Fuel cell durability and verification module test bench

Abstract

A test bench for a fuel cell module includes a power supply system, a fuel supply system, an exhaust system, and a cooling system. The power supply system includes a direct current (DC) generated from a fuel cell stack that powers a load electrically connected to the fuel cell module, the fuel cell stack responsive to receiving fuel and generating exhaust gas. The fuel supply system includes a mass flow meter and provides fuel at an adjustable pressure from a remote fuel source through at least one adjustable reservoir to the fuel cell stack. The exhaust system includes a collection device and is operable to receive exhaust gas from the fuel cell stack. The cooling system is operable to circulate a coolant and includes a first heat exchanger and a second heat exchanger in parallel with each other.

Description

Technical Field

[0001] This disclosure generally relates to a test bench adapted for fuel cell durability testing and validation. When a fuel cell (e.g., a fuel cell configured to power a vehicle) is connected to or equipped at a fuel cell test bench, the test bench allows the user to perform operational and durability tests on the fuel cell. For example, such testing allows the user to replicate the operation of a fuel cell in a vehicle in an effort to validate functionality and obtain data related to the performance of the fuel cell and associated components. This testing also tests the durability of the fuel cell module before installation in a vehicle, and thus identifies necessary changes or modifications to the fuel cell before installation. The ease of testing increases when the fuel cell is equipped at a test bench compared to at a vehicle. Furthermore, if changes to the fuel cell are required, these changes are generally easier and more feasible before the fuel cell is installed in the vehicle. Background Technology

[0002] The information provided in this section is for the purpose of presenting the general context of this disclosure. The work of the currently named inventors, to the extent described in this section, and in aspects that may not qualify as prior art at the time of filing, is neither expressly nor implicitly acknowledged as prior art to this disclosure.

[0003] While fuel cell test benches facilitate the validation of fuel cells before installation in vehicles, they typically occupy a large floor space, limiting the number of test benches that can be housed in testing areas such as vehicle engineering labs. Furthermore, the overall size of these benches restricts the flexibility of test area layout within the laboratory. Additionally, fuel cell test benches often have fixed configurations and may not be adaptable to different test parameters and / or different data acquisition methods. Summary of the Invention

[0004] One aspect of this disclosure provides a fuel cell module. The fuel cell module includes a power system, a fuel supply system, an exhaust system, and a cooling system. The power system includes direct current (DC) generated from a fuel cell stack to power loads electrically connected to the fuel cell module, the fuel cell stack responding to receiving fuel and generating exhaust gas. The fuel supply system is operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure through at least one adjustable reservoir, and includes a mass flow meter from the fuel supply system to measure the mass flow rate of fuel supplied to the fuel cell stack. The exhaust system is operable to receive exhaust gas from the fuel cell stack, and includes a collection device for capturing water from the exhaust gas. The cooling system is operable to circulate a coolant, the cooling system including a first heat exchanger and a second heat exchanger connected in parallel with each other, and is operable to extract heat from the coolant and remove heat away from the fuel cell module.

[0005] Embodiments of this disclosure may include one or more of the following optional features. In some instances, the mass flow meter includes a first mass flow meter and a second mass flow meter, which are connected in parallel between the remote fuel source and the fuel cell stack.

[0006] In some other examples, when the fuel supply system is operated to supply fuel to the fuel cell stack at a first flow rate, fuel flows from a remote fuel source through a first mass flow meter but not through a second mass flow meter, and when the fuel supply system is operated to supply fuel to the fuel cell stack at a second flow rate greater than the first flow rate, fuel flows from a remote fuel source through both the first and second mass flow meters.

[0007] In some other examples, the first and second mass flow meters include Coriolis mass flow meters.

[0008] In some implementations, the fuel supply system is operable to adjust the volume of the adjustable reservoir.

[0009] In some aspects, the collection device includes a vapor separator, which captures liquid water and vapor from the exhaust gas.

[0010] In some configurations, the exhaust system includes a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack.

