Performance Analysis and Optimization of Fuel Cell Vehicle Stack Based on Second-Generation Mirai Vehicle Data

To accurately investigate the loss characteristics of fuel cell vehicles (FCVs) under actual operating conditions and enhance their power performance and economic efficiency, this study establishes a numerical model of the proton exchange membrane fuel cell (PEMFC) stack based on real-world data from the second-generation Mirai. The stack model incorporates leakage current losses and imposes a limit on maximum current density. Besides, this study analyzes the effects of operating parameters (PEM water content, hydrogen partial pressure, current density, oxygen partial pressure, and operating temperature) on stack power output, efficiency, and eco-performance coefficient (ECOP). Furthermore, Non-Dominated Sequential Genetic Algorithm (NSGA-II) is employed to optimize the PEMFC stack performance, yielding the optimal operating parameter set for FCV operation. Further simulations are conducted on dynamic performance characteristics of the second-generation Mirai under two typical driving cycles, evaluating the power performance and economy of the FCV before and after optimization. Results demonstrate that the established PEMFC stack model accurately analyzes the output performance of an actual FCV when compared with real-world performance test data from the second-generation Mirai. Through optimization, output power increases by 7.4%, efficiency improves by 1.95%, and ECOP rises by 3.84%, providing guidance for enhancing vehicle power performance and improving overall vehicle economy. This study provides a practical framework for enhancing the power performance and overall energy sustainability of fuel cell vehicles, contributing to the advancement of sustainable transportation.