Our Projects

Our current research projects include numerous aspects of fuel cell design. Researchers are in the process of modelling a flowing electrolyte direct methanol fuel cell (FE-DMFC) unit-cell, while experiments currently underway aim to validate theoretical models. Using COMSOL Multiphyics, Pro Engineer/Wildfire 5.0, and MatLAB, theoretical 1D, 2D and eventual 3D numerical models and simulations will soon be capable of accurately producing results comparable to those attained through in-house prototype experimentation.

The machine shop in the Mechanical and Aerospace department at Carleton is more than adequately capable of fabricating all stainless-steel endplates, copper electrodes, and graphite plates of a fuel cell. At present we have successfully completed the production of a prototype FE-DMFC unit-cell, and testing unit-cell performance through controlled conditions, and producing near-competitive polarization curves. As such tests are conducted on the unit-cell in our labs, we are simultaneously in the process of manufacturing a prototype 10-cell stack.

Theoretical Designwork

Below is an exploded 3D model of our first generation FE-DMFC prototype, which has been completely designed using PTC Pro Engineer and was manufactured in-house. Numerical modelling provided through COMSOL Multiphysics indicates an internal cell temperature transfered through the fuel cell substrate from our Omega heating elements to be an optimal 80 degrees Celsius.

Design Synthesis - Theory to Reality

To the right is a photograph taken of the first-generation physical prototype currently undergoing testing. Made accordingto the specifications determined in the Pro Engineer model, the physical model includes the Omega heating elements and assembly hardware. The electrical outlet which can be seen if strictly for applying power to the dual heating elements which simulate operational temperature.

Thanks to the introduction of new materials and design modifications, we have successfully eliminated the number of substrate components from 14 (as shown in the figure below), to 8. Preliminary computational tests based on such a new design promise drastic improvements in performance and cost reduction. The simplified components, shown below, has been installed in the current fuel cell support structure and is currently undergoing testing to confirm an improvement over the first-generation prototype.

-- IMAGE COMING SOON --

The Proving Grounds

To conduct physical tests our new designs, we rely on a 250 W max Fideris Brand Electronic Load Bank supplied by TesSol Inc., operated by a custom state-of-the-art computer terminal. This unit is capable of ultra-low impedance operation, and due to the availability of interchangeable

shunts, precise operation over a wide dynamic range is

available. To decipher output and control the load bank, we are currently using FCPower Software, arguably the most dynamic, the most powerful, fuel cell testing platform in the industry. The intent of unit-cell testing is to isolate the efficiency of the flowing electrolyte in the DMFC, with a stead-state output nearing 1 Watt.

What's Next?

Next generation designs are mean to consider weight, materials, cost, and overall size. Such designs are near completion, and should soon be ready for manufacture. In the near future, prototype stacks first aim to produce 10, 20, and 50 Watt output capactiy, followed by 100, 200, and 250 Watt (maxing out the available Fideris electronic load capacity).

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