Fuel cells multi-stack power architectures and experimental validation of 1 kW parallel twin stack PEFC generator based on high frequency magnetic coupling dedicated to on board power unit

This paper presents a study of a polymer electrolyte fuel cell (PEFC) multi-stack generator and its power electronic interface dedicated to an on board vehicle power unit. A parallel electric architecture has been designed and tested. First, a dynamic model of the PEFC stack, valid for high frequencies and compatible with power converter interactions, has been developed. This model is used for simulations of the global fuel cell and power converter behaviors. Second, an inventory of generic multi-stack fuel cells architectures is presented in order to couple electrically the fuel cell stacks to an on board DC bus (in series, parallel, through magnetic coupling…). This state of the art is completed by an overview of several candidate power converter topologies for fuel cells. Then, among all the possible technical solutions, an original power converter architecture using a high frequency planar transformer is proposed, which allows parallel and series magnetic couplings of two fuel cell stacks. Then, the study focuses on a first step, which is the association of two PEFC stacks. Such a structure, having good efficiency, is well adapted for testing and operation of fuel cells in normal and degraded working modes, which correspond to real constraints on board a vehicle. Finally, experimental validations on a 2 × 500 W twin stack PEFC with power converter interface demonstrate the technological feasibility for the embarked multi-stack fuel cells generator. The 1 kW power level chosen for the experimentation is close to that of a small on board PEFC auxiliary power unit (APU).