Analysis of cooling system topology of dual stack proton exchange membrane fuel cell system for heavy-duty truck

This study investigates the influence of cooling system topologies on the power and energy management of dual-stack proton exchange membrane fuel cell (PEMFC) systems designed for heavy-duty trucks. When two module stacks are equipped, the cooling system architectures are important to maintain stack temperature under dynamic load follow-up. A comprehensive MATLAB/Simulink model of a fuel cell heavy-duty truck was developed to compare three cooling architectures: a single continuous loop, a single pump with dual radiators, and dual independent cooling loops. This study simulates dual stacks with different cooling system architectures under the Worldwide Harmonized Vehicle Cycle (WHVC) that is suitable for heavy duty trucks. The results reveal that the independent dual-loop architecture (Configuration C) allows flexible thermal control for each stack, leading to a 33 % reduction in total parasitic energy consumption and a 60 % decrease in pump energy compared with the conventional single-loop system. These reductions result in more efficient use of the available stack output power, increasing net fuel cell power output and improving battery SOC stability. Fuel cell heavy-duty truck model: (a) powertrain, (b) fuel cell system