Fuel cell system with modular power electronic modules

Abstract

The present invention relates to fuel cell systems with modular power electronic modules. A fuel cell module is disclosed comprising: a fuel cell stack comprising a first one or more external interfaces; and modular power electronic modules (MPEMs), wherein each of the MPEMs comprises at least one subsystem module configured to perform an operation with respect to the fuel cell stack and a respective one or more external interfaces, each of the one or more external interfaces being standardized and configured to be coupled to each of the first one or more external interfaces. The one or more external interfaces of one of the MPEMs are configured to be coupled to other external interfaces of other ones of the MPEMs.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of this disclosure. To the extent described in this section, the works of the currently attributed inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor implicitly considered to be prior art of this disclosure. Technical Field

[0003] This disclosure relates to fuel cells. Background Technology

[0004] A fuel cell receives fuel consisting of hydrogen and oxygen, and the hydrogen is split into protons and electrons via the anode. The protons travel through an electrolyte membrane to the cathode, where they combine with oxygen atoms and electrons to produce water and electricity. As an example, when fuel cells are implemented in vehicles, the electricity can be used for propulsion. As another example, fuel cells can be used as generators to power various loads. Summary of the Invention

[0005] A fuel cell module is disclosed, comprising: a fuel cell stack including a first or more external interfaces; and a modular power electronic module (MPEM), wherein each MPEM includes at least one subsystem module configured to perform operations relating to the fuel cell stack and a corresponding one or more external interfaces, each of the one or more external interfaces being standardized and configured to be coupled to each of the first or more external interfaces. One or more external interfaces of one MPEM are configured to be coupled to other external interfaces of other MPEMs.

[0006] Among other features, each of the first one or more external interfaces and the one or more external interfaces of the MPEM includes a communication bus terminal and a power supply terminal.

[0007] Among other features, each of the first one or more external interfaces and the MPEM's one or more external interfaces includes a cooling channel.

[0008] Among other features, the power supply terminals include low-voltage terminals having a voltage of less than or equal to 48V and high-voltage terminals having a voltage of greater than or equal to 50V.

[0009] Among other features, each of the MPEMs includes a subsystem module, which includes at least one corresponding subsystem module of the MPEM. Each of the subsystem modules includes at least one internal interface, which is standardized to connect one of the internal interfaces of the corresponding subsystem module of the MPEM to each other.

[0010] Among other features, the MPEM includes: a first MPEM implemented as a power conversion module (PCM); and a second MPEM implemented as a power distribution control and safety module (PDCSM).

[0011] Among other features, the PCM includes at least one of a power conversion module, a sensing module, a high-frequency resistance sensing module, and a filtering module.

[0012] Among other features, the PDCSM includes at least one of the following: a stacked sensing module, a high-frequency resistance sensing module, a filter module, an application sensing module, a fuse module, a pyrotechnics module, a contactor module, and an inverter module.

[0013] Among other features, the PDCSM includes a subsystem module for controlling the PDCSM and an electrical domain control module for the operation of the fuel cell stack.

[0014] Among other features, the electrical domain control module controls the operation of at least one of the PCM and the fluid domain control module.

[0015] Among other features, at least one of the MPEMs includes a bus and a busbar, the busbar including a communication bus and a power busbar extending between at least one of the external interfaces of the MPEM.

[0016] Among other features, one of the MPEMs is implemented as a fluid domain control module and includes hardware drivers, fuses, and a main local interconnect network.

[0017] Among other features, one or more external interfaces of one of the MPEMs are connected to the electric air compressor of the fuel cell module driven by the inverter.

[0018] Among other features, one of the MPEMs includes: a high-voltage balance of plant interface configured to connect to a pump; one or more access panels for access to at least one subsystem module of the MPEM; a low-voltage data and power output interface configured to connect to a load; and a high-voltage output interface configured to connect to a load.

[0019] Among other features, MPEMs are configured to be interconnected with each other and the fuel cell stack in different arrangements.

[0020] Among other features, different arrangements include: a stacked arrangement in which a first MPEM is connected between a second MPEM and a fuel cell stack, wherein the MPEM includes a first MPEM and a second MPEM; a centralized arrangement in which both the first MPEM and the second MPEM are connected to the fuel cell stack; and a combined arrangement in which two or more MPEMs are connected to the fuel cell stack, and one or more other MPEMs are not connected to the fuel cell stack, but are connected to one of the MPEMs.

[0021] Among other features, MPEM integrates with non-repetitive hardware of fuel cell stacks.

[0022] Among other features, the non-repetitive hardware includes at least one of the following: one or more housings; fuel cell end caps; and compression hardware.

[0023] Among other features, a vehicle is disclosed, comprising: one or more fuel cell modules configured to generate electrical energy and including an electrical domain control module; and a vehicle control module configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and to control the distribution of electrical energy to the vehicle's equipment.

[0024] Among other features, a stationary power station is disclosed, comprising: one or more fuel cell modules configured to generate electrical energy and including an electrical domain control module; and a main control module configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and control the distribution of electrical energy to loads connected to the stationary power station.

[0025] The present invention provides the following technical solutions.

[0026] Technical Solution 1. A fuel cell module, comprising:

[0027] Fuel cell stack, comprising a first or more external interfaces; and

[0028] Multiple modular power electronic modules (MPEMs), wherein each of the multiple MPEMs includes

[0029] At least one subsystem module is configured to perform operations relating to the fuel cell stack; and

[0030] One or more corresponding external interfaces, each of which is standardized and configured to connect to each of the first one or more external interfaces, wherein one or more external interfaces of one of the plurality of MPEMs is configured to connect to other external interfaces of the other MPEMs of the plurality of MPEMs.

[0031] Technical Solution 2. The fuel cell module according to Technical Solution 1, wherein each of the first one or more external interfaces and each of the one or more external interfaces of the plurality of MPEMs includes a communication bus terminal and a power supply terminal.

[0032] Technical Solution 3. The fuel cell module according to Technical Solution 2, wherein each of the first one or more external interfaces and each of the one or more external interfaces of the plurality of MPEMs includes a cooling channel.

[0033] Technical Solution 4. The fuel cell module according to Technical Solution 2, wherein the power supply terminals include a low-voltage terminal having a voltage of less than or equal to 48V and a high-voltage terminal having a voltage of greater than or equal to 50V.

[0034] Technical Solution 5. The fuel cell module according to Technical Solution 1, wherein:

[0035] Each of the plurality of MPEMs includes a plurality of subsystem modules, the plurality of subsystem modules including at least one subsystem module corresponding to one of the plurality of MPEMs; and

[0036] Each of the plurality of subsystem modules includes at least one internal interface, which is standardized to connect one of the internal interfaces of the plurality of subsystem modules corresponding to one of the plurality of MPEMs to each other.

[0037] Technical Solution 6. The fuel cell module according to Technical Solution 5, wherein the plurality of MPEMs includes:

[0038] The first MPEM, which includes or is implemented as a power conversion module (PCM); and

[0039] The second MPEM is implemented as a power distribution control and safety module (PDCSM).