[0011] In some instances, the exhaust system includes one or more sensors operable to detect at least one selected from the group consisting of (i) the hydrogen concentration of the exhaust gas, (ii) the temperature of the exhaust gas, and (iii) the pressure of the exhaust gas.

[0012] In some embodiments, the fuel cell module also includes a control module operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the alternating current (AC) applied to the fuel cell stack.

[0013] In some respects, the test bench houses the power supply system, fuel supply system, exhaust system, and cooling system.

[0014] Another aspect of this disclosure provides a test system. The test system includes a fuel cell stack, a power system, a fuel supply system, an exhaust system, a cooling system, and a control module. The fuel cell stack is operable to generate direct current (DC) and exhaust gas in response to receiving fuel, the DC power supplying a load electrically connected to the test system. The power system includes the DC power generated from the fuel cell stack. The fuel supply system is operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure through at least one adjustable reservoir, and includes a mass flow meter from the fuel supply system measuring the mass flow rate of fuel supplied to the fuel cell stack. The exhaust system is operable to receive exhaust gas from the fuel cell stack, and includes a collection device for capturing water from the exhaust gas. The cooling system is operable to circulate coolant, and includes a first heat exchanger and a second heat exchanger connected in parallel with each other, and is operable to extract heat from the coolant and from the test system. The control module is operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the alternating current (AC) applied to the fuel cell stack.

[0015] Embodiments of this aspect of the disclosure may include one or more of the following optional features. In some instances, the mass flow meter includes a first mass flow meter and a second mass flow meter, which are connected in parallel between the remote fuel source and the fuel cell stack.

[0016] In some implementations, the fuel supply system is operable to adjust the volume of the adjustable reservoir.

[0017] In some aspects, the collection device includes a vapor separator, which captures liquid water and vapor from the exhaust gas.

[0018] In some configurations, the exhaust system includes a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack.

[0019] Another aspect of this disclosure provides a test system. The test system includes a first cabinet, a second cabinet, and a third cabinet. The first cabinet houses a power supply system, a fuel supply system, an exhaust system, and a cooling system. The power supply system includes direct current (DC) generated from a fuel cell stack, which supplies power to loads electrically connected to the fuel cell stack, which generates exhaust gas in response to receiving fuel. The fuel supply system is operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure through at least one adjustable reservoir, and includes a mass flow meter from the fuel supply system measuring the mass flow rate of fuel supplied to the fuel cell stack. The exhaust system is operable to receive exhaust gas from the fuel cell stack and includes a collection device for capturing water from the exhaust gas. The cooling system is operable to circulate coolant and includes a first heat exchanger and a second heat exchanger connected in parallel with each other, and is operable to extract heat from the coolant and remove heat away from the fuel cell stack. The second cabinet houses a DC electrical panel and an AC electrical panel, the DC electrical panel being electrically operable to deliver power to the first cabinet, and the AC electrical panel being electrically operable to deliver power to the first cabinet. The third cabinet houses a control module operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the AC load applied to the fuel cell stack.

[0020] Embodiments of this aspect of the disclosure may include one or more of the following optional features. In some instances, the mass flow meter includes a first mass flow meter and a second mass flow meter, which are connected in parallel between the remote fuel source and the fuel cell stack.

[0021] In some implementations, the fuel supply system is operable to adjust the volume of the adjustable reservoir.

[0022] In some aspects, the collection device includes a vapor separator, which captures liquid water and vapor from the exhaust gas.

[0023] In some configurations, the exhaust system includes a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack. Attached Figure Description

[0024] The accompanying drawings described herein are for illustrative purposes only for the selected configurations and are not intended to limit the scope of this disclosure.

[0025] Figure 1 This is a perspective view of the fuel cell test bench.

[0026] Figure 2 yes Figure 1A perspective view of a fuel cell test bench, in which the first cabinet has been removed to show the fuel cell module housed within the first cabinet.

[0027] Figure 3 This is a front view of the exhaust system of the fuel cell module.

[0028] Figure 4 This is a front view of the high-temperature cooling circuit of the fuel cell module.

