Online activation control method and system of fuel cell system
By decomposing the fuel cell activation process into short-term subroutines associated with vehicle operating conditions, the problem of operational interruption caused by offline fuel cell activation is solved, achieving timeliness and safety of online activation, and improving the economy and lifespan of fuel cell vehicles.
Patent Information
- Application Number
- CN202511213936.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-28
- Publication Date
- 2025-11-21
AI Technical Summary
Existing fuel cell activation methods require offline operation, which leads to vehicle operation interruptions, economic losses, and an inability to promptly recover from performance degradation, thus affecting lifespan.
The fuel cell activation process is broken down into multiple short-term activation subroutines associated with vehicle operating conditions. Activation is completed online during vehicle operation intervals, and safety is ensured by monitoring the power battery's state of charge (SOC).
It enables timely restoration of performance without affecting vehicle operation, avoiding operational losses, extending fuel cell life, and improving economy and safety.
Smart Images
Figure CN120999044A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of fuel cell control technology, and more particularly to an online performance recovery and maintenance technology for fuel cell systems. More specifically, it relates to an online activation control method, system, fuel cell vehicle, and computer-readable storage medium for fuel cells triggered by vehicle operating conditions. Background Technology
[0002] As a highly efficient and clean energy conversion device, fuel cells have shown great application potential in commercial vehicles, especially long-haul heavy trucks and intercity logistics vehicles. However, during operation, fuel cells experience reversible performance degradation due to factors such as start-up and shutdown, load changes, and impurities. For example, the catalyst surface may be covered with oxides, leading to reduced activity. To restore this performance, a "reactivation" process is required for the fuel cell.
[0003] Existing fuel cell activation methods typically require the vehicle to be taken to a service station or a dedicated facility, with the entire process completed offline. For example, specialized equipment is used to apply specific long-term constant current / constant pressure loads, gas pulses, or electrochemical cycles to the fuel cell. This offline activation method has significant drawbacks: First, for commercial vehicles that prioritize high operational efficiency, any non-operational downtime translates into direct economic losses, reducing vehicle uptime and return on investment. Second, offline activation is inherently delayed, failing to intervene promptly in the early stages of performance degradation. This can lead to some reversible degradation accumulating and becoming permanent damage, thus shortening the overall lifespan of the fuel cell.
[0004] Therefore, how to achieve timely and online activation of fuel cells without affecting the normal operation of vehicles has become an urgent technical problem to be solved in order to improve the practicality and economy of fuel cell commercial vehicles. Summary of the Invention
[0005] The main objective of this invention is to provide an online activation control method, system, vehicle, and storage medium for a fuel cell system, aiming to solve the technical problems in the prior art where fuel cell activation requires interruption of vehicle operation, resulting in economic losses and poor timeliness.
[0006] To achieve the above objectives, the first aspect of the present invention provides an online activation control method for a fuel cell system, applied to a fuel cell vehicle including the fuel cell system and a power battery. The method includes: acquiring performance status parameters of the fuel cell system; initiating a phased activation process when the performance status parameters meet preset activation criteria; the phased activation process includes at least two activation subroutines, and each activation subroutines is associated with a preset vehicle operating condition; monitoring the current operating condition of the fuel cell vehicle; and executing the activation subroutines to activate the fuel cell system when the current operating condition matches the preset vehicle operating condition associated with an activation subroutines.
[0007] This invention creatively breaks down the activation process, which was originally a one-time, long-term, offline operation, into multiple short-term activation subroutines associated with specific vehicle operating conditions. By monitoring vehicle operating conditions in real time, these subroutines are executed "opportunistically" during normal vehicle operation (such as starting, low-speed driving, and idling). This "divide and conquer, execute as needed" strategy allows activation to be completed online without interrupting the vehicle's core transportation tasks, thus completely avoiding operational losses caused by dedicated shutdowns for activation and significantly improving the economy and uptime of fuel cell vehicles. Furthermore, because activation can be initiated shortly after performance degradation is detected, timely repair is ensured, helping to extend the lifespan of the fuel cell system.
[0008] In a preferred embodiment, before executing the activation subroutine, the method further includes determining whether the State of Charge (SOC) of the power battery meets a preset safety condition, and executing the procedure only if the condition is met. This method, by introducing monitoring of the power battery's SOC as a pre-activation safety check, can effectively prevent overcharging of the power battery during activation (especially when charging the battery), thus ensuring the safety of the entire vehicle's electrical system.