[0040] Technical Solution 7. The fuel cell module according to Technical Solution 6, wherein the first MPEM includes at least one of a power conversion module, a sensing module, a high-frequency resistance sensing module, and a filtering module.

[0041] Technical Solution 8. The fuel cell module according to Technical Solution 6, wherein the PDCSM includes at least one of the following: a stacked sensing module, a high-frequency resistance sensing module, a filter module, an application sensing module, a fuse module, a pyrotechnics module, a contactor module, and an inverter module.

[0042] Technical Solution 9. The fuel cell module according to Technical Solution 6, wherein the PDCSM includes an electrical domain control module for controlling the plurality of subsystem modules of the PDCSM and the operation of the fuel cell stack.

[0043] Technical Solution 10. The fuel cell module according to Technical Solution 9, wherein the electrical domain control module controls the operation of at least one of the PCM and the fluid domain control module.

[0044] Technical Solution 11. The fuel cell module according to Technical Solution 5, wherein at least one of the plurality of MPEMs includes a plurality of busbars, the plurality of busbars including a communication bus and a power busbar extending between the external interfaces of the at least one of the plurality of MPEMs.

[0045] Technical Solution 12. The fuel cell module according to Technical Solution 5, wherein one of the plurality of MPEMs is implemented as a fluid domain control module and includes a hardware driver, a fuse and a main local interconnect network.

[0046] Technical Solution 13. The fuel cell module according to Technical Solution 1, wherein one or more external interfaces of one of the plurality of MPEMs are connected to an electric air compressor of the fuel cell module driven by an inverter.

[0047] Technical Solution 14. The fuel cell module according to Technical Solution 13, wherein one of the plurality of MPEMs includes:

[0048] A high-voltage peripheral device interface, which is configured to connect to multiple pumps;

[0049] One or more access panels for accessing at least one subsystem module of one of the plurality of MPEMs;

[0050] Low-voltage data and power output interfaces, which are configured to be connected to a load; and

[0051] A high-voltage output interface is configured to be connected to the load.

[0052] Technical Solution 15. The fuel cell module according to Technical Solution 1, wherein the plurality of MPEMs are configured to be connected to each other and the fuel cell stack in a plurality of different arrangements.

[0053] Technical Solution 16. The fuel cell module according to Technical Solution 15, wherein the plurality of different arrangements include:

[0054] A stacked arrangement in which a first MPEM is connected between a second MPEM and the fuel cell stack, wherein the plurality of MPEMs includes the first MPEM and the second MPEM;

[0055] A centralized arrangement, in which both the first MPEM and the second MPEM are connected to the fuel cell stack; and

[0056] In a combined arrangement, two or more of the plurality of MPEMs are connected to the fuel cell stack, and one or more of the other MPEMs are not connected to the fuel cell stack, but are connected to one of the plurality of MPEMs.

[0057] Technical Solution 17. The fuel cell module according to Technical Solution 1, wherein:

[0058] The multiple MPEMs are integrated with the non-repetitive hardware of the fuel cell stack;

[0059] The non-repetitive hardware includes at least one of the following: one or more housings; fuel cell end caps; and

[0060] Compress hardware.

[0061] Technical Solution 18. A means of transportation, comprising:

[0062] According to one or more of the fuel cell modules described in technical solution 1, the fuel cell module is configured to generate electrical energy and includes an electrical domain control module; and

[0063] A vehicle control module is configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and to control the distribution of electrical energy to the vehicle's equipment.

[0064] Technical Solution 19. A stationary power station, comprising:

[0065] According to one or more of the fuel cell modules described in technical solution 1, the fuel cell module is configured to generate electrical energy and includes an electrical domain control module; and

[0066] The main control module is configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and control the distribution of electrical energy to loads connected to the stationary power station.

[0067] Technical Solution 20. A fuel cell module, comprising:

[0068] Fuel cell stack, comprising a first or more external interfaces; and

[0069] Multiple modular power electronic modules (MPEMs), wherein each of the multiple MPEMs includes

[0070] At least one subsystem module is configured to perform operations relating to the fuel cell stack; and

[0071] One or more corresponding external interfaces, each of which is standardized and configured to connect to each of the first one or more external interfaces, wherein one or more external interfaces of one of the plurality of MPEMs are configured to connect to other external interfaces of the other MPEMs in the plurality of MPEMs.

[0072] Among them, the plurality of MPEMs include

[0073] The first MPEM includes a power conversion module and a filtering module, and

[0074] The second MPEM includes a stacked sensing module, a high-frequency resistance sensing module, a filtering module, an application sensing module, a fuse module, and a pyrotechnics module.

[0075] Further applications of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0076] This disclosure will be understood more fully from the detailed description and accompanying drawings, in which:

[0077] Figure 1 This is a functional block diagram of a vehicle including an example fuel cell system according to this disclosure;

[0078] Figure 2 This is a functional block diagram of a stationary power station including an example fuel cell system, based on this disclosure;

[0079] Figure 3 This is a functional block diagram of an example control system for multiple fuel cell modules (FCMs) according to the present disclosure;

[0080] Figure 4 The functional signals and fluid flow diagrams of the example fuel cell system according to this disclosure;

[0081] Figure 5 These are schematic and functional block diagrams of a portion of an example fuel cell system with various different sensors, as illustrated in this disclosure.

[0082] Figure 6 The schematic and functional block diagram of the example FCM based on this disclosure;

[0083] Figure 7 This is a functional block diagram of a first example modular power electronics module (MPEM) (also known as a power distribution control and safety module) according to this disclosure;

[0084] Figure 8 This is a functional block diagram of the second example MPEM (or power conversion module) according to this disclosure;

[0085] Figure 9 This is a functional block diagram of the third example MPEM (or fluid domain control module) according to this disclosure;

[0086] Figure 10 According to another example MPEM functional block diagram of this disclosure, it can represent Figures 7 to 9 Each of the MPEMs is illustrated with the internal and external interfaces relative to the subsystem module.

[0087] Figure 11 This is a front view of the example external interface based on this disclosure;

[0088] Figure 12 This is a front view of the example internal interface based on this disclosure;

[0089] Figure 13 This is an example subsystem module according to the present disclosure having a through cooling loop that provides internal and / or through cooling;

[0090] Figure 14 This is an example subsystem module with a non-through cooling loop according to the present disclosure;

[0091] Figure 15 This is an example subsystem module with a low-voltage electrical pass-through circuit according to the present disclosure;

[0092] Figure 16 This is an example subsystem module with low-voltage electrical non-straight-through circuitry according to the present disclosure;

[0093] Figure 17 This is an example subsystem module with a high-voltage electrical pass-through circuit according to the present disclosure;

[0094] Figure 18 This is an example subsystem module with high-voltage electrical non-straight-through circuit according to the present disclosure;

[0095] Figure 19 Based on this disclosure Figure 6 The hierarchical representation of FCM;

[0096] Figure 20 This is a functional block diagram of an example portion of the FCM in the first arrangement of this disclosure;

[0097] Figure 21 This is a functional block diagram of an example portion of the FCM in the second arrangement of this disclosure;

[0098] Figure 22 This is a perspective view of a portion of the FCM in the third arrangement according to this disclosure;