[0029] Figure 5 This is a front view of the pressurized air cooling circuit of the fuel cell module.

[0030] Figure 6 This is a front view of the cryogenic cooling circuit of the fuel cell module.

[0031] Figure 7 This is a schematic diagram of the fuel, air, and nitrogen supply circuits of a fuel cell module.

[0032] Figure 8 This is a schematic diagram of the control module of the fuel cell module.

[0033] Figure 9 This is a schematic diagram of the electrical connection between the fuel cell module and the load connected to the fuel cell test bench.

[0034] Figure 10 This is a schematic diagram of a hydrogen concentration measurement system.

[0035] Figure 11 It is a schematic diagram of the high-temperature cooling circuit, the pressurized air cooling circuit, and the low-temperature cooling circuit.

[0036] Figure 12 This is a schematic diagram of the exhaust system of a fuel cell module.

[0037] In all the accompanying drawings, the corresponding reference numerals denote the corresponding parts. Detailed Implementation

[0038] The example configuration will now be described more fully with reference to the accompanying drawings. The example configuration is provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, apparatus, and methods, are set forth to provide a thorough understanding of the configuration of this disclosure. It will be apparent to those skilled in the art that specific details are not required, the example configuration may be embodied in many different forms, and the specific details and example configuration should not be construed as limiting the scope of this disclosure.

[0039] The terminology used herein is for the purpose of describing a particular exemplary configuration only and is not intended to be limiting. As used herein, the singular articles “a” and “the” may also be intended to include plural forms unless the context clearly indicates otherwise. The terms “containing,” “including,” “comprising,” and “having” are inclusive and therefore specify the presence of a feature, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0040] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, connected to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0041] The terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers, and / or parts. These elements, components, regions, layers, and / or parts should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, region, layer, or part discussed below may be referred to as the second element, component, region, layer, or part.

[0042] In this application, including the following definitions, the term "module" may be replaced by the term "circuit". The term "module" may refer to, be part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor (shared, dedicated, or grouped) that executes code; memory (shared, dedicated, or grouped) that stores code executed by the processor; other suitable hardware components that provide the described functionality; or combinations of some or all of the foregoing, such as in a system-on-a-chip.

[0043] The term "code" as used above can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" includes a single processor that executes some or all of the code from multiple modules. The term "group processor" includes processors that, in combination with additional processors, execute some or all of the code from one or more modules. The term "shared memory" covers a single memory that stores some or all of the code from multiple modules. The term "group memory" includes memory that, in combination with additional memory, stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium." The term "computer-readable medium" does not include transient electrical and electromagnetic signals propagating through the medium, and therefore can be considered tangible and non-transitory memory. Non-limiting examples of non-transitory memory include tangible computer-readable media, which include non-volatile memory, magnetic memory, and optical memory.

[0044] The apparatus and methods described in this application can be implemented, partially or entirely, by one or more computer programs executed by one or more processors. The computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. The computer program may also include and / or depend on stored data.

[0045] A software application (i.e., a software resource) can refer to computer software that enables a computing device to perform tasks. In some examples, a software application may be referred to as an "application," "app," or "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and game applications.

[0046] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., instruction sequences) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used in firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase-change memory (PCM), and magnetic disks or magnetic tapes.

[0047] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and can be implemented using high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) used to provide machine instructions and / or data to a programmable processor, including machine-readable media that receive machine instructions as machine-readable signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0048] Various implementations of the systems and techniques described herein can be implemented in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (Application-Specific Integrated Circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementations in one or more computer programs executable and / or interpretable on a programmable system, which includes at least one programmable processor, which may be dedicated or general-purpose, coupled to receive data and instructions from a storage system, at least one input device, and at least one output device, and to transmit data and instructions to the storage system, at least one input device, and at least one output device.

