The compressor for air supply to the fuel cell stack is a critical component of the balance of plant, especially for mobile applications. The main requirements of the compressor are the performance regarding pressure ratio, mass flow and efficiency at minimal size and weight. The turbo compressor technology is ideally suited to cope with these requirements. The lifetime requirement and the necessity of oil and particle free air supply advised to employ air bearings. The fuel cell air supply requirements are in conflict with the turbo compressor pressure ratio and mass flow characteristics. Possible solutions and their impact onto compressor design and fuel cell operation are described in this paper. The chosen system design approach considering all design aspects and its interactions during the design phase is beneficial in order to achieve the most lightweight and efficient air supply system for fuel cells. Experimental validation of an air bearing turbo compressor for a 100 kW fuel cell stack on an aerodynamic test rig verifies the predicted performance.

Air bearing radial turbo (also called centrifugal) compressors prevail in most mobile fuel cell air supply applications due to the small size and weight, the high efficiency and the oil- and maintenance free operation. An important aspect in mobile fuel cell applications is the vibration resistance of all system components, including the compressor, with vibration requirements up to 20 g in automotive applications. This paper gives the background of the air bearing vibration characteristics, depicting the dependencies of vibration resistance on inlet conditions and operating points. The critical operating conditions concerning vibration resistance are identified, and it is outlined how vibration requirements can be included in the design process of an air bearing turbo compressor. A visualization of vibration resistance in the commonly used compressor map is presented, allowing the fuel cell system integrator to take qualified decisions for the mechanical integration of the compressor concerning vibrations.

Indiana University-Purdue University Indianapolis (IUPUI) / This thesis concentrates on the study of hybrid gas journal bearings (bearings with externally pressurized mass addition). It differs from most work in that it goes back to “basics” to explore the hydrodynamic phenomena in the bearing gap. The thesis compares geometrically identical bearings with 2 configurations of external pressurization, porous liners where mass-addition compensation is varied by varying the liner’s permeability, and bushings with 2 rows of 6 feedholes where the mass-addition compensation is varied by the feedhole diameter. Experimentally, prototype bearings with mass-addition compensation that spans 2 orders of magnitude with differing clearances are built and their aerostatic properties and mass addition characteristics are thoroughly tested. The fundamental equations for compressible, laminar, Poiseuille flow are used to suggest how the mass flow “compensation” should be mathematically modeled. This is back-checked against the experimental mass flow measurements and is used to determine a mass-addition compensation parameter (called Kmeas) for each prototype bushing. In so doing, the methodology of modeling and measuring the mass addition in a hybrid gas bearing is re-examined and an innovative, practical, and simple method is found that makes it possible to make an “apples-to-apples” comparison between different configurations of external pressurization. This mass addition model is used in conjunction with the Reynolds equation to perform theory-based numerical analysis of virtual hybrid gas journal bearings (CFD experiments). The first CFD experiments performed use virtual bearings modeled to be identical to the experimental prototypes and replicate the experimental work. The results are compared and the CFD model is validated. The ontological significance of appropriate dimensionless similitude parameters is re-examined and a, previously lacking, complete set of similitude factors is found for hybrid bearings. A new practical method is developed to study in unprecedented detail the aerostatic component of the hybrid bearings. It is used to definitively compare the feedhole bearings to the porous liner bearings. The hydrostatic bearing efficiency (HBE) is defined and it is determined that the maximum achievable hydrostatic bearing efficiency (MAHBE) is determined solely by the bearing’s mass addition configuration. The MAHBE of the porous liner bearings is determined to be over 5 times that of the feedhole bearings. The method also presents a means to tune the Kmeas to the clearance to achieve the MAHBE as well as giving a complete mapping of the hitherto misunderstood complex shapes of aerostatic load versus radial deflection curves. This method also rediscovers the obscure phenomenon of static instability which is called in this thesis the “near surface effect” and appears to be the first work to present a practical method to predict the range of static instability and quantify its resultant stiffness fall-off. It determines that porous liner type bearings are not subject to the phenomenon which appears for feedhole type bearings when the clearance exceeds a critical value relative to its mass-addition compensation. The standing pressure waves of hydrostatic and hybrid bearings with the 2 configurations of external pressurization as well as a geometrically identical hydrodynamic bearing are studied in detail under the methodology of the “CFD microscope”. This method is used to characterize and identify the development, growth, and movement of the pressure wave extrema with increased hydrodynamic action (either increasing speed or increasing eccentricity). This method is also used to determine the “cause” of the “near surface effect”. A gedanken experiment is performed based on these results which indicates that a bearing with a “stronger aerostatic strength” component should be more stable than one with a low aerostatic strength component. Numerical instability “speed limits” are found that are also related to the hydrostatic strength of the bearing. The local conditions in the standing waves are characterized in terms of their local Mach number, Knudsen number, Reynolds number, and Taylor Number. It is concluded that low eccentricity bearing whirl can be attributed to the off load-line orientation of the bearing load force caused by the overlay of the hydrodynamic bearing standing wave onto the hydrostatic bearing wave of the hybrid bearing, whereas it is hypothesized that aperiodic and random self-excited vibration which occurs at high eccentricity, as reported in the literature, is probably due to shock waves, turbulence, near surface effect, and slip at local areas of the standing wave.