[0099] Figure 23 This is a perspective view of an example portion of the FCM in the fourth arrangement according to this disclosure;

[0100] Figure 24 It is based on the present disclosure and has an inspection panel with similar features. Figure 22 A cross-sectional view of an example section of the FCM layout;

[0101] Figure 25 This is a functional block diagram of an example subsystem module based on this disclosure;

[0102] Figure 26 This is a functional block diagram of another example subsystem module according to this disclosure;

[0103] Figure 27 This is a top view of an example subsystem module (or layer) based on this disclosure;

[0104] Figure 28 This is a top view of an example subsystem module (or layer) based on this disclosure;

[0105] Figure 29 It is stacked according to this disclosure Figure 27 On the subsystem module Figure 28 A top view of the subsystem module;

[0106] Figure 30 This is a representative perspective view of the power brick of the power conversion module according to this disclosure;

[0107] Figure 31 The diagram illustrates the first arrangement according to this disclosure. Figure 30 A view of the high-voltage terminals and parallel connections of the power brick;

[0108] Figure 32 The diagram illustrates the second arrangement according to this disclosure. Figure 30 End view of the high-voltage terminal of the power brick;

[0109] Figure 33 It is based on the present disclosure that the section cut at point AA passes through Figure 30 A cross-sectional view of one of the power bricks;

[0110] Figure 34 It is based on the present disclosure that the section cut at the cross-sectional plane BB passes through Figure 30A cross-sectional view of one of the power bricks;

[0111] Figure 35 It is based on the present disclosure that the section cut at the cross-section plane CC passes through Figure 30 A cross-sectional view of one of the power bricks; and

[0112] Figure 36 It is based on the present disclosure that the section cut at the cross-section plane DD passes through Figure 30 A cross-sectional view of one of the power bricks.

[0113] In the accompanying drawings, reference numerals may be reused to identify similar and / or identical elements. Detailed Implementation

[0114] A fuel cell powertrain (or system) may include a fuel cell stack, heaters and / or pumps (e.g., hydrogen pumps and high-voltage coolant (HVC) pumps), air compressors, valves, converters, one or more heaters, water separators, humidifiers, recirculation fans, coolant lines (or conduits), low-voltage and high-voltage power lines, etc. The items of the fuel cell system are designed, configured, connected, and arranged for a specific application. Fuel cell systems can be implemented in both transportation and non-transportation applications, such as for stationary power applications. The fuel cell systems disclosed herein can be implemented in, for example, road vehicles, off-road vehicles, locomotives, large and small marine applications, aircraft, stationary power applications, etc. Road vehicles include commercial and civilian vehicles, medium-duty trucks, heavy-duty trucks (e.g., Class 8 trucks), passenger vehicles, etc. Heavy-duty off-road vehicles include mining equipment trucks and vehicles, excavating and earthmoving equipment, transport equipment, construction machinery (e.g., cranes, cement mixers, etc.), rolling platforms, etc. Locomotive applications include auxiliary power equipment and traction power equipment. Marine applications include auxiliary power applications and prime mover applications. Aircraft applications include aircraft propulsion, aircraft auxiliary power units, unmanned aerial vehicles (UAVs), and unmanned vehicles. Stationary power applications include backup generators installed in commercial locations, as well as other generators and charging stations (e.g., generators and charging stations implemented on trailers). Each of the modular fuel cell systems disclosed herein can be configured and reconfigured for implementation in any of these applications.

[0115] It can be difficult to modify one item and / or part (e.g., a fuel cell stack) without requiring changes to the specifications, bolt patterns, components, connection arrangements, etc., of other items and / or parts of the fuel system. As an example, some hardware of a fuel cell system is designed to be mechanically, electrically, and fluidly connected together to the fuel cell stack, and is sized and arranged to fit within a dedicated space with space constraints for a given application. For example, if increased output is required, the size of the fuel cell stack may increase. This change may necessitate redesigning many other components of the fuel cell system to connect to the new fuel cell stack and adapt to the specifications of the current application or the requirements of different applications. As an example, the voltage, current, and / or power requirements of the fuel cell stack may increase, resulting in an increase in the size and / or number of plates in the fuel cell stack. Consequently, the specifications, dimensions, connection arrangements, etc., of other items also need to be changed. This may require time-consuming and costly redesign, reprocessing, and remanufacturing of various items. Therefore, many different fuel cell systems and corresponding components for various fuel cell applications can exist.

[0116] The examples described herein include fuel cell systems comprising modular power electronics modules configured for various applications with diverse voltage, current, and power requirements, and connected in various arrangements. The examples are flexible for different fuel cell systems with different fuel cell stacks of varying specifications, including different sizes, shapes, voltage requirements, current requirements, power requirements, and cooling requirements.

[0117] The example provides a high-power-density fuel cell electrical architecture designed to offer modular flexibility for fuel cell system control, safety, stack sensing, and power conversion. This architecture allows for the integration and interchangeability of components, including stack sensing elements, power conversion modules, safety systems, and power distribution hardware, without requiring significant modifications to the overall fuel cell system design.

[0118] The example provides a scalable and adaptable platform capable of integration flexibility based on application-specific requirements. These requirements may involve power conversion, control options, or safety features. The disclosed system modularity enhances ease of maintenance, scalability for different power levels, and optimization of fuel cell performance across a variety of use cases, including transportation applications, energy storage, and grid export. The adaptable platform is flexible, customizable, and suitable for a wide range of fuel cell applications while maintaining high power density and safety.

[0119] The disclosed fuel cell electrical architecture features a modular design and allows for the integration of modular components. For example, the modular design allows for easy exchange and / or upgrading of components (e.g., stack sensing components, power conversion modules, safety hardware, etc.) without requiring major redesign or alteration of the core fuel cell stack.

[0120] Examples include one or more control modules (e.g., electrical domain control module, vehicle control module, main control module, etc.) that are dynamically configurable and serve multiple functions, such as acting as a main domain controller, data aggregator, or general-purpose fuel cell controller. This allows the control system to be customized for specific application needs, whether the control module operates independently, is used in a vehicle application, or is part of a larger multi-fuel cell configuration.

[0121] The example provides multi-channel communication support, including support for a range of communication protocols such as LIN (Link In-Network), CAN (Controller Area Network), SENT (Serial Network), and variants of Ethernet communication protocols, enabling integration with a variety of systems. The example also provides reconfigurable power conversion. The power conversion modules within this architecture are modular and can be reconfigured based on specific application requirements, whether isolated or non-isolated topologies. This reconfigurability allows the system to balance critical design trade-offs, such as between isolated conversion, which provides electrical isolation required for safety in high-voltage systems but typically comes with higher cost and lower efficiency; and non-isolated conversion, which offers higher efficiency and lower cost, making it ideal for applications where safety isolation is not critical. This modularity allows system designers to select appropriate power conversion strategies without redesigning the entire system, thereby improving flexibility for applications such as energy storage, grid export, or direct DC power use.

[0122] The example also provides an integrated safety system. The modular architecture incorporates multiple safety features, such as fire deactivation, active / passive discharge hardware, and isolated sensing systems. These are implemented in a modular and reconfigurable manner, providing the ability to flag unsafe conditions and safely disconnect the fuel cell stack from the high-voltage bus without affecting the overall system.