[0049] The processes and logical flows described in this specification can be executed by one or more programmable processors (also known as data processing hardware) that execute one or more computer programs to perform functions by manipulating input data and generating output. The processes and logical flows can also be executed by special-purpose logic circuitry (e.g., FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits). As an example, processors suitable for executing computer programs include both general-purpose and special-purpose microprocessors, as well as any one or more processors of any type of digital computer. Typically, the processor receives instructions and data from read-only memory or random access memory, or both. The basic elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data, or operatively coupled to receive data from or transfer data to, or both. However, a computer does not need to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, for example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks or removable disks; magneto-optical disks; and CD-ROMs and DVD-ROMs. Processors and memory may be supplemented by or incorporated into dedicated logic circuitry.

[0050] To provide interaction with a user, one or more aspects of this disclosure can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen) for displaying information to the user and optionally a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the computer. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback, such as visual, auditory, or tactile feedback; and input from the user can be received in any form, including sound, speech, or tactile input. Additionally, the computer can interact with the user by sending documents to and receiving documents from the device used by the user; for example, by sending a webpage to a web browser on the user's client device in response to a request received from a web browser.

[0051] refer to Figure 1 and 2The fuel cell test bench or test system 10 includes features of a fuel cell module 12 to allow a user to test and validate a fuel cell stack 32 connected to the fuel cell module 12. In this case, the fuel cell stack 32 is removed from the vehicle environment in which it is configured to be installed. In other words, the fuel cell test bench 10 includes components or subsystems of the fuel cell module 12 to provide fuel, exhaust, cooling, and control signals when the fuel cell stack 32 generates electricity based on a load or load group 40 connected to the fuel cell test bench 10. The fuel cell test bench 10 is configured to acquire data representing the operation of the fuel cell stack 32 and the fuel cell module 12 during testing. The tests adapted to the test system 10 may include any tests required by the user of the test system to properly validate the fuel cell module 12 and obtain data from it, such as durability testing, performance testing, life testing, etc. As discussed further below, the features of the fuel cell test bench 10 and the fuel cell module 12 are configured such that the fuel cell test bench 10 provides a reduced footprint, thereby allowing greater flexibility in the test environment. Furthermore, the fuel cell module 12 allows the user to adjust the operating parameters of the fuel cell module 12 to simulate the varying conditions experienced by the fuel cell stack 32.

[0052] The test system 10 includes a first cabinet 14, a second cabinet 16, and a third cabinet 18 arranged side-by-side as individual units. The internal portions or compartments of the cabinets 14, 16, and 18 may be at least partially defined or separated from each other by ports, fluid conduits, electrical wires, and other connectors extending between the cabinets 14, 16, and 18 for operating the test system 10. Although the cabinets 14, 16, and 18 are arranged side-by-side, their specific dimensions, orientation, configuration, and shape may vary without departing from the context of this disclosure.

[0053] The test system 10 includes a frame 20 having multiple legs or feet 22 that support cabinets 14, 16, and 18 on a surface where the test system 10 is located, such as the floor of an automotive engineering laboratory. Additionally, the frame 20 supports multiple panels 24 extending between corresponding components of the frame 20, which cooperate to define respective cabinets 14, 16, and 18 surrounding the test system 10. The panels 24 also serve to separate or connect the internal portions or compartments of the individual cabinets 14, 16, and 18 to each other, wherein openings, ports, or through-holes extend through the panels 24 to provide interaction between components included in the individual cabinets 14, 16, and 18 via conduits, wiring, etc. Both the frame 20 and the panels 24 can serve as mounting surfaces for the components included in the test system 10.

[0054] For example, and as further described below, a first cabinet 14 may define a first compartment 14a that houses the fuel cell module 12 and accommodates mechanical components associated with operating the fuel cell stack 32. A second cabinet 16 may define a second compartment 16a that houses one or more electrical panels (e.g., for supplying power to components within the fuel cell module 12), such as DC electrical panel 26 and AC electrical panel 28. A third cabinet 18 may define a third compartment 18a that houses a control module 30 configured to control the operation of the test system 10.

