Validation plan of automotive PEM fuel cell system and cold start test simulation

The increasing focus on hydrogen fuel cell electric vehicles (FCEVs) within the automotive industry necessitates the development of comprehensive and efficient validation procedures to ensure system reliability, safety, and durability. A robust test plan is critical for verifying component and system performance against stringent industry standards and real-world operating conditions. This thesis presents a systematic methodology for the creation, organization, and optimization of a Design Validation Plan and Report (DVP&R) for an automotive Proton Exchange Membrane (PEM) fuel cell system, following the principles of the industry-standard V-diagram development process. The work's core methodology involved an extensive synthesis of knowledge from literature, international standards and industry regulations. This led to the creation of a comprehensive catalog tests systematically categorized across all integration levels - single cell, stack, and complete system - and according to their primary objective: engineering, mechanical, parameter check, environmental, safety, durability, and electrical. This structured database of requirements formed the foundation for the subsequent design validation phase. From this foundation, a series of sequential Test Legs was structured, combining the individual tests according to key industrial constraints, such as minimizing testbed setup time and respecting logical dependencies. Finally, a simulation of the critical cold start procedure was conducted using AVL CRUISE M. This analysis, supported by a targeted literature review, culminated in the development of a detailed test specification for its experimental validation. In conclusion, this thesis provides a structured and holistic framework for developing a robust validation plan for automotive PEMFC systems. The primary contribution is a tangible, optimized test plan that balances comprehensive coverage of standardized tests with the practical demands of industrial efficiency. By integrating systematic research, logical sequencing, and detailed simulation of a critical use case, this work offers a valuable methodology for accelerating the validation process and enhancing the reliability of future fuel cell vehicles.