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Fuel Cell Test Bench: Experimenting for Efficiency with Horizon Stack


Introduction

In the world of renewable energy, innovation starts with experimentation—and nothing showcases that better than a test bench. These devices allow engineers and researchers to push the boundaries of hydrogen technology, optimizing fuel cells for efficiency and performance. In this article, we highlight the inspiring work of Jon Aranguren, an engineer who built his own test bench using a Horizon H-1000 Fuel Cell stack bought from Horizon Educational. From flow control experiments to developing hybrid energy systems, Jon’s journey is a testament to how hands-on projects can drive real-world impact and pave the way for a more sustainable future.

 

What’s Fuel Cell Test Bench?

test bench is a specialized device designed to rigorously test fuel cells or electrolysers for their performance and properties under controlled conditions. Equipped with advanced sensors and electrical controls, test benches allow researchers and engineers to analyze the behavior of these systems across a wide range of operating conditions.

In the rapidly evolving hydrogen sector, development test benches play a crucial role. These systems rely on precise sensors to analyze and optimize fuel cells or electrolysers step by step, ensuring better performance while using fewer resources. Additionally, as the hydrogen industry transitions from semi-automated to fully automated production, quality and functional test benches are becoming essential for mass-produced hydrogen technologies. These advanced tools verify the functionality and quality of components to ensure they meet the highest standards.

We’re proud to see Horizon stacks used in test benches across Europe and the world . We have one such application below, from – and we have one such story below

  Inside a PEM Fuel Cell


Jon Aranguren’s Vision: Experimenting for Efficiency

Jon Aranguren, a Lecturer & Researcher at Spain’s Mondragon University, saw the potential of a test bench to add a new diamention to his hydrpogen research. Using a Horizon Educational H-Series fuel cell, Jon designed and built a system that not only tested the efficiency of the fuel cells but also allowed him to experiment with flow control and hybrid energy systems.

“Open-cathode fuel cell performance is strongly influenced by ambient conditions. During the experimental tests we have conducted with the H-1000 fuel cell, we have observed that the output power of the cell can be increased with temperature and humidity adjustment,” Jon tells us. 

“The development of advanced control algorithms to operate open-cathode fuel cells under varying load and ambient conditions is an ongoing research topic. In this testbench we have implemented several algorithms for Maximum Efficiency Point Tracking (MEPT) of the H-1000 cell. So far, the Perturb and Observe (P&O) algorithm has shown a good compromise between obtained results (efficiencies of up to 42%) and ease of implementation”.  

Inside a Fuel Cell

We ask Jon how he would explain this to someone outside of the field:

“The idea is basically, we add this flow control, we have a controller, and basically we just do some experiments to see if we can improve the efficiency by controlling the flow,” Jon explains.

“Everyone needs to do simulation but in order to really understand how the advantages and also the limitations of the fuel cells, you need to do some experimental work”, Jon explains, “that’s where a test bench comes in to play.”

Jon’s test bench incorporates a modular design, enabling him to test various strategies to optimize energy usage. By adjusting the flow of hydrogen within the fuel cells, he’s been able to collect data and identify ways to boost efficiency without significantly increasing resource consumption.

The quality of the Horizon H-1000 stack also impressed Jon: “I would say from my experience, it’s been robust and very reliable…. I would also say you have really good customer service, extremely fast responses to any questions”.

 

Pushing the Boundaries: Exploring Hybrid Energy Systems

But Jon’s vision doesn’t stop at improving fuel cell efficiency. His ultimate goal is to develop a hybrid energy system that integrates fuel cells, batteries, and advanced energy management strategies.

“Then our idea is to basically move from here and then have a hybrid system, have some vertebrates as well and a DC-DC converter, then perhaps evaluate hybrid strategies as well so that we can control the amount of energy given by the fuel cell and the battery at every moment,” he shares.

This forward-thinking approach aims to balance energy delivery between the fuel cell and the battery, improving system performance while ensuring sustainability. By experimenting with hybrid systems, Jon is laying the groundwork for innovative energy solutions that could revolutionize the way we think about renewable energy applications.

 

Empowering Engineers and Educators

Jon’s work with his test bench is a testament to how Horizon Educational’s fuel cells empower engineers, educators, and students to explore cutting-edge hydrogen technologies. By making advanced tools accessible, user-friendly, and reasonably priced, Horizon enables users like Jon to turn ambitious ideas into practical experiments that inspire innovation.

 

Your Turn to Innovate

Jon’s story highlights how test benches can bridge the gap between experimentation and real-world application, driving progress in hydrogen technology. Whether you’re an engineer exploring hybrid energy systems or an educator looking to inspire your students, Horizon Educational’s products provide the tools you need to innovate and succeed.

Ready to build your own test bench

 

Jon Aranguren completed his studies in Electronic Engineering at the Universitat Politecnica de Catalunya (UPC). Since September 2011, he has been a lecturer at Mondragon University and has participated in numerous industrial projects focused on the development of electronic hardware, and also several publicly funded research projects related to hydrogen. Among them is the ERABILH+ project where technological solutions have been developed to integrate hydrogen-based systems in mobility applications.