[0055] Continue to refer to Figure 1 and Figure 2 And also refer to Figures 3 to 12 The fuel cell module 12 includes various components and subsystems located within a first cabinet 14 of the test system 10, wherein the layout, configuration, and / or orientation of the components and subsystems contribute to the compact nature and minimal footprint of the test system 10. In the illustrated example, the fuel cell module 12 is located remotely from the fuel cell stack 32, which is operable to generate a direct current (DC) output 34 and exhaust gas 36 (e.g., air, liquid water, and / or steam) in response to receiving fuel 38 (e.g., hydrogen). A load bank 40 requires the DC output 34 of the fuel cell stack 32, and both the load bank 40 and the fuel cell stack 32 are electrically connected to the fuel cell module 12 via a power system. As shown, the load bank 40 interacts with the fuel cell module 12 via a hardwired connection, and the load bank 40 itself is located remotely from cabinets 14, 16, 18 and can be positioned anywhere convenient in the test environment, provided the connection between the load bank 40 and the fuel cell module 12 is accommodated. Therefore, the load bank 40 can be adjusted or swapped based on the testing needs of the system 10. Furthermore, the load bank 40 is bidirectional, meaning it is controlled via a dedicated contactor to allow power to the fuel cell module 12 and the generation of loads on it. This bidirectional nature of the load bank 40 creates a more realistic test system 10, closely resembling a real-world scenario of a fuel cell-powered vehicle. When the fuel cell stack 32 generates a DC output 34 that is transferred to the load bank 40, the load bank 40 can measure the DC output 34 of the fuel cell stack 32 for testing and analysis purposes.

[0056] The fuel cell module 12 also includes a fuel supply system 42 operable to facilitate the delivery of fuel 38 at an adjustable pressure from a remote fuel source to the fuel cell stack 32 and the fuel cell module 12 via at least one adjustable reservoir 44. For example, the pressure of the fuel 38 supplied to the fuel cell stack 32 can be adjusted based on operating parameters of the load group 40 and the fuel cell stack 32. The flow rate of the supplied fuel 38 can be read by a first mass flow meter 46a and a second mass flow meter 46b of the fuel supply system 42 for controlling the fuel supply. The two mass flow meters 46a and 46b monitor the mass flow rate measurement of the fuel 38 to allow the user and / or control module 30 of the test system 10 to obtain fuel flow data and adjust the flow rate of the fuel 38.

[0057] In the example shown, mass flow meters 46a and 46b are Coriolis mass flow meters. Coriolis mass flow meters can be relatively small in size, thus contributing to a small footprint for the test system 10. Furthermore, because Coriolis mass flow meters 46a and 46b measure mass flow rate rather than volumetric flow rate and do not require laminar flow, the piping fed into the mass flow meters 46a and 46b can be curved, curved, or contoured to accommodate other components of the test system 10. In other words, the piping at the respective inlets of the mass flow meters 46a and 46b can be bent or angled, which helps reduce the space requirements of the fuel cell module 12.

[0058] Furthermore, mass flow meters 46a and 46b are arranged in parallel with each other within the fuel cell module 12. Therefore, when the fuel supply system 42 operates within a first flow rate range, the first mass flow meter 46a can provide a mass flow rate measurement, and when the fuel supply system operates within a second flow rate range, the second mass flow meter 46b can provide a mass flow rate measurement. The first and second flow rate ranges may at least partially overlap, with the second flow rate range including flow rates higher than the first flow rate range. For example, when the fuel supply system 42 operates at a first lower flow rate, fuel 38 flows through the first mass flow meter 46a to the fuel cell stack 32, and fuel 38 does not pass through the second mass flow meter 46b. When the fuel supply system 42 operates at a higher second flow rate, fuel 38 flows through both the first and second mass flow meters 46a to the fuel cell stack 32. The use of two mass flow meters 46a and 46b allows for greater reliability in the accuracy of fuel flow rate readings at both higher and lower flow rates, resulting in a more robust and accurate test system 10. Therefore, the flow rate of the supplied fuel 38 can be adjusted based on the mass flow rate measurement of the fuel 38 supplied to the fuel cell stack 32 from at least one of the first mass flow meter 46a and the second mass flow meter 46b.

