Optimal Sizing of Fuel Cell and Battery in a Direct-Hybrid for Electric Aircraft

The climate impact of aviation can be reduced using powertrains based on hydrogen fuel cells and batteries. Combining both technologies in a direct-hybrid without a DC/DC converter is a promising approach for light-weight systems. Depending on the power demand, both the fuel cell and battery are used to provide power or only the fuel cell is connected to the powertrain. The system voltage in a direct-hybrid is determined by the fuel cell and battery, but the performance of fuel cells is affected by low-ambient pressure at high altitudes and the battery voltage is affected by state of charge and discharge rate. Taking this into account, the presented work demonstrates how a direct-hybrid system must be designed based on a scaled mission profile of a 40-seater aircraft. The fuel cell and battery are configured and sized according to the power demand in different flight phases while considering voltage limits given by the powertrain. The energy requirement from the fuel cell and the battery is calculated for a flight based on a realistic mission profile and different battery and fuel cell configurations are evaluated. By optimizing the battery and fuel cell size, the energy required from the battery was reduced by 57% and the total weight of the fuel cell and battery was reduced by 11%.