Startup optimization of gas foil bearings-rotor system in proton exchange membrane fuel cells

The startup performance is crucial to the high-efficient operation of the sustainable power generation system. Current literature usually focuses on catalysts and startup strategy to improve startup performance of the proton exchange membrane fuel cell, which ignores the gas foil bearings-rotor system that directly affects startup response. Therefore, in this paper, the effects of bump foil structure, coating, and nominal clearance on the startup response of the bearings-rotor system are first investigated experimentally. Multi-objectives optimization mathematical model considering simultaneously lower power consumption, takeoff speed, and vibration is presented based on grey relational analysis. The optimal bearings-rotor system with radial trisection bump foil, coating MoS2, and nominal clearance of 50 μm is identified. Compared to average values, the power consumption of the optimal system is diminished by 27.2% while the takeoff speed and nonlinear vibration are reduced by 16.2% and 47.3%, respectively. These findings can be used to improve energy efficiency and startup performance for fuel cells. The systematic methodology proposed in this study can be extended to other investigations about the startup. •Bump foil type, coating, and nominal clearance are first considered in PEMFCs.•Multi-objective optimization mathematical model is presented.•Optimal gas foil bearings-rotor system is proposed and verified.•Startup performance of the proposed system is improved.•Power consumption of the proposed system is diminished by 27.2%.