Gm Global Technolgoy Operations, Inc.

Kiran Mallavarapu

Sriram Ganapathy

Frank Leo

Bruce Jeffrey Clingerman

Balasubramanian Lakshmanan

John P Salvador

Abdullah Basar Alp

Manish Sinha

Patrick Frost

Craig S Gittleman

Daniel I Harris

Yanyan Zhang

Akbar Chowdhury

Robert W Chalfant

John B Ruhl

Bryan P Tipton

Rodney J Rhodes

Lihling Tzuu

Stefan W Lixfeld

A method for controlling a fuel cell system, capable of quickly detecting the pressure rise caused by a faulted open anode injector, reducing pressure in the fuel cell stack when the fault occurs, and taking remedial action to allow continued operation of the fuel cell stack, and militate against a walk-home incident.

Method to reduce pressure when injectors are stuck open under faulted conditions and remedial action to prevent walk-home incident

A system and method for redistribution of the flow of fuel under faulted conditions in a fuel cell system is disclosed. The fuel cell system includes a fuel cell stack; a fuel tank for storing fuel; fuel injectors that sequentially supply fuel from the fuel tank to the fuel cell stack; and a controller for determining whether a fault condition exists in one of the fuel injectors. If a fault condition exists in the first injector, the controller is capable of redistributing the flow of fuel from a first injector to a second injector.

System and method for redistribution of the flow of fuel under faulted conditions in a fuel cell system

A system and method for converting a fuel cell stack power request signal to a stack current set-point that considers stack performance parameters. The method includes obtaining a power-current relationship curve of the fuel cell stack to provide stack parameters including exchange current density and mass transfer coefficient. The method then calculates a slope for the stack using the parameters from the power-current relationship curve estimation that includes calculating a cell voltage at two predetermined stack current densities. The method then calculates a change in current in response to the power request signal, the stack voltage, the stack current and the calculated slope, and uses the change in current to update the current set-point for the stack.

Adaptive method for conversion of external power request to current setpoint to a fuel cell system based on stack performance

A method including shutting down an electrochemical fuel cell stack wherein anode pressure is controlled according to a stack discharge fuel consumption estimate.

Fuel cell stack shutdown operation controlling anode pressure using discharge fuel consumption estimate

A method for providing a current density set-point for a fuel cell stack in response to a power request from the stack where the set-point is determined based on system parameters that identify the life and degradation of the stack. The method includes dividing a current density range of the fuel cell stack into a predetermined number of sample regions, and selecting the sample regions in order from low to high during the current set-point analysis. The method calculates an average cell voltage for the current density of the selected sample region, and stack power from the average cell voltage. The method then determines whether a power request signal is less than the stack power for the selected sample region and greater than the calculated power for the previous sample region, and if so, calculates the current density set-point at the requested power based on these values.

Algorithm for stack current controller based on polarization curve estimation of a fuel cell stack

A system for estimating parameters of a fuel cell stack. The system includes a stack health monitor for monitoring minimum cell voltage, stack voltage and current density of the fuel cell stack. The stack health monitor also indicates when a predetermined minimum cell voltage threshold level has been achieved. The system further includes a controller configured to control the fuel cell stack, where the controller determines and records the average fuel cell voltage. The controller generates and stores artificial data points proximate to the one or more predetermined minimum cell voltage threshold levels each time the minimum cell voltage drops below the one or more predetermined minimum cell voltage threshold levels so as to provide an estimation of the fuel cell stack parameters including a minimum cell voltage trend and a minimum cell voltage polarization curve.

Method to predict min cell voltage from discrete min cell voltage output of stack health monitor

An algorithm for determining the maximum net power available from a fuel cell stack as the stack degrades over time using an online adaptive estimation of a polarization curve of the stack. The algorithm separates the current density range of the stack into sample regions, and selects a first sample region from the far left of the estimated polarization curve. The algorithm then calculates the cell voltage for that current density sample region, and determines whether the calculated cell voltage is less than or equal to a predetermined cell voltage limit. If the calculated cell voltage is not less than the cell voltage limit, then the algorithm selects the next sample region along the polarization curve. When the calculated cell voltage does reach the cell voltage limit, then the algorithm uses that current density for the sample region being analyzed to calculate the maximum power of the fuel cell stack.

Method for maximum net power calculation for fuel cell system based on online polarization curve estimation

Hydrogen in a fuel cell is vented and purged with a fail-closed valve using stored energy (e.g. from a capacitor) when a diagnostic parameter is outside of an acceptable operating range. The valve closes after the stored energy has depleted. A safety switch in the relay circuit of the solenoid switch (or solenoid valve) is also grounded in computer-implemented shutdowns. Benefits from the invention include use of air-compatible catalysts, minimized parasitic losses to power output, minimized contamination of fuel cell internal surfaces after venting, minimized risk of explosive mixture buildup, and efficient operation.

Method and apparatus for venting and purging of a fuel cell

A PSA unit for purifying hydrogen in a fuel processor system. The PSA unit employs rotary valves that cycle the pressurization of vessels, including an adsorbent, between a high pressure state and a low pressure state. The purified hydrogen is released from the vessels through a purified gas output port when the vessels are in the high pressure state and the impurities are released through an exhaust port when the vessels are in the low pressure state. The PSA unit also employs a mass flow control device and a pressure sensor in the purified gas output port. A controller receives a pressure signal from the pressure sensor, and controls the flow through the mass flow control device and the speed of the rotary valves so that the proper pressure is maintained at the hydrogen output port.

Control of a hydrogen purifying pressure swing adsorption unit in fuel processor module for hydrogen generation

A fuel cell generation system employing a load following algorithm that provides the desired output power from the fuel cell on demand. The system includes a draw current sensor that measures the current drawn from the fuel cell used to satisfy the system load demands. The load following algorithm uses the measured draw current to identify the proper amount of fuel and air to meet the load demands, and then provides a buffer of extra fuel and air to the fuel cell so if the load demand suddenly increases, the fuel cell is able to immediately produce the extra output power. As the current drawn from the fuel cell changes in response to changing load demands, the load following algorithm causes the amount of fuel and air being applied to the fuel cell stack to increase and decrease so that the buffer of extra fuel and air is maintained substantially constant.

Growing community of inventors

Honeoye Falls, NY, United States of America

Kiran Mallavarapu