Optimization of air-cooled PEM fuel cell system with battery hybridization and experimental validation on hydrogen powered fuel cell bike

Antima Kumari, Kapil Sonkar, Chinmay Chaudhari, Tarun Jindal, Amit Katiyar, Sauhard Singh, Tapan Bera, Rajesh M. Badhe, Umish Srivastva and Alok Sharma

Renewable Energy, 2025, vol. 250, issue C

Abstract: Highly efficient, zero-emission fuel cell technology provides a sustainable alternative to fossil fuels, delivering continuous power, high density, longer range, and faster refueling than battery-electric vehicles. In this paper, a novel hybrid control methodology is developed using MATLAB to minimize fuel consumption for a 300W fuel cell (FC) bike. The methodology is utilized to optimize an air-cooled fuel cell (FC) stack to 250W, operating within a voltage range of 27V–36V and a current of 9.3A, in combination with a 24V, 2Ah Li-Po battery. A Type-III cylinder with a 2L water capacity is used for hydrogen storage at 350 bar and regulated at 0.4–0.7 bar fuel supply. FC bike is validated on test bench based on control methodology and developed drive cycle of 610sec with maximum motor/load power demand of 249.92W. The FC bike, validated through on-road tests, achieves a 100 km range per 50 gm hydrogen refill-double that of a battery bike while offering significantly faster refueling times.

Keywords: Hydrogen; Fuel cell battery hybrid vehicle; Drive cycle; Battery; Controller; Data acquisition system (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:renene:v:250:y:2025:i:c:s096014812501002x

DOI: 10.1016/j.renene.2025.123340

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