Optimization of Fuel Cell Manifold and Structural Design of End Plates Using Computational Fluid Dynamics and Genetic Algorithm Approach

Ensuring uniform fluid distribution in high-power fuel cell stacks is crucial for automotive applications. This study introduces and evaluates novel X1- and X2-shaped manifold designs against the conventional U-shaped manifold to enhance distribution uniformity across cells. Computational Fluid Dynamics simulations demonstrated the superiority of the proposed designs, with the X2 manifold exhibiting improved pressure uniformity and reduced pressure drop due to its double-inlet configuration. Further optimization was conducted using a multi-objective genetic algorithm and topology optimization techniques, refining the flow area for enhanced performance. Results indicated that reducing the inlet size while maintaining the outlet size significantly improved gas distribution across all manifold configurations. Additionally, integrating a C-type inlet pipe in the X2 manifold further enhanced flow consistency and reduced manifold size by 50 percent. These findings highlight the effectiveness of advanced computational and optimization strategies in fuel cell manifold design, offering practical solutions to enhance flow distribution and overall stack performance.