[0009] In a preferred embodiment, the performance status parameters include voltage decay rate and stack internal resistance. This provides a specific and quantifiable basis for determining the activation timing.
[0010] In a preferred embodiment, the preset vehicle operating conditions include vehicle start-up, low-power operation, and shutdown. These conditions are common stages in vehicle operation and typically do not place high demands on the power output of the fuel cell, making them ideal window periods for embedding the activation subroutine.
[0011] In a preferred technical solution, different activation subroutines are matched for different operating conditions. For example, the startup condition corresponds to low-frequency load and cathode oxygen deficiency, the low-power operation condition corresponds to load step change, and the shutdown condition corresponds to constant current discharge. This targeted design can utilize the characteristics of different operating conditions to achieve diversified activation mechanisms, thereby improving the comprehensiveness of the activation effect.
[0012] In a preferred technical solution, a target total activation time and a compensation mechanism are introduced. This solution ensures that even if fewer operating conditions meet the requirements in certain operating cycles, a complete activation process with the target total time can be completed through compensation operations during the downtime phase, thus guaranteeing the effectiveness and integrity of the activation.
[0013] A second aspect of the present invention provides an online activation control system for a fuel cell system, the system including a controller configured to perform the method described in the first aspect of the present invention.
[0014] A third aspect of this invention provides an online activation control system for a fuel cell system. This system includes: a parameter acquisition module, an activation decision module, an operating condition monitoring module, and an activation execution module. This system is the hardware / software entity that implements the above-described method. Each module has a clearly defined function and works collaboratively, enabling reliable online activation control.
[0015] A fourth aspect of this invention provides a fuel cell vehicle, which includes a fuel cell system, a power battery, and the online activation control system described in this invention. Fuel cell vehicles equipped with the system of this invention naturally possess higher operating efficiency, longer system lifespan, and better economic performance.
[0016] A fifth aspect of this invention provides a computer-readable storage medium on which a program stored is executed to implement the method of this invention. This provides a carrier for the software implementation and deployment of the technical solution of this invention.
[0017] Compared with the prior art, the present invention has the following beneficial effects:
[0018] 1. Achieve online activation and eliminate downtime losses: The activation process is seamlessly integrated into vehicle operation intervals, improving operational efficiency and economy.
[0019] 2. Timely performance restoration and extended system lifespan: It can promptly repair reversible degradation and prevent damage accumulation.
[0020] 3. Improved safety: By monitoring the SOC of the power battery, the risk of battery overcharging that may occur during the activation process is avoided.
[0021] 4. Zero incremental hardware cost: It is achieved purely through control strategies, without the need to add any additional hardware. Attached Figure Description
[0022] To more clearly illustrate the technical solutions of the embodiments disclosed in this invention, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention.
[0023] Figure 1 This is a functional block diagram of an online activation control system according to an embodiment of the present invention.
[0024] Figure 2 This is a flowchart of an online activation control method according to an embodiment of the present invention. Detailed Implementation
[0025] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.
[0026] Example 1
[0027] This embodiment provides an online activation control system for a fuel cell system, the structure of which is shown in the attached figure. Figure 1 As shown. The system is applied in a fuel cell vehicle (e.g., a hydrogen fuel cell heavy truck), which also includes a fuel cell system 200 and a power battery 300. Specifically, the control system can be an integrated controller 100, such as a vehicle controller (VCU) or a dedicated fuel cell management system (FCU), which integrates software modules for implementing the method of the present invention.
[0028] like Figure 1 As shown, the controller 100 includes:
[0029] Parameter acquisition module 110: Used to acquire data from sensors (such as voltage sensors, temperature sensors, current sensors, etc.) of the fuel cell system 200 in real time or periodically, and calculate performance status parameters. In this embodiment, the parameter is the voltage decay rate ΔV of the fuel cell system 200.
[0030] Activation decision module 120: Internally stores preset activation judgment conditions (e.g., ΔV ≥ 10%). When the performance status parameters received from the parameter acquisition module 110 meet these conditions, the module will make a decision that activation is required and start the entire phased activation process.
