundred repeated cells connected in series. The power density, that is, the ratio of stack output power to volume or weight is now an important indicator measuring the development level of PEM fuel cells.…”

mentioning

confidence: 99%

Structure Design for Ultrahigh Power Density Proton Exchange Membrane Fuel Cell

Zhang

Tongsh

et al. 2023

Small Methods

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electric vehicles (BEVs) have been gaining popularity. [9,10] In comparison to BEVs, [11] FCVs get rid of range anxiety and long charging time concerns [12] and have the advantage of subzero environment adaptability. [13] However, their commercial application is still largely hindered by the unsatisfactory fuel cell power density, [14] cost, [15] and durability [16] and undeveloped hydrogen infrastructure.As shown in Figure 1, the proton exchange membrane (PEM) fuel cell stack is the core of FCVs, which consists of several hundred repeated cells connected in series. The power density, that is, the ratio of stack output power to volume or weight is now an important indicator measuring the development level of PEM fuel cells. In general, an increase in power density not only means power improvement along with a more compact cell/stack structure but also cost reduction because of fewer cells needed at a fixed power demand. The New Energy and Industrial Technology Development Organization (NEDO) in Japan set stack power density (including end plates) targets of 6.0 (by 2030) and 9.0 kW L −1 (by 2040). [17,18] Meanwhile, the European Union Fuel Cells and Hydrogen 2 Joint Undertaking (EU-FCH2JU) set a similar goal of 9.3 kW L −1 . [19] At present, the state-of-theart commercial PEM fuel cell stack power density is about Next-generation ultrahigh power density proton exchange membrane fuel cells rely not only on high-performance membrane electrode assembly (MEA) but also on an optimal cell structure. To this end, this work comprehensively investigates the cell performance under various structures, and it is revealed that there is unexploited performance improvement in structure design because its positive effect enhancing gas supply is often inhibited by worse proton/electron conduction. Utilizing fine channel/rib or the porous flow field is feasible to eliminate the gas diffusion layer (GDL) and hence increase the power density significantly due to the decrease of cell thickness and gas/electron transfer resistances. The cell structure combining fine channel/rib, GDL elimination and double-cell structure is believed to increase the power density from 4.4 to 6.52 kW L −1 with the existing MEA, showing nearly equal importance with the new MEA development in achieving the target of 9.0 kW L −1 .

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Intelligent optimization of clamping design of PEM fuel cell stack for high consistency and uniformity of contact pressure

Cited by 7 publications

References 29 publications

Analysis and Experimental Verification of the Sealing Performance of PEM Fuel Cell Based on Fractal Theory

Analysis and Experimental Verification of the Sealing Performance of PEM Fuel Cell Based on Fractal Theory

A Multi-Field Coupled PEMFC Model with Force-Temperature-Humidity and Experimental Validation for High Electrochemical Performance Design

Structure Design for Ultrahigh Power Density Proton Exchange Membrane Fuel Cell

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