[0059] In some examples, the fuel supply system 42 is operable to adjust the volume of the adjustable reservoir 44, the available volume of the adjustable reservoir 44, and / or the volume of fuel 38 supplied from the adjustable reservoir 44 each time via a remote fuel source. For example, the fuel supply system 42 may include a series of valves between the fuel cell stack 32 and the adjustable reservoir. Activating or opening, and deactivating or closing different valves, can adjust the volume of fuel 38 available to the fuel cell module 12 to simulate different installation scenarios of the fuel cell stack 32.

[0060] In addition, the fuel cell module 12 includes an exhaust system 48 that operates to receive exhaust gas 36 from the fuel cell stack 32 during its operation. The exhaust system 48 includes a collection device, dehydration device, or vapor separator 50 that captures water and / or vapor from the exhaust gas 36 during operation of the fuel cell module 12. As exhaust gas 36 flows into or through the collection device 50, the collection device 50 captures one or both of liquid water and vapor for analytical purposes. For example, the collection device 50 may include a vapor line that delivers vapor from the exhaust gas 36 to a condenser 53, causing the vapor to condense into liquid water that can be analyzed. The collection device 50 may also include a water line that delivers water from the exhaust gas 36 and / or the condenser 53 to sensors or testing devices for analysis. Analysis of the water collected at the collection device 50 can determine the health condition of the fuel cell stack 32. For example, the collected water can indicate whether the fuel cell stack 32 has experienced a higher or lower level of anticipated degradation after the service life of the test system 10.

[0061] The exhaust system 48 also includes a back pressure valve 52, operable to introduce different levels of back pressure to the fuel cell module 12 via the exhaust system 48 to simulate real-world scenarios in a vehicle equipped with a fuel cell. As an example, the back pressure valve 52 can be operated to apply increased pressure at the fuel cell stack 32 to configure the test system 10 as accurately as the performance of a fuel cell application included in a vehicle. In doing so, the operation of the fuel cell module 12 can react to the level of back pressure applied by the operation of the back pressure valve 52 and produce different test results. The back pressure valve 52 does not generate pressure but allows pressure to build up in the exhaust system 48.

[0062] The exhaust system 48 also includes instruments for measuring the hydrogen concentration, temperature, and / or pressure of the exhaust gas 36 produced by the fuel cell stack 32. Specifically, the exhaust system 48 includes a sensor 51 operable to detect one or more characteristics of the exhaust gas 36, such as based on water collected by the collection device 50 or based on the exhaust gas 36 exiting the exhaust system 48. For example, the sensor 51 is operable to detect the hydrogen concentration, temperature, and / or pressure of the exhaust gas 36.

[0063] The fuel cell module 12 also includes a cooling system 54 operable to circulate coolant throughout the fuel cell module 12. The cooling system 54 operates to control the temperature of one or more components of the fuel cell module 12. As configured in the first cabinet 14, the cooling system 54 is vertically positioned below the fuel supply system 42, thereby allowing for a reduction in the footprint of both the cooling system 54 and the fuel supply system 42, and thus a reduction in the footprint of the test system 10. In the illustrated example, the cooling system 54 includes a high-temperature cooling circuit 54a, a pressurized air cooling circuit 54b, and a low-temperature cooling circuit 54c. The pressurized air cooling circuit 54b and the low-temperature cooling circuit 54c are operable to circulate coolant to portions or subsystems of the fuel cell module 12 that operate at lower temperatures, thus requiring less cooling, such as small electronic devices and small circuits. The high-temperature cooling circuit 54a is operable to circulate coolant to portions or subsystems of the fuel cell module 12 that operate at higher temperatures and therefore require greater cooling. Additionally, the high-temperature cooling circuit 54a provides cooling to the fuel cell stack 32 located away from the fuel cell module 12.

