Comprehensive Methodology for the Design of Fuel Cell Vehicles: A Layered Approach

This paper presents a hierarchical model architecture for the analysis and optimization of Fuel Cell Electric Vehicles (FCEVs). The model encompasses the levels of cell, stack, and complete vehicle, which are interconnected through clearly defined transfer parameters. At the cell level, electrochemical and thermodynamic processes are mapped, the results of which are aggregated at the stack level into characteristic maps such as current–voltage curves and efficiency profiles. These maps serve as interfaces to the vehicle level, where the electric powertrain—comprising the fuel cell, energy storage, electric motor, and auxiliary consumers—is integrated. Special attention is given to the trade-off between the lifetime and dynamics of the fuel cell, which is methodically captured through variable parameter vectors. The transfer parameters enable consistent and scalable modelling that considers both detailed cell and stack information as well as vehicle-side requirements. On this basis, various vehicle configurations can be evaluated and optimized with regard to efficiency, lifetime, and drivability.