Holistic Dynamic Modeling of Open-Cathode PEM Fuel Cells for Sustainable Hydrogen Propulsion in UAVs

The adoption of proton exchange membrane fuel cells (PEMFCs) in unmanned aerial vehicles (UAVs) offers a sustainable pathway to zero-emission propulsion, supporting aviation decarbonization by replacing battery or fossil fuel systems with efficient hydrogen technology. This work presents the development, validation, and application of a comprehensive dynamic model of a 1 kW open-cathode PEMFC system, including complete balance of plant (BOP) and control logic for four cooling fans, a purge valve, and a short-circuit unit (SCU). The model was validated through extensive experiments with step, triangular, and real-world UAV current profiles. Under steady-state conditions, it reproduces stack voltage with a <1 V average error and a temperature of 2.5 °C. Dynamic modeling accurately predicts fan behavior, purge/SCU events, and transient voltage drops. Applied to a 25 min UAV flight, the model quantifies reactant-management impacts: purge events increase H2 usage by 4.8%, with SCU raising total to 5.6% above stoichiometric consumption. Altitude analysis shows ambient temperature reduction dominates the oxygen partial pressure effects, yielding net cell voltage increase under current-based fan control. These insights underscore explicit BOP and ambient modeling for accurate UAV endurance estimation and strategy optimization, providing a basis for future altitude-chamber validation. By enabling precise BOP dynamics simulation and H2 optimization, this model advances the achievement of affordable clean energy, facilitating an extended endurance with minimal environmental impact.