Abstract
Single-use pyrotechnic and compressed-gas actuators currently meet industrial safety tasks that demand rapid response and high force. An integrated hydrogen production and combustion-driven actuation system is proposed as a clean and reusable alternative. Hydrogen is generated on demand inside the unit by water electrolysis. It is stored in a metal hydride module and burned with air under controlled conditions to drive a double-piston mechanism. A combined approach of modeling, such as thermodynamic analysis, ideal gas laws, and Engineering Equation Solver (EES) simulations, was used to predict the hydrogen demand and system performance. In addition, the combustion behavior and chamber pressure distribution were investigated using COMSOL Multiphysics. It was shown that hydrogen–air combustion allows for more stable and controllable operating conditions than hydrogen–oxygen combustion, while still satisfying the required in-cylinder pressure of about 350 bar. The designed proton exchange membrane (PEM) electrolyzer consumes about 221 W of power from a 24 V DC power source and produces 0.16 g of hydrogen in 135 s, which is sufficient for a high-force actuation stroke. Unlike conventional pyrotechnic cartridges and pneumatic and hydraulic actuators, the suggested system generates no solid combustion residues and does not require single-use consumables. It is reusable for many cycles, with water vapor as the main combustion product. Overall, the findings support hydrogen-powered actuation on demand as a viable and clean option for high-force safety tasks, ranging from closing emergency shut-off valves at oil and gas facilities to pressurizing fire protection and other safety systems, making it particularly attractive for remote facilities without a continuous grid power supply.