A comparative analysis of power control strategies for a plug-in extended-range FCHEV with battery and PEMFC durability considerations

Fuel cell hybrid electric vehicles employ fuel cells along with batteries or ultracapacitors as power sources, and energy management systems can control their power split. This study investigates energy management strategies for lightweight plug-in extended-range fuel cell hybrid electric vehicles to optimise fuel economy, extend component lifespans, and enhance vehicle efficiency. Comparisons between power follower and dynamic programming-based strategies are conducted, focusing on incorporating PEMFC health constraints to prolong stack durability via on-off binary mode operation. Using the New European Driving Cycle, performance evaluation is conducted on a parallel architecture featuring a 16-kW motor, regenerative braking system, eight 420-Wh batteries in series, and six 1-kW fuel cell stacks. Dynamic programming strategies demonstrated potential improvements, with savings in hydrogen consumption of 62–72 L per driving cycle and SOC levels of 3.9%. Moreover, optimised battery lifespan enabled the system to achieve approximately 18,087 -18,745 charge/discharge cycles. Implementing PEMFC health constraints facilitated reductions in average accumulated active time to 205 seconds per driving cycle and startup/shutdown cycle frequency to 36.5 cycles per hour, promoting enhanced system durability and operational efficiency.