Rated Power Performance Optimization and Efficiency Enhancement Strategies for 60 kW Proton Exchange Membrane Fuel Cell Systems

ABSTRACT As a clean energy conversion technology, proton exchange membrane fuel cells require systematic optimization of rated power performance and operational efficiency to enable large‐scale applications in new energy vehicles. This study presents a comprehensive optimization framework for 60 kW proton exchange membrane fuel cell systems through hydrogen utilization enhancement and multi‐physics coupling management. Key innovations include the implementation of proportional bypass valve control, dynamic pressure‐flow balancing of reactant gases, and adaptive exhaust valve frequency modulation. A coordinated temperature‐pressure‐flow regulation strategy was established and validated through multiple iterative system‐level experiments. The optimized system demonstrates significant improvements: 47.4% rated efficiency (12.5% increase from baseline), 72.2 kW stack power output, and 18% enhancement in volumetric power density. All performance metrics were rigorously validated through Certification Platform testing protocols. This work provides a replicable technical pathway for fuel cell parameter optimization while demonstrating the potential for implementing intelligent control algorithms in next‐generation energy systems.