Multi-level collaborative fault diagnosis and self-healing framework for proton exchange membrane fuel cell

Proton exchange membrane fuel cells (PEMFC) represent a key technology for energy transition, yet their reliability and lifespan are severely constrained by multi-source coupled failures. Current research predominantly focuses on isolated fault diagnosis or localized mitigation strategies, lacking a systematic governance framework to achieve closed-loop management from sensing to healing. This paper aims to address this challenge by systematically reviewing recent advances in fault diagnosis and self-healing strategies, proposing a forward-looking Hierarchical Collaborative Healing Framework (HCHF). First, it establishes a unified classification system integrating three major failure sources: the stack, sensors, and actuators. Subsequently, it comprehensively reviews model-based, signal processing, and data-driven diagnostic methods, comparing their respective advantages and limitations. Building upon this foundation, the core contribution is the HCHF framework, which organizes healing strategies into three synergistic tiers: (1) in-situ self-repair at the material and component level; (2) active fault-tolerant control at the system level; and (3) predictive health management at the system level. This framework enables cross-scale collaborative governance—from micro-level damage repair to macro-level system performance optimization—through a closed-loop interaction of diagnosis, decision-making, and healing. Finally, future research directions are explored by integrating cutting-edge trends such as digital twins and federated learning. This framework provides a systematic theoretical blueprint for the paradigm shift of PEMFC from “passive maintenance” to “active self-healing,” offering significant guidance for advancing the development of highly reliable fuel cell systems. • Covering all types of faults in the entire fuel cell system. • Summarizes the existing mainstream fault diagnosis methods. • A multi-level collaborative fault healing system has been proposed. • Propose a healing technology chain for future fuel cells.