Simulation, Design, and Validation of an UAV SOFC Propulsion System

A physically-based model for design and optimization of a fuel cell powered electric propulsion system for an unmanned aerial vehicle (UAV) is presented. Components of the system include a solid oxide fuel cell (SOFC) providing power, motor controller, brushless dc (BLDC) motor, and a propeller. Steady-state models for these components are integrated into a simulation program and solved numerically. This allows an operator to select constraints and explore design trade-offs between components, including fuel cell, controller, motor, and propeller options. We also present a graphical procedure using this model that allows rapid assessment and selection of design choices, including fuel cell characteristics and hybridization with multiple sources. A series of experiments conducted on an instrumented propulsion system in a low-speed wind tunnel were performed for comparison of individual component and full propulsion system performance with simulation model predictions. Data from these experiments are provided and are consistent with model predictions.