[0064] The high-temperature cooling circuit 54a includes a first heat exchanger 56 and a second heat exchanger 58, which are connected in parallel along the high-temperature cooling circuit 54a and operate to draw heat away from the coolant and from components within the fuel cell module 12. The use of parallel first heat exchangers 56 and second heat exchangers 58 in the fuel cell module 12 reduces the footprint of the cooling system 54 compared to a single heat exchanger large enough to provide cooling equivalent to that of the parallel heat exchangers, and thus reduces the footprint of the test system 10, while still providing sufficient cooling capacity for proper operation of the test system 10.

[0065] Reference Figure 2 and Figure 9The second cabinet 16 houses a DC electrical panel 26 and an AC electrical panel 28. The DC electrical panel 26 is electrically connected to the fuel cell module 12 located in the first cabinet 14 and is operable to provide power to components within the fuel cell module 12, such as various sensors and valves. The power supplied from the DC electrical panel 26 is separate from the DC output 34 generated by the fuel cell stack 32. Regarding the AC electrical panel 28, a bidirectional power supply 59 provides power to the AC electrical panel 28 to distribute power to various components within the fuel cell module 12, similar to the function of the DC electrical panel 26. The power supplied to the fuel cell module 12 via the AC electrical panel 28 is separate from the AC load 60 received by the fuel cell stack 32 to simulate the electrical load on the fuel cell module 12. This simulates a real-world scenario on the test system 10 and will be explained in more detail below. Additionally, the AC electrical panel 28 is capable of modulating the amount of power applied to the fuel cell module 12, and its settings can be configured by the user of the test system 10.

[0066] The third cabinet 18 houses the control module 30 of the test system 10. The control module 30 may include processing circuitry and associated software operable to configure the high-frequency resistance (HFR) unit 62 to provide an AC load 60 to the fuel cell stack 32, both of which are housed in the third cabinet 18. In other words, the control module 30 allows the user to operate and obtain data from the fuel cell module 12, and specifically, controls operations related to the AC load 60 provided by the HFR unit 62, and obtains data related to the HFR unit 62, the fuel cell stack 32, and the fuel cell module 12 due to the AC load 60 applied to the fuel cell stack 32. The obtained data related to the HFR unit 62 may include the performance and lifespan of the fuel cell module 12 and the fuel cell stack 32. In addition to obtaining data related to the HFR unit 62, the control module 30 may include additional software for operational and recording purposes. As an example, software may be included to analyze the security of the test system 10 and for input / output management. Control module 30 monitors the high-voltage electrical current and high-voltage power from fuel cell module 12, as well as the local hydrogen level, to maintain a sufficient level of safety for the user. To monitor these readings, control module 30 allows various levels of access to fuel cell module 12, even while the product is in operation, such as during troubleshooting scenarios. Input / output management allows the user to acquire data related to flow measurement, pressure, temperature, and conductivity, as well as other data, associated with various applicable components of test system 10. Control module 30 allows the collection, reading, and storage of any acquired data during operation of test system 10 for product development and validation purposes. Furthermore, control module 30 is responsible for facilitating specific validation tests desired by the user. In other words, the user can configure control module 30 to run specific tests, read and acquire data obtained as test results, and analyze the data as needed. Any software used within control module 30 is specifically configured for use with test system 10, in which control module 30 is installed.

[0067] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are within the scope of the appended claims.

[0068] The foregoing description is provided for illustrative and descriptive purposes. It is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in selected configurations, even if not specifically shown or described. They can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A fuel cell module, comprising: A power system comprising direct current (DC) generated from a fuel cell stack to power loads electrically connected to the fuel cell module, the fuel cell stack responding to receiving fuel and generating exhaust gas; A fuel supply system operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure via at least one adjustable reservoir, and further comprising a mass flow measurement of the fuel supplied to the fuel cell stack from a mass flow meter of the fuel supply system; An exhaust system operable to receive exhaust gas from the fuel cell stack, the exhaust system including a collection device for capturing water from the exhaust gas; as well as A cooling system operable to circulate coolant, the cooling system including a first heat exchanger and a second heat exchanger connected in parallel with each other and operable to extract heat from the coolant and remove heat away from the fuel cell module.