[0123] Figure 1A main vehicle 100 including an example fuel cell system 102 is shown. The fuel cell system 102 includes one or more FCMs 103, a fuel source 104, and a vehicle control module 107. The vehicle control module 107 may simply provide power requirements to the FCMs 103 or, in one embodiment, communicate with and control the operation of the FCMs 103. Each of the FCMs may include one or more control modules, as further described below. The control modules of the FCMs may be dedicated to controlling the operation of the FCMs, or the vehicle control module may control the operation of the FCMs, or a combination thereof. The fuel source may include a hydrogen source, an oxygen source, and / or an air source. The fuel source may include a tank and a pump. Figures 2 to 36 Examples of FCM103 and its components are shown and described in the document.

[0124] The primary vehicle 100 can be a non-autonomous, partially autonomous, or fully autonomous vehicle. The primary vehicle 100 can be an electric vehicle. A vehicle control module 107 controls the operation of the primary vehicle 100; a visual sensing (or perception) system 108 includes an object detection sensor 109; other sensors 110 (e.g., temperature and pressure sensors, composition and actuator sensors, acceleration and speed sensors, occupant sensors, etc.); multiple power sources 111; an infotainment module 112; and other control modules 113. The power source 111 includes one or more battery packs (one battery pack 114 is shown) and control circuitry 115. The battery packs can be recharged via an FCM 103. The object detection sensor 109 may include a camera, radar sensor, lidar sensor, etc. The other sensors 110 may include temperature sensors, accelerometers, gyroscopes, steering angle sensors, wheel speed sensors, vehicle speed sensors, and / or other sensors, some of which are described above. Energy source 111 may include a low-voltage energy source (e.g., a 5V, 12V, or 48V energy source) and a high-voltage energy source (e.g., a 240-800V energy source) for powering low-voltage and high-voltage loads. Energy is stored and then converted into useful work for the low-voltage and high-voltage loads, the prime mover, auxiliary loads(s), etc. Vehicle control module 107 may include a mode selection module 117 and a parameter adjustment module 118.

[0125] Modules 107, 112, 113, 117, and 118 can communicate with each other and access memory 119 via one or more buses and / or network interfaces 120. Network interface 120 may include a CAN bus, LIN bus, Ethernet network interface, automotive network communication protocol bus, and / or other network buses.

[0126] The vehicle control module 107 controls the operation of the vehicle system. The mode selection module 117 can select the vehicle operation mode. The parameter adjustment module 118 can be used to adjust, acquire, and / or determine the parameters of the main vehicle 100 based on signals from, for example, sensors 109, 110 and / or other devices and modules mentioned herein.

[0127] The main vehicle 100 may also include a display 120, an audio system 122, and one or more transceivers 124. The display 120 and / or the audio system 122 may be implemented as part of an infotainment system together with the infotainment module 112.

[0128] The main vehicle 100 may also include a Global Positioning System (GPS) receiver 128 and a map module 129. The GPS receiver 128 may provide vehicle speed and / or vehicle direction (or heading) and / or global clock timing information. The GPS receiver 128 may also provide vehicle location information, including lane information. The map module 129 provides map information. The map information may include traffic-controlled objects, the route being traveled, and / or the route to be traveled between the starting position (or origin) and the destination. The visual sensing system 108, GPS receiver 128, and / or map module 129 may be used to determine the position of objects and the positioning of the main vehicle 100 relative to the objects. This information may also be used to determine i) the heading information of the main vehicle 100 and / or the objects, and ii) the relative speed of the main vehicle 100 relative to the objects.

[0129] Memory 119 may store sensor data 130, vehicle parameters 132, and application program 136. Application program 136 may include applications executed by modules 107, 112, and 113. Although memory 119 and vehicle control module 107 are shown as separate devices, they can be implemented as a single device. Memory 119 may be accessible to braking control system 141 and / or steering system 142.

[0130] The vehicle control module 107 can control the operation of system 141, 142 and propulsion system 143, which may include converter / generator 146, transmission 148 and / or electric motor 160. This control may be based on parameters set by modules 107, 112, 113, 117, and 118. The vehicle control module 107 can set some of the vehicle parameters 132 based on signals received from sensors 109 and 110. The vehicle control module 107 can receive power from energy source 111, which can be supplied to the braking control system 141, converter / generator 146, transmission 148, electric motor 160, etc. Some of the vehicle control operations may include starting and running the electric motor 160, providing power to any of systems 102, 141, 142, and 143, and / or performing other operations as further described herein.

[0131] Systems 141, 142, converter / generator 146, transmission 148, brake actuator system 158, and / or electric motor 160 may include actuators controlled by vehicle control module 107 to, for example, adjust airflow, fuel flow, steering wheel angle, speed, acceleration, braking force, etc. This control may be based on the outputs of sensors 109, 110, GPS receiver 128, map module 129, and the aforementioned data and information stored in memory 119. Vehicle control module 107 can determine various vehicle parameters, including voltage, current level, vehicle speed, motor speed, motor torque, yaw angle, yaw rate, gear position, accelerometer position, brake pedal position, amount of regenerative (charging) power, understeer coefficient and / or value, oversteer coefficient and / or value, and / or other parameters. These parameters may be stored in memory 119. Propulsion system 143 may also include one or more axles 164, which include one or more differentials 166 of one or more axles 164 of the main vehicle 100. As an example, the braking control system 141 can be implemented as a brake-by-wire system, such as an electromechanical braking system or an electrohydraulic braking system. The steering system 142 can be an electric power steering system.

[0132] Figure 2 A stationary power station 200 including an example fuel cell system 202 is shown. The fuel cell system 202 includes a fuel source 204, an FCM 206, a main control module 208, a load interface 210, a transceiver 212, and a memory 214. The fuel source 204 can be a hydrogen source and an oxygen source. The FCM 206 can be configured as any FCM mentioned herein. The main control module 208 can request power from the FCM 206 and / or can control the operation of the FCM 206. The load interface 210 may include low-voltage terminals and / or high-voltage terminals for connecting to one or more loads 230. Figure 2 In this designation, the fluid line (or channel) is designated as 220, and the wire is designated as 222. Although shown as a stationary power station in which the load is separated from the stationary power station 200, the stationary power station 200 can be implemented as a machine and include a load, which includes actuators, motors, etc.

[0133] Figure 3 A control system 300 for multiple fuel cell modules (FCMs) 302, 304 is shown, which can communicate with and / or be controlled by an application control module 306. Although two FCMs are shown, any number of FCMs can be connected to the application control module 306, which can direct... Figure 1 Vehicle control module 107 Figure 2 The main control module 208 or other application control modules. Each of FCMs 302 and 304 includes a corresponding Electrical Domain Control (EDC) module 306, 308 and Fluid Domain Control (FDC) module 310, 312.

