Experimental investigation of fuel cell system operational parameters for powertrain sizing and energy management in light commercial fuel cell electric transporters

Power demand and dynamic response are primary control objectives for automotive fuel cell systems (FCSs). Their operational impact in fuel cell electric transporters is underexplored, with most studies limited to simulations and optimization-based energy management systems (EMSs) that lack practical interpretability. This study presents experimental analysis on a powertrain test bench with components of a light commercial transporter, employing rule-based EMS to derive design guidelines. The analysis considers FCS operating range, dynamic response, and power distribution. Results show that narrowing the operating range from 65 to 45 kW improves average efficiency by 1.4%. Varying the dynamic response between 5–30 kW/s does not affect efficiency. A 5% efficiency span is observed across load-following, charge-sustaining, and average-power strategies. Sizing guidelines are derived from battery stress analysis. An operating range of 45 kW with ramp rates of 5–10 kW/s (positive) and −30 kW/s (negative) is recommended for EMS design. • Study on a light commercial powertrain test bench with real automotive components. • Analysis based on representative rule-based energy management systems (EMSs). • Evaluates effects of fuel cell operating range, dynamics, and power distribution. • Average fuel cell efficiency insignificantly affected by dynamic rates of 5–30 kW/s . • A 5% efficiency span observed across load-following and average-power EMSs.