BeHyPSy – Lightweight, Air-cooled Fuel Cell Drives for Aviation

Fuel cell systems in high power ranges generally use liquid cooling. However, when it comes to alternative drives for aviation, minimum weight is important. The ZBT and its project partners are therefore jointly developing a fuel cell system with air cooling for unmanned aerial vehicles (UAVs, drones) and aircraft with a take-off weight of between 25 kilograms and two tons.

The aim of the BeHyPSy project is to develop, integrate and test an innovative propulsion system in a relevant power range that is based on hydrogen as an energy source. The drive system will be integrated into a laboratory prototype, characterized in the overall system and validated in an aircraft. The aim is to demonstrate that the scaled system architecture can also be used at higher take-off weights, which will open up an important market.

In contrast to conventional fuel cell systems in the high power range (>50kW), the system developed here does not use liquid cooling, which significantly reduces weight and volume. This means that the air management of the fuel cell system is of central importance, as both the reactant supply and the cooling air supply must be adapted to the system.

Another important feature of the desired system architecture is the multi-phase electric motor to increase reliability and availability. Each phase of the electric motor is supplied with power by a multi-stack fuel cell system.

The aim of the ZBT’s work within the project is “Lightweight fuel cell development for aviation applications” in order to meet this system concept with the development of particularly lightweight, air-cooled fuel cell stacks.

The most important approaches to increasing power density are

  • the use of thin, formed metal foils for the bipolar plates compared to the composite bipolar plates primarily used in air-cooled fuel cell stacks,
  • increasing space utilization at cell level through particularly compact cell designs and seal integration,
  • the development of a lightweight bracing system
  • an increased level of integration

If these measures succeed in reducing the stack weight, the potential of the system architecture can be fully exploited.

 

Partner
  • ZAL – Zentrum für angewandte Luftfahrtforschung
  • BREEZER Aircraft
  • HAW – Hochschule für angewandte Wissenschaften Hamburg
  • HSU – Helmut-Schmidt-Universität Hamburg
  • RST – Rostock System-Technik
  • ZBT – Zentrum für BrennstoffzellenTechnik
LUFO-Nr

20M2249

Funding provider:

Bundesministerium für Wirtschaft und Klimaschutz

Authorization period

01.05.2024 – 31.07.2027

Department Fuel Cells and Stacks

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BeHyPSy – Lightweight, Air-cooled Fuel Cell Drives for Aviation

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Test-Brennstoffzelle

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