Design and manufacture of a high-temperature PEMFC and its cooling system to power a lightweight UAV for a high altitude mission

In the present study, the optimal design of a high-temperature proton exchange membrane fuel cell (HT-PEMFC) that will be used to power an unmanned aerial vehicle (UAV) in a high altitude mission is performed. The use of PEMFCs for service ceiling above 10 km implies overcoming a number of problems caused by the harsh environmental conditions. Among them, new strategies to manage the heat generated by electrochemical reactions are needed. The maximum power required by the UAV was determined solving the aerodynamic problem, and the design of the lightweight HT-PEMFC, including its cooling system, was optimized. To perform the numerical solution of the heat transfer problem, a computational code was implemented using the EES software. The decisions adopted resulted in a 40-cells stack with an electric power above 1 kW and a weight around 3.65 kg. Besides, it is demonstrated that, for the configuration considered in the study, a passive cooling system without any additional fan system can be used to maintain the stack temperature in 160 °C.