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The focus of research and development on electric motorcycle range extender are system integration and energy regulation and management but the present fuel cell stack range extender still has defects, such as large volume, heavy weight and high cost. Its volume and weight will have a strong impact on the endurance of electric motorcycle. The bipolar plate takes most volume and weight of a proton exchange membrane fuel cell (PEMFC) stack and it is the key component influencing the overall power density and cost. Therefore, how to thin and lighten the bipolar plate and to enhance the performance and life of PEMFC stack is an urgent research subject to be solved for the moment and will be the key to whether the PEMFC stack range extender can be put in the electric motorcycle or not. In addition, the internal temperature, humidity, flow, voltage and current in the operation of PEMFC stack will influence its performance and life and the overall performance and life of fuel cell stack will be directly influenced by different external operating conditions. As nonuniform distribution of temperature, humidity, flow, voltage and current will occur in various regions inside the fuel cell stack, this study will use micro-electro-mechanical systems (MEMS) technology to develop a flexible five-in-one microsensor, which is embedded in the PEMFC stack range extender for real-time wireless microscopic diagnosis and the reliability test is performed, so that the actual operating condition inside the fuel cell stack range extender can be mastered instantly and correctly and the internal information is fed back instantly, the fuel cell stack range extender control system can be modified to the optimum operating parameters immediately, so as to enhance the performance and prolong the lifetime effectively.

Flexible Five-in-One Microsensor for Real-Time Wireless Microscopic Diagnosis inside Electric Motorcycle Fuel Cell Stack Range Extender