Performance Analysis of an Open-Cathode PEM Fuel Cell System Under Dynamic Power Profiles Using an Energy-Based Approach

Open-cathode Proton Exchange Membrane Fuel Cells (PEMFCs) are a promising technology for increasing the endurance of small Unmanned Aerial Vehicles (UAVs), ground robots, e-bikes, and light electric vehicles. However, their performance under realistic operating conditions is strongly influenced by rapid variations in load, temperature, and ambient pressure, which are often neglected in design-oriented or quasi-steady-state analyses. This study experimentally investigates a 1 kW open-cathode PEMFC system, including its balance of plant and a passive supercapacitor buffer, under a representative UAV flight power profile. Steady-state and dynamic tests were conducted to assess polarization characteristics, thermal behavior, parasitic power consumption, and hydrogen utilization. Results revealed significant thermal inertia and hysteresis effects during load transients, causing voltage deviations from steady-state performance and stabilization times exceeding 90 s. The supercapacitor effectively reduced stack current ramp rates, although some high-frequency oscillations remained. Under flight-representative conditions, the system achieved stable operation with average voltaic efficiency ranging from 55.3% to 60.7% and net efficiency ranging from 50.2% to 54.2%. Auxiliary components had a measurable impact on overall performance: cooling fans accounted for 2–6% of stack power during steady operation and approximately 2.5% of total mission energy, while hydrogen purge losses can significantly reduce vehicle endurance. The findings demonstrate the importance of energy-based performance assessment, including auxiliary loads and purge losses, to obtain realistic estimates of efficiency and endurance in dynamic PEMFC-powered applications.