The need for clean mobility launched multiple research directions in the powertrain field. While initially the battery electric vehicle (BEV) seemed the universal solution, the succession of pandemic emergencies and the resulting energetic crisis have defined a new scenario based on the multi-energy approach. One of the most promising technologies is the use of hydrogen in a fuel cell to generate electricity. This type of electric vehicle guarantees a shorter refueling time and a longer driving range than the battery electric one, becoming an enabling solution for long-haul or high-energy applications.
In this study a combined 3D-CFD and 0D system analysis of an automotive Proton Exchange Membrane Fuel Cell (PEMFC) and system was carried out to provide a multi-scale analysis. In the first part, starting from a conventional parallel channel flow field configuration, the use of an optimization tool coupled with 3D-CFD simulations allowed to identify the optimal configuration in terms of width of feed channels and the thickness of Gas Diffusion Layers (GDL) of both cathode and anode side to maximize the current density output. Besides, the 3D-CFD fuel cell analysis was carried out using an in-house developed model for the simulation of water phase-transition and membrane transport mechanisms. In the second part, the optimized cell geometry was compared to the conventional one at a system level, using an in-house developed MATLAB/Simulink model of parallel hybrid FC/battery Balance of Plant (BoP) with the capability of investigating the degradation rate of the membrane. The study shows the benefits of combined 3D-0D modelling for the advancement of fuel cells development for mobile applications.