[0134] As an example, the control system 300 can be implemented in a truck application. EDC modules 306, 308 may include control code and algorithms and are capable of arbitrating multiple FCMs and communicating with a system communication gateway. FDC modules 310, 312 can drive the anode and cathode of the fuel cell stack. Data can be transferred between EDC modules 306, 308 and FDC modules 310, 312. Data and stimulus signals can be transferred between application control module 306 and EDC modules 306, 308. Control signals can be transmitted from application control module 306 to EDC modules 306, 308. Control signals can be transmitted from EDC modules 306, 308 to FDC modules 310, 312, which may or may not have been originally generated in EDC modules 306, 308. In another embodiment, application control module 306 may include FCM code and algorithms and arbitrate multiple FCMs. EDC modules 306, 308 may be switched to facilitate algorithms through features and / or include one or more hardware drivers.

[0135] Figure 4A signal and fluid flow diagram 400 of an example fuel cell system (such as any of the fuel cell systems mentioned herein) is shown. Figure 400 includes fuel cell stack energy generation 402, stack sensing 404, power conversion 406, high-voltage (HV) power distribution and sensing 408, and application load and energy storage 410. The fuel cell stack generates electrical energy, which is sensed by stack sensing 404. The power from the fuel cell stack is converted via power conversion 406, and the resulting power is distributed and sensed by HV power distribution and sensing 408. The power can be supplied to a DC-to-AC converter 420, a DC-DC converter 422, and another DC-DC converter 424, respectively, to power an air compressor 426, an HVC 428, and a hydrogen pump 430. Heat losses may occur during power conversion 406 and / or at converters 420, 422, and 424, as indicated by 426. Peripheral operating system (BOP) 432 can be used to direct fluids, including fuel, air, and coolant, to the fuel cell stack, as indicated by arrow 440. Figure 4 In the diagram, fluid lines (or channels) are represented by dashed lines 442, and electrical wires are represented by solid lines 444. Control data can be generated during stack sensing 404 and HV power distribution and sensing 408, as represented by 446, and can be used to control actuators, valves, pumps, etc.

[0136] Safety systems can be implemented during operations associated with 402, 404, 406, 408, and 410. This can include sensing voltage, current levels, temperature, etc., and performing operations based on the sensed parameters to prevent system and / or component degradation. Low voltages (e.g., 0-350V) can be used, and low-voltage operation can be implemented during fuel cell stack energy generation 402, stack sensing 404, and power conversion 406. High voltages (e.g., 400-850V) can be used, and high-voltage operation can be implemented during power conversion 406 and HV power distribution and sensing 408. DC and / or AC power can be output to one or more application loads via one or more voltage buses and / or power terminals. DC power can be provided to energy storage, which may include one or more battery packs.

[0137] Figure 5 A portion 500 of an example fuel cell system, illustrating various different sensors, is shown. Portion 500 includes a fuel cell stack 502, a first sensing circuit 504, power electronics 506, a second sensing circuit 508, and an application load and energy storage 510. The fuel cell stack may comprise a stack as an assembly of plates (e.g., stainless steel plates, graphite plates, composite plates, etc.) and membranes through which air and hydrogen pass to generate electrical energy, which is then converted into a usable voltage. Sensing circuits 504 and 508 may be... Figure 4 The stacked sensing 404 and / or HV power distribution and sensing 408 are implemented partially or completely by one or more MPEMs, examples of which are in Figure 6 As shown in the image.

[0138] The first sensing circuit 504 may include a high-voltage high-side rail 509, a high-voltage low-side rail 511, current sensors 512 and 514, voltage sensors 516, 518, and 520, a pyrotechnic discharge device 522, and a switch 524. Current sensor 512 is connected along rail 509 to the fuel cell stack 502 and power electronics 506. Current sensor 514 is connected along rail 511 to the fuel cell stack 502 and power electronics 506. Voltage sensor 516 is connected across rails 509 and 511 and is connected to current sensors 512 and 514. Voltage sensors 518 and 520 are connected in series across rails 509 and 511, and the series connection of 518 and 520 is connected in parallel with voltage sensor 516. Pyrotechnic discharge device 522 is connected in series with switch 524, and the series connection of the device is connected across rails 509 and 511, and in series and parallel with the connection of voltage sensors 518 and 520. Voltage sensors 518 and 520 and switch 524 are connected to ground. Switch 524 may be a perturbation switch used to isolate a monitor.

[0139] Current sensor 512 can be a primary DC current sensor for the fuel cell stack. Current sensor 514 can be a secondary DC current sensor for the fuel cell stack. Voltage sensor 516 can be an HV+ to HV- sensor for the fuel cell stack. Voltage sensor 518 can be an HV+ to chassis voltage sensor for the fuel cell stack. Voltage sensor 520 can be a chassis to HV- voltage sensor for the fuel cell stack. Pyrotechnic discharge device 522 can be a fast fuel cell stack discharge device.

[0140] The second sensing circuit 508 may include a high-voltage high-side rail 527, a low-voltage low-side rail 529, voltage sensors 530, 532, and 534, current sensors 536 and 537, a pyrotechnic disconnect device 538, and a pyrotechnic disconnect device 540. Voltage sensor 530 is connected across rails 527 and 529 and may be an HV+ to HV- sensor. Voltage sensors 532 and 534 are connected in series across rails 527 and 529 and connected to ground. Voltage sensor 532 may be an HV+ to chassis sensor. Voltage sensor 534 may be a chassis to HV- sensor. Current sensor 536 is on the low-side rail 529 and may be a total FCM DC current sensor. Current sensor 537 is connected along the high-side rail 527 and may be a net FCM DC current sensor. Pyrotechnic disconnect device 538 is connected along the high-side rail 527 and may be used for the HV+ terminal. Pyrotechnic disconnect device 540 is connected along the low-side rail and may be used for the HV- terminal.

[0141] Figure 6 An FCM 600 with a modular and adaptable platform is shown, which includes a fuel cell stack 602 and MPEMs 604, 606, 608, a fuel and air circuit 610, a steam transfer device 612, an air machine (or air compressor) 614, a hydrogen pump 616, and an HVC pump 618. MPEM 604 may be a power conversion module (PCM). MPEM 606 may be a power distribution control and sensing module. MPEM 608 may be an FDC module.

[0142] MPEMs 604, 606, and 608 may include subsystem modules. As an example, MPEM 604 may include subsystem module 620, and MPEM 606 may include subsystem module 622. Subsystem modules 620 and 622 may be dedicated to performing various operations further described below and may be easily accessible, serviceable, connected, enabled, replaced, and interchangeable with different subsystem modules. Components of subsystem modules 620 and 622 may also be easily accessible, serviceable, connected, enabled, replaced, and interchangeable with different components. MPEMs 604, 606, and 608 may also include one or more communication buses and terminals for communicating with other MPEMs, modules within other MPEMs, and / or other devices. MPEMs 604, 606, and 608 may also include low-voltage and / or high-voltage busbars and terminals, as well as cooling channels. As an example, MPEM 604 is shown having multiple power buses 630, communication buses 632, and cooling channels 634 that can extend across MPEM 604 and connect to MPEM 606 and / or MPEM 608. In embodiments, MPEMs 604, 606, and 608 have a common external hardpoint to allow for rearrangement of MPEMs 604, 606, and 608 in different arrangements, but have different internal hardware for performing different functional operations.

