Prototype System

Overview

The Prototype System is a configurable balance-of-plant (BoP) test platform designed to validate fuel cell prototype hardware and control strategies at meaningful power levels. Built as a modular test bench, it reproduces real operating conditions by managing reactant delivery, recirculation, humidification, thermal control, and pressure regulation under closed-loop automation.

Principle of Operation

The system conditions air and hydrogen to defined flow, pressure, temperature, and humidity setpoints, then delivers them to a stack (or stack simulator). A sensor network (flow, pressure, temperature, dew point, and differential pressure) feeds the DAQ layer and control software, enabling stable, repeatable operation. Core control loops regulate:

• Air supply via blower/compressor control
• Hydrogen recirculation using a recirculation blower or ejector
• Humidification using an external humidifier or self-humidifying operation
• Thermal management via stack liquid circulation with heating and cooling
• Back-pressure using automated back-pressure control for stable operating pressure
  
  

Key Features and Configuration Options

• Fuel cell prototype test capability: typically 15 kW to ~200 kW system development work
• Dead-end operation support for hydrogen utilisation and water-management studies
• Automated safety logic (interlocks, alarms, and controlled shutdown sequencing)
• High-precision flow-control architecture (MFC-based, configurable ranges; high turndown capability)
• Stable pressure regulation architecture (auto back-pressure control used across advanced test stations)
• Expandable I/O for stack voltage taps, auxiliary pumps/valves, and future sensor upgrades
  
  

Compatibility and Integrations

Designed to interface with common fuel cell stacks, external electronic loads/DC power supplies, and auxiliary measurement tools. For deeper electrochemistry diagnostics, the BoP can be paired with potentiostats/galvanostats, HFR/EIS modules, and application-specific gas analysis or spectroscopy workflows.

Typical Applications

• BoP component validation (blowers, recirculation devices, humidifiers, pumps)
• Control strategy development (start-up/shutdown, purge logic, fault handling)
• Thermal and water-management optimisation
• System-level performance and durability testing for prototype fuel cell systems
  
  

Why ScienceGears

ScienceGears supports researchers and engineers across Australia and New Zealand with configuration guidance, integration planning, and cross-compatibility with related electrochemistry and energy test station instrumentation.