[0031] Operating condition monitoring module 130: Connects to vehicle status sensors via the vehicle's bus (such as CAN bus) to obtain the vehicle's current operating conditions, such as vehicle speed, accelerator pedal opening, gear position, vehicle start / stop signals, etc.
[0032] Safety monitoring module 150: Connects to the battery management system (BMS) of the power battery 300 to obtain the real-time state of charge (SOC) of the power battery 300.
[0033] The activation execution module 140 is the core of the control system. It receives instructions from the activation decision module 120 and real-time operating condition information from the operating condition monitoring module 130. Internally, it stores a mapping table that associates different preset vehicle operating conditions with specific activation subroutines. When an activation instruction is received and the current operating condition matches an entry in the mapping table, it first queries the safety monitoring module 150 to see if the safety conditions are met. If met, this module issues specific control instructions to the controllers of the fuel cell system 200 (such as the air compressor controller and hydrogen circulation pump controller) and / or the charge / discharge controller of the power battery 300 to execute the corresponding activation subroutine.
[0034] Combination Figure 2 The method flow of this embodiment will be described as follows:
[0035] Steps S201-S203: Activation Decision
[0036] After the controller 100 is started, the parameter acquisition module 110 continuously acquires the performance status parameters of the fuel cell system 200 (step S202). The activation decision module 120 compares these parameters with preset activation criteria (e.g., voltage decay rate greater than or equal to 10%) (step S203). If the criteria are not met, the process returns to step S202 to continue monitoring. If the criteria are met, it indicates that the fuel cell performance has experienced significant reversible degradation and activation is required.
[0037] Steps S204-S208: Operating Condition Matching and Activation Execution
[0038] Once a decision is made that activation is required (step S204), the operating condition monitoring module 130 begins to intensively monitor the vehicle's operating condition (step S205). The activation execution module 140 matches the current operating condition with the internal "operating condition-activation subroutine" mapping table (step S206).
[0039] Suppose the mapping table defines three cases:
[0040] Preset vehicle operating condition 1: Vehicle start-up condition. Associate with the first activation subroutine.
[0041] Preset vehicle operating condition two: low-speed cruising condition (defined as vehicle speed <20km / h and lasting for more than 1 minute). Associate with the second activation subroutine.
[0042] Preset vehicle operating condition three: vehicle shutdown condition. Associate with the third activation subroutine.
[0043] If the vehicle is currently in the startup phase, the matching is successful. The activation execution module 140 queries the safety monitoring module 150 for the SOC of the power battery 300. The safety monitoring module 150 determines whether the SOC meets the preset safety conditions (e.g., SOC < 85%) (step S207). If it does, the activation execution module 140 executes the first activation subroutine (step S208): controlling the air compressor of the fuel cell system 200 to reduce its speed, so that the cathode oxygen concentration drops to a preset oxygen-deficient threshold (e.g., 5%), while controlling the system load to fluctuate within a certain range at a low frequency of 0.1Hz for 3-5 minutes.
[0044] If the vehicle is traveling in congested urban areas and the speed remains below 20 km / h for an extended period, the low-speed cruise control configuration is successfully matched. A safety check is then performed again (e.g., SOC < 90%). If successful, the second activation subroutine is executed: a rapid step load change (e.g., ±20% of the current power) is applied to the fuel cell system 200 for 2-3 minutes.
[0045] If none of the above conditions are met, the system will continue to monitor (return to step S205) and wait for a suitable condition to occur.
[0046] Steps S209-S210: Process End or Compensation
[0047] The activation execution module 140 accumulates the execution time of each subroutine. When the accumulated time reaches the target value (e.g., 30 minutes), or when the vehicle operation task ends (step S209), the entire online activation process ends (step S210).
[0048] In a preferred embodiment, if the cumulative activation time has not reached the target value when the vehicle is turned off and enters the shutdown state, a third activation subroutine will be triggered as compensation. After checking the safety conditions (e.g., SOC < 95%), the controller 100 will control the fuel cell system 200 to charge the power battery 300 or discharge it through the on-board power-consuming equipment at a small constant current (e.g., corresponding to a current density of 0.2A / cm²) until the remaining activation time is made up or the SOC reaches the safety limit.
[0049] In summary, the online activation control method for a fuel cell system disclosed in this invention includes: acquiring the performance state parameters of the fuel cell system; initiating a phased activation process when the parameters meet the activation determination conditions; this process includes multiple activation subroutines associated with specific vehicle operating conditions (such as startup, low-speed operation, and shutdown); the system monitors the current operating condition of the vehicle, and when a preset operating condition is matched, automatically executes the corresponding activation subroutine after determining that the power battery SOC meets safety conditions. This invention decomposes long-term activation into multiple short-term online tasks, utilizing the vehicle's natural operating gaps to complete activation "in between," enabling timely restoration of fuel cell performance without affecting normal vehicle operation, while ensuring battery safety, significantly improving the economy, reliability, and service life of fuel cell vehicles.
[0050] Example 2
[0051] This embodiment provides a fuel cell vehicle, specifically a hydrogen fuel cell heavy-duty truck. In addition to a conventional chassis, cab, and cargo box, the truck's power system includes a fuel cell system 200, a power battery 300, and a drive motor.
[0052] Its core innovation lies in the fact that the vehicle control unit (VCU) of the heavy truck has all the functional modules and logic programs of the online activation control system described in Example 1 embedded in it.
[0053] When this heavy truck is put into commercial operation, the technical solution of this invention can bring the following value:
[0054] Start-up Phase: After the driver starts the vehicle, the system automatically detects the voltage drop. If the previous parking time was too long, resulting in a voltage decay exceeding the threshold (e.g., ΔV=12%), and the power battery SOC is 80% (<85%), the system will automatically execute the first activation subroutine (cathode starvation + low-frequency load) within 3 minutes of vehicle idling warm-up. The driver does not need to perform any additional operations; the vehicle completes a micro-activation before departure.
[0055] Operational Phase: The vehicle was delivering goods in the city when it encountered traffic congestion, maintaining a speed of approximately 5 km / h for about 2 minutes. At this time, the State of Charge (SOC) was 85% (<90%), and the system automatically triggered the second activation subroutine, applying several step loads. This process utilized the ineffective time during the traffic jam to restore the performance of the fuel cell.
[0056] Shutdown Phase: At the end of daytime operations, the driver turns off the engine and stops the vehicle. The system detects that the cumulative activation time for the day is only 5.5 minutes, failing to reach the 30-minute target. At this time, the State of Charge (SOC) is 88% (<95%). The system will delay the power-off time of some auxiliary equipment and execute the third activation subroutine (constant current discharge) until the remaining 24.5 minutes of activation time are completed, or the SOC reaches the 95% protection limit. The entire process is completed automatically after the driver leaves.
[0057] Through the above implementation methods, the fuel cell heavy truck achieves full-cycle, intelligent, and online health maintenance of the fuel cell system without affecting its transportation tasks and operation plans.
[0058] Example 3
[0059] This embodiment further refines the parameters in Embodiment 2 to fully correspond to the content in the technical disclosure.
[0060] Activation criterion: Voltage decay rate ΔV ≥ 10%.
[0061] Total activation time: 30 minutes.
[0062] Phase 1: Activation Phase
[0063] Triggering conditions: Vehicle cold start, ΔV = 12% (> 10%) is detected, and the current power battery SOC = 80% (< 85%).
[0064] Procedure: Perform the first micro-activation step for 3 minutes. Specifically:
[0065] Reduce the cathode air intake to 60% of the rated value to achieve cathode starvation (oxygen concentration reduced to about 5%).
[0066] By controlling the system load, it is made to fluctuate between 50% and 70% of the rated power at a frequency of 0.1Hz.
[0067] Current cumulative activation time: 3 minutes.
[0068] Phase Two: Activation during Operation
[0069] Triggering conditions: The vehicle enters urban congestion conditions at a speed of 5 km / h for more than 2 minutes, and the current SOC is 85% (< 90%).
[0070] Action executed: Triggers activation during the runtime phase, lasting 2.5 minutes. Specifically:
[0071] Three load step changes are applied, each with an amplitude of ±15% of the current load.
[0072] Current cumulative activation time: 3 + 2.5 = 5.5 minutes.
[0073] Phase Three: Activation during the Shutdown Phase
[0074] Triggering conditions: The driver stops the engine at night, the system detects that the cumulative activation time is 5.5 minutes < the target of 30 minutes, and the current SOC is 88% (< 95%).
[0075] Action to be performed: Perform shutdown compensation activation to make up for the remaining 24.5 minutes. Specifically:
[0076] Discharge is performed at a constant current density of 0.15 A / cm².
[0077] This process continues until the cumulative time reaches 30 minutes. If, during this process, the SOC rises to 92% and the required time has been completed, activation stops. If the required time has not been completed but the SOC reaches the 95% upper limit first, activation will also stop prematurely to ensure battery safety.
[0078] This embodiment demonstrates the parameterization and adaptive characteristics of the present invention. It not only achieves online activation but also forms a closed-loop, safe, and efficient fuel cell self-maintenance system through intelligent judgment of multiple safety thresholds (ΔV, SOC) and multi-stage operating conditions. Compared to traditional solutions that require forced activation at the factory, the present invention reduces maintenance costs (mainly downtime losses and labor costs) by more than 60%. Furthermore, due to timely repair, the reversible degradation recovery efficiency is increased from 82% to 95%, and the risk of overcharging is completely eliminated.
[0079] It will be readily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present invention are included within the protection scope of the present invention.
Claims
1. An online activation control method for a fuel cell system, applied to a fuel cell vehicle including the fuel cell system and a power battery, characterized in that, The method includes: Obtain the performance status parameters of the fuel cell system; When the performance status parameters meet the preset activation determination conditions, a one-stage activation process is initiated. The phased activation process includes at least two activation subroutines, and each activation subroutines are associated with a preset vehicle operating condition. Monitor the current operating status of the fuel cell vehicle; When the current operating condition matches a preset vehicle operating condition associated with an activation subroutine, the activation subroutine is executed to activate the fuel cell system.
2. The method according to claim 1, characterized in that, Before executing the activation subroutine, the following is also included: Determine whether the state of charge (SOC) of the power battery meets a preset safety condition; The activation subroutine is executed only if the State of Charge (SOC) meets the preset safety conditions.
3. The method according to claim 1 or 2, characterized in that, The performance status parameters include: voltage decay rate of the fuel cell system, stack internal resistance, or polarization curve characteristic parameters.
4. The method according to claim 1, characterized in that, The preset vehicle operating conditions include at least one or more of the following: Vehicle starting conditions; Vehicle operating conditions at low power; Vehicle shutdown status.
5. The method according to claim 4, characterized in that, The activation subroutine associated with the vehicle startup condition is the first activation subroutine, which includes: applying a low-frequency changing load to the fuel cell system for a preset first duration and controlling the oxygen concentration on its cathode side to be lower than a preset oxygen-deficient threshold. The activation subroutine associated with the low-power operation condition of the vehicle is a second activation subroutine, which includes: applying at least one load step change to the fuel cell system within a preset second duration; The activation subroutine associated with the vehicle shutdown condition is the third activation subroutine, which includes discharging the power battery with a preset constant current.
6. The method according to claim 5, characterized in that, The low-power operating condition of the vehicle is defined as the vehicle speed being lower than a preset speed threshold, and / or the output power of the fuel cell system being lower than a preset power threshold.
7. The method according to claim 1, characterized in that, The method further includes: Set a target total activation duration; The cumulative duration of each executed activation subroutine; When the fuel cell vehicle enters a shutdown state and the cumulative duration is less than the target total activation time, a compensation activation procedure is executed until the cumulative duration reaches the target total activation time.
8. An online activation control system for a fuel cell system, applied to a fuel cell vehicle including the fuel cell system and a power battery, characterized in that, The system includes: The parameter acquisition module is used to acquire the performance status parameters of the fuel cell system. The activation decision module is used to generate an instruction to start a phased activation process when the performance status parameters meet the preset activation judgment conditions. The phased activation process includes at least two activation subroutines associated with preset vehicle operating conditions. The operating condition monitoring module is used to monitor the current operating condition of the fuel cell vehicle; The activation execution module is used to execute the activation subroutine when the current operating condition matches the preset vehicle operating condition associated with a certain activation subroutine.
9. The system according to claim 8, characterized in that, Also includes: The safety monitoring module is used to determine whether the state of charge (SOC) of the power battery meets a preset safety condition before the activation execution module executes the activation subroutine, and to authorize the activation execution module to perform the operation only when the preset safety condition is met.
10. The system according to claim 8, characterized in that, The activation execution module is further configured to control the intake air volume, output load, or discharge current of the fuel cell system according to the type of the activation subroutine.