[0143] Subsystem modules 620 and 622 may be dedicated to performing various operations further described below and may be connected to power bus 630, communication bus 632, and / or cooling aisle 634. Power bus 630, communication bus 632, and cooling aisle 634 may be connected to one or more of external interfaces 636 and 638 and / or one or more other external interfaces. Power bus 630 may be a low-voltage and / or high-voltage DC and / or AC power bus. External interfaces 636 and 638 may be connected to external interfaces 640 and 642 of MPEM 608 and 606, respectively.

[0144] MPEM 606 may include another external interface 646 connected to external interface 648 of fuel cell stack housing 650. External interfaces 642 and 646 may be connected to the communication bus and / or voltage busbar 652 and cooling channel 654 of MPEM 606. MPEM 606 may include another external interface 658 connected to external interface 660 of air machine (or air compressor) 614. External interface 658 may be connected to one of the bus and busbar 652, cooling channel 654 and / or subsystem module 622. Modules 604 and 606 may have standardized cooling, such that they have cooling ports of the same shape and size and used to circulate the same coolant (or cooling fluid).

[0145] External interfaces 636, 638, 640, 642, 658, and 660 can be configured similarly or identically. Examples are provided in... Figure 11 As shown in the diagram, external interfaces 636, 638, 640, 642, 658, and 660 are standardized to allow for modular arrangements of MPEMs 604, 606, and 608. Although MPEMs 604, 606, and 608 are shown with a certain number of external interfaces, each of MPEMs 604, 606, and 608 can have any number of external interfaces as described to allow for additional connection arrangements. By having standardized (or common) external interfaces, MPEMs can be moved and connected in different arrangements.

[0146] The MPEM 606 may also include: a low-voltage data and power output interface 670 for communication and powering low-voltage loads; one or more access panels 672 to allow access to, repair, and replacement of MPEM 606 components, including the change subsystem module 622 and / or its components; a high-voltage output interface 674; a high-voltage BOP interface 676 for powering the HVC pump 618; and a high-voltage BOP interface 678 for powering the hydrogen pump 616. Although Figure 6 Not shown, but each of the subsystem modules 622 can be directly or via an internal interface connected to external interfaces 642, 646, 658, 670 (low voltage data and power output), 674 (high voltage output), 676 (HV BOP), and 678 (HV BOP). MPEM 608 may also include a low voltage data and power output interface 680.

[0147] The air machine 614 may include a cooling circuit 690 and a compressor inverter module (CPIM) communication interface 692, which can be connected to an external interface 660.

[0148] Figure 7 It shows Figure 6The modular power electronics module (MPEM) 606 (also known as a power distribution control and safety module) includes subsystem modules 622, external interfaces 642, 646, 658, output interfaces 670, 674, a service panel 672, and HVBOP interfaces 676, 678. The external interfaces may be HV BOP interfaces. HV BOP interface 658 can be connected via interface 660 to CPIM communication interface 673 and / or cooling channel 675. HV BOP interface 658 may include cooling and / or low-voltage communication terminals. Each of the subsystem modules 622 includes a corresponding functional and / or application module. For example, the first of the subsystem modules 622 is shown as including an EDC module 710, a stacked sensing module 712, a high-frequency resistance (HFR) sensing module 714, a filter module 716, a pyrotechnic module 718, and / or one or more other functional and / or application modules. The EDC module 710 can control the operation of the MPEM 606. The MPEM 606 can be controlled from, for example, by... Figure 1 Vehicle control module 107 or Figure 2 The central control module of the main control module 208 receives power request signals and / or other command signals. The power request signal requests a certain amount of power to be output from the corresponding fuel cell stack. The stack sensing module 712 monitors the state of the fuel cell stack, such as the voltage, current level, power output, and temperature of the fuel cell stack.

[0149] HFR sensing module 714 determines one or more HFRs of the fuel cell stack (or its membrane). Filtering module 716 filters the power conversion elements in PCM 604. Pyrotechnic module 718 can release current when certain conditions occur. For example, when the temperature of the fuel cell stack exceeds a set threshold, pyrotechnic module 718 can be used to discharge the fuel cell stack in the event of overvoltage or impact, and disconnect the fuel cell stack from the high-voltage bus in the event of an impact. To control the fuel cell stack temperature, coolant flow is increased, and if the temperature continues to rise, the controller will derating the power when the temperature reaches a certain threshold.

[0150] EDC module 710 enables the safety control processes mentioned herein, including safety and fault-tolerant operation. EDC module 710 can control high-voltage isolation and stack-up discharge hardware operation, smoke and fire disconnection operation, and system sensing and isolation operation for fault detection and response. EDC module 710 can be integrated with… Figure 6 The EDC module 710 can control the operation of the corresponding fuel cell stack, or a centralized control module (e.g., ...) for communicating, sharing parameters, and / or controlling these modules. Figure 1 Vehicle control module 107 or Figure 2The main control module 208 can control the operation of the fuel cell stack by instructing the EDC module 710.

[0151] As another example, the second subsystem module 622 includes an application sensing module 720, a fuse module 722, and / or one or more other functional and / or application modules. The application sensing module 720 may include and monitor application-specific sensors. The fuse module 722 may include a fuse that can be "blown" when certain conditions occur. As another example, the third subsystem module 622 includes a contactor 724 and an inverter 726.

[0152] Figure 8 It shows Figure 6 The MPEM 604 (or power conversion module). The MPEM 604 may include... Figure 6 The subsystem module 620 includes a power bus 630, a communication bus 632, a cooling channel 634, and external interfaces 636 and 638. As an example, MPEM 604 may include a power conversion module 810, a sensing module 812, an HFR (perturbation) module 814, a filtering module 816, and / or other functional and / or application modules. The power conversion module 810 converts DC power from the corresponding fuel cell stack into DC and AC voltages for output to one or more loads. The stack feeds power from busbar 652 to the power bus 630, and the power bus 630 distributes power to one or more power conversion modules. The converted power is then returned to module 606 via an output-side bus (not shown), which may be another power bus located in each of modules 604 and 606 and may be connected to external interfaces 638 and 642. The output-side bus is then used to distribute power from 606 to application loads outside module 606 via, for example, an HV output 674. External interfaces 538 and 540 can be used to isolate the fuel cell module from the application load. DC and AC voltages can be supplied via power bus 630. Figure 7 The busbar 652 can then provide DC and AC voltages to the LV output interface 670 and the HV output interface 674. The sensing module 812 measures the voltage, current, and temperature of other terminals and / or components of the fuel cell stack and / or the corresponding FCM. The sensors monitored by the sensing module 812 can interact with... Figure 7 The sensors monitored by the stack sensing module 712 are separate and monitor the voltage, current levels, and / or temperature of the same or different terminals and / or components of the FCM. The sensors monitored by the sensing module 812 and the stack sensing module 712 can be located on the fuel cell stack, outside the fuel cell stack and separate from the fuel cell stack, in MPEM 604, 606, or other locations. Modules 814, 816 can be similar to... Figure 7 Operations of modules 714 and 716.