2. The fuel cell module according to claim 1, wherein the mass flow meter includes a first mass flow meter and a second mass flow meter, and the first mass flow meter and the second mass flow meter further include a Coriolis mass flow meter connected in parallel between the remote fuel source and the fuel cell stack.

3. The fuel cell module according to claim 2, wherein, When the fuel supply system is operated to supply fuel to the fuel cell stack at a first flow rate, the fuel flows from the remote fuel source through the first mass flow meter but not through the second mass flow meter, and when the fuel supply system is operated to supply fuel to the fuel cell stack at a second flow rate greater than the first flow rate, the fuel flows from the remote fuel source through both the first and second mass flow meters.

4. The fuel cell module of claim 1, wherein the fuel supply system is operable to adjust the volume of the adjustable reservoir.

5. The fuel cell module according to claim 1, wherein, The collection device includes a steam separator that captures liquid water and steam from the exhaust gas.

6. The fuel cell module of claim 1, wherein the exhaust system includes a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack, and wherein the exhaust system further includes one or more sensors operable to detect at least one selected from the group consisting of (i) hydrogen concentration of the exhaust, (ii) temperature of the exhaust, and (iii) pressure of the exhaust.

7. The fuel cell module of claim 1 further includes a control module operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the alternating current (AC) applied to the fuel cell stack.

8. The fuel cell module according to claim 1, wherein, The test bench houses the power system, the fuel supply system, the exhaust system, and the cooling system.

9. A testing system, comprising: A fuel cell stack operable to generate direct current (DC) and exhaust gas in response to receiving fuel, the DC power supply supplying a load electrically connected to the test system; A power system, the power system including direct current (DC) generated from the fuel cell stack; A fuel supply system operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure via at least one adjustable reservoir, and further comprising measuring the mass flow rate of fuel supplied to the fuel cell stack from a mass flow meter of the fuel supply system, the fuel supply system also operable to adjust the volume of the at least one adjustable reservoir, the mass flow meter comprising a first mass flow meter and a second mass flow meter, the first mass flow meter and the second mass flow meter being arranged in parallel between the remote fuel source and the fuel cell stack; An exhaust system operable to receive exhaust gas from the fuel cell stack, the exhaust system including a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack, and the exhaust system further including a collection device for capturing water from the exhaust gas, the collection device including a steam separator; A cooling system operable to circulate coolant, the cooling system including a first heat exchanger and a second heat exchanger connected in parallel with each other and operable to extract heat from the coolant and remove heat away from the test system; as well as A control module operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the alternating current (AC) applied to the fuel cell stack.

10. A testing system, comprising: The first rack, the first rack contains: A power system comprising direct current (DC) generated from a fuel cell stack, the DC power supply supplying loads electrically connected to the fuel cell stack, the fuel cell stack responding to receiving fuel and generating exhaust gas; A fuel supply system operable to supply fuel from a remote fuel source to the fuel cell stack at an adjustable pressure via at least one adjustable reservoir, and further comprising measuring the mass flow rate of fuel supplied to the fuel cell stack from a mass flow meter of the fuel supply system, the fuel supply system also operable to adjust the volume of the at least one adjustable reservoir, the mass flow meter comprising a first mass flow meter and a second mass flow meter, the first mass flow meter and the second mass flow meter being arranged in parallel between the remote fuel source and the fuel cell stack; An exhaust system operable to receive exhaust gas from the fuel cell stack, the exhaust system including a back pressure valve operable to regulate the back pressure level experienced at the fuel cell stack, and the exhaust system further including a collection device for capturing water from the exhaust gas, the collection device including a steam separator; A cooling system operable to circulate coolant, the cooling system including a first heat exchanger and a second heat exchanger connected in parallel with each other and operable to extract heat from the coolant and remove heat away from the test system; The second rack, which accommodates: A DC electrical panel, electrically operable to deliver power to the first cabinet; and An AC electrical panel, which is electrically operable to deliver power to the first cabinet; as well as The third cabinet, which accommodates: A control module operable to determine the high-frequency resistance (HFR) of the fuel cell stack based on the AC load applied to the fuel cell stack.

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