[0153] Figure 9 It shows Figure 6 The MPEM 608 (or fluid domain control module) may include a hardware driver 912, a fuse 914, a main LIN 916, and / or other functional and / or application modules. The MPEM 608 can control the status of valves, pumps, actuators, air machines, etc., and monitor various sensors. In this embodiment, the control and monitoring are minimized and controlled by… Figure 7 EDC module 710 or centralized control module (e.g., Figure 1 Vehicle control module 107 or Figure 2 The main control module 208 executes the commands. The MPEM 608 can control... Figure 6 The FCM 600 includes fuel and air circuits 610, pumps 616, 618, and / or other equipment. The MPEM 608 may include an external interface 640 and an LV data and power interface 680.

[0154] although Figures 7 to 9 Each of the subsystem modules in MPEMs 604, 606, and 608 is shown as having certain functional and / or application modules, but each of the subsystem modules may include additional or other functional and / or application modules. Furthermore, the functional and / or application modules shown as implemented by MPEM 604 may be implemented by MPEM 606, and vice versa. Figures 7 to 9 MPEM604, 606, and 608 are shown without internal interfaces and without external interfaces for connecting to subsystem modules. MPEM604, 606, and 608 may include and / or connect to external interfaces, and may include internal interfaces. Examples of these interfaces are provided in... Figures 11 to 12 As shown in the figure. In embodiments, the functional and / or application modules of each of MPEM604, 606, and 608 include the same type on internal and / or external interfaces to allow the functional and / or application modules to be arranged in different orders and connected differently for different applications.

[0155] Figure 10 The MPEM 1000 is shown, which can represent Figures 6 to 9 Each of MPEMs 604, 606, and 608 illustrates the internal and external interfaces relative to the subsystem module. MPEM 1000 includes subsystem module 1002, which includes an internal interface 1004 and an external interface 1006. The external interface can represent... Figure 6External interfaces 636, 638, 640, 642, 646, 658 and / or similar interfaces are configured. Subsystem module 1002 may include any of the functional and / or application modules mentioned herein.

[0156] Figure 11 It shows what can be represented Figures 6 to 10 External interface 1100 is any one of the external interfaces. External interface 1100 may include: a communication connector 1102 having a communication signal terminal 1103 (e.g., current or voltage signal) and a power terminal 1104; a hot and cold cooling channel 1105; and a positive and negative high voltage bus bar 1106 and corresponding terminals.

[0157] Figure 12 It shows what can be represented Figure 10 Example internal interface 1200 of any of the internal interfaces. Internal interface 1200 may include: a communication connector 1202 having a communication signal terminal 1203 (e.g., current or voltage signal) and a power supply terminal 1204; and positive and negative high voltage busbars 1206 and corresponding terminals.

[0158] The subsystem modules mentioned above can be similar to Figures 13 to 18 Any of the subsystem modules is configured, wherein the internal interface may include any of the connectors, terminals and / or busbars mentioned below.

[0159] Figure 13 A subsystem module 1300 with a through-cooling loop is shown, the through-cooling loop including an input channel 1302 and an output channel 1304 that provide internal and / or through-cooling. Figure 14 An example subsystem module 1400 is shown, having a non-through cooling loop including an input channel 1402 and an output channel 1404. Figure 15 An example subsystem module 1500 with a low-voltage electrical pass-through circuit is shown, which includes an input connector 1502 and an output connector 1504. Terminals of the input connector 1502 can be connected to components within the subsystem module 1500 and to terminals of the output connector 1504. The terminals of connectors 1502 and 1504 may include communication terminals and power terminals.

[0160] Figure 16 An example subsystem module 1600 with a low-voltage electrical non-pass circuit is shown. The low-voltage electrical non-pass circuit includes a connector 1602, which may include input and / or output terminals, including communication terminals and power terminals. Figure 17An example subsystem module 1700 with a high-voltage electrical pass-through circuit is shown, which includes a terminal 1702 that can be connected to a first or more busbars and a terminal 1704 that can be connected to a second or more busbars. Figure 18 An example subsystem module 1800 with a high-voltage electrical non-pass circuit is shown, which may include one or more input terminals 1802 and one or more output terminals 1804.

[0161] Figure 19 It shows Figure 6 The FCM600 is layered as shown in 1900. The MPEM of the FCM can be implemented as layers stacked on the fuel cell stack 1902. These layers can be implemented in one or more side boxes physically connected to the housing (or casing) of the fuel cell stack 1902. As an example, each layer can have four sidewalls and open ends. The sidewalls of each layer are then stacked, and the components of the layers are joined together. One or more stacks of the resulting layers are attached to the housing of the fuel cell stack 1902. Several example layers are shown, and they may include a cooling layer 1904, a stack HV layer 1906, a control panel layer 1908 with a substructure housing, and an application voltage layer 1910. A safety and service layer 1912 may be coupled to layers 1906, 1908, and 1910. Layers 1904, 1906, 1908, and 1910 may be disposed between the FCM boundary stack side 1914 and the FCM boundary 1916. An integrated HV module 1920 for HVC pumps and hydrogen pumps can be connected to the application voltage layer 1910 and the FCM boundary 1916. The FCM boundary stack side 1914 may include connection points 1922 and 1924. The FCM boundary 1916 may include HV connection point 1926 and access panel 1928. A cooling layer 1930 can be connected to layers 1908 and 1910.

[0162] Although layers 1904, 1906, 1908, 1910, 1912, and 1930 are shown in a specific arrangement and stacked in a specific order, layers 1904, 1906, 1908, 1910, 1912, and 1930 may be arranged differently and / or stacked in a different order. In embodiments, layers 1904, 1906, 1908, 1910, 1912, and 1930 have standardized interfaces, such as the external and internal interfaces mentioned herein, to allow the layers to be connected in different arrangements.

[0163] Figure 20A functional block diagram of part 2000 of the FCM in a first (or centralized) arrangement is shown. Part 2000 includes a power conversion module (PCM) 2002, a power distribution control and sensing module (PDCSM) 2004, a fuel cell stack 2006, a compressor inverter module 2008, an air compressor 2010, an HVC pump 2012, and a hydrogen pump 2014. In this example, PCM 2002 and PDCSM 2004 are connected via an external interface (…). Figure 20 (Not shown, but can be configured similarly to any of the external interfaces disclosed herein) to be connected to the fuel cell stack 2006 and to each other.

[0164] Figure 21 A functional block diagram of portion 2100 of the FCM in a second (or stacked) arrangement is shown. Portion 2100 includes PCM 2102, PDCSM 2104, fuel cell stack 2106, compressor inverter module 2108, air compressor 2110, HVC pump 2112, and hydrogen pump 2114. In this example, PCM 2102 is coupled to fuel cell stack 2106 and is coupled between fuel cell stack 2106 and PDCSM 2104. PCM 2102 can be connected via an external interface (…). Figure 21 (Not shown, but can be configured similarly to any of the external interfaces disclosed herein) is connected to fuel cell stack 2106 and PDCSM 2104. In another embodiment, PDCSM 2104 is connected between fuel cell stack 2106 and PCM 2102.

[0165] Figure 22 A portion 2200 of the FCM in a third (or centralized) arrangement is shown. Portion 2200 includes a fuel cell stack 2202, a PCM 2204, and a PDCSM 2206. The PCM 2204 is coupled on top of the fuel cell stack 2202 and the PDCSM 2206. This can be achieved via an external interface disclosed herein. The PDCSM 2206 may include, for example, a “punch” 2210, which can be removed when additional subsystem modules are added to the PDCSM 2206.

[0166] Figure 23A portion 2300 of the FCM in a fourth (or stacked) arrangement is shown. Portion 2300 includes a fuel cell stack 2302, a PCM 2304, and a PDCSM 2306. The PDCSM 2306 is coupled between the PCM 2304 and the fuel cell stack 2302, and is coupled to both via external interfaces as disclosed herein. The PDCSM 2306 may include, for example, a punched portion 2310, which can be removed when an additional subsystem module is added to the PDCSM 2306.

[0167] Figure 24 It shows a similar Figure 22 The arrangement includes a portion 2400 of the FCM, having access panels 2402 and 2404. The portion 2400 includes a PCM 2410, a PDCSM 2412, and a fuel cell stack 2414. Access panels 2402 and 2404 provide maintenance, repair, and tooling windows for accessing, repairing, and replacing components and modules of the PCM 2410 and PDCSM 2412. This allows for easy modification, replacement, and reconfiguration of subsystem modules of the PCM 2410 and PDCSM 2412. An O-ring 2424 may be disposed between the PCM 2410 and PDCSM 2412 and around openings 2426 and / or external interfaces of the PCM 2410 and PDCSM 2412. A tortuous path 2430 for liquids may be included in the PDCSM 2412 and between the PCM 2410 and PDCSM 2412. A pair of busbars 2432 and 2434 are shown and connected to the subsystem modules of PCM 2410 and PDCSM 2412.

[0168] Figures 25 to 26 An example subsystem module with distributed functionality is shown. Figure 25 An example subsystem module 2500 is shown, which includes a busbar 2502, a stacked sensing module 2504, an HFR sensing module 2506, a pyrotechnics module 2508, a filtering module 2510, and an EDC control module 2512. Busbar 2502 and modules 2504, 2506, 2508, 2510, and 2512 can be configured and function similarly to other similarly named busbars and modules mentioned herein.

[0169] Figure 26Another example subsystem module 2600 is shown, which includes a filtering module 2602, an application sensing module 2604, a fuse module 2605, a pyrotechnics module 2606, a busbar 2608, and an HV data and power output interface 2610. Modules 2602, 2604, 2605, 2606, and busbar 2608 can be configured and function similarly to other similarly named busbars and modules mentioned herein.

[0170] Figure 27 An example subsystem module (or layer) 2700 is shown, which can be... Figure 25 An example of subsystem module 2500 is provided, configured to perform fuel cell stack sensing, busbar cooling, and filtering. Layer 2700 includes busbar 2702, connector 2704, sensing, cooling, and filtering components (shown as current sensor 2706), short-circuit device (e.g., pyrotechnic device 2708), interface 2710, and internal interface 2712. Interface 2710 can be an external interface or an internal interface. Busbar 2702, connector 2704, and sensing, cooling, and filtering components 2706 can be mounted on substrate 2720. Short-circuit device 2708 and interfaces 2710, 2712 can be mounted on substrate 2720 or can be detached from substrate 2720. Connector 2704 can be an external interface.

[0171] Figure 28 The subsystem module (or layer) 2800 is shown, which can be... Figure 26 An example of subsystem module 2600. Subsystem module 2800 may include pyrotechnic device 2802 and fuses 2804, 2806, which are connected to busbar 2808 and mounted on substrate 2810, substrate 2810 may include sensors ( Figure 28 (Not shown in the image). Subsystem module 2800 may include: Figure 27 The interface 2710 and another internal interface 2810 that can be connected to the busbar 2808 and the pyrotechnic device 2802; and the connector 2804, which can be an external interface.

[0172] Figure 29 The stacking is shown Figure 27 On the subsystem module 2700 Figure 28Subsystem module 2800. Subsystem modules 2700 and 2800 can be installed in and / or mounted to a non-repeating hardware housing 2910, which can be connected to a fuel cell stack. The non-repeating hardware housing 2910 includes non-repeating hardware. This may include hardware for fuel cell stacks where multiple units do not exist. The non-repeating hardware housing 2910 and / or the corresponding cooling layer may include hot cooling channels 2912 and cold cooling channels 2914. Fuse 2806 and busbar 2808 are connected to CPIM interface 2920. Some of the busbars are connected to HV main connector 2940, and other busbars can be connected to HVC pump and hydrogen pump connector 2942.

[0173] Figure 30 This is a perspective view of the PCM power bricks 3000, 3002, 3004, and 3006. Power bricks 3000, 3002, 3004, and 3006 can each have corresponding HV+ and HV- busbars 3010 that can be connected in parallel, as shown below. Figure 31 As shown in the figure. As an example, each of the power bricks 3000, 3002, 3004, and 3006 can output 50 kilowatts of power. Figure 31 The parallel connection of HV terminals 3012 of HV+ and HV- busbars 3010 and power bricks 3000, 3002, 3004, and 3006 in the first arrangement is shown. Figure 32 The diagram shows an end view of the busbar 2010 and HV terminals of the power bricks 3000, 3002, 3004, and 3006 in the second arrangement. The busbar 3010 can be connected to the PDCSM 3014.

[0174] Each of the power bricks 3000, 3002, 3004, and 3006 can be configured to be identical. Regarding... Figures 33 to 36 The following items shown can be included in each of power bricks 3000, 3002, 3004, and 3006. Figure 33 The passage cut at the cutting plane AA is shown. Figure 30 A cross-sectional view 3300 of the power brick 3000. Cross-sectional view 3300 includes side cooling channels 3302, inductors L1 and L2, a hot plate 3304, and a power module 3306. The hot plate 3304 engages with the next module in the power brick 3000 for shared cooling.

[0175] Figure 34 The passage cut at the cross-section plane BB is shown. Figure 30A cross-sectional view 3400 of the power block 3002 is shown. The power block 3002 includes inductors L1, L2, a central cooling channel 3402, and a capacitor 3406. Based on the power conversion characteristics, the power block 3002 may contain multiple sets of connected power inductors or individual inductors. In an embodiment, the power block 3002 operates in multiples of three power phases to allow hardware conversion between a DC-DC converter and a DC-DC inverter.

[0176] Figure 35 The passage cut at the cross-section plane CC is shown. Figure 30 A cross-sectional view 3500 of the power brick 3004. The power brick 3004 includes a capacitor 3502, a control board 3504, an electromagnetic interference shield 3506 on a plastic housing, and a power module 3508.

[0177] Figure 36 The passage cut at the cutting plane DD is shown. Figure 30 A cross-sectional view 3600 of the power brick 3006. The power brick 3006 includes a capacitor 3602, a control board 3604, a coolant pipe 3606, and a three-phase output terminal 3608 for a three-phase system for DC-AC, but may be a two-terminal output for DC-DC.

[0178] The examples above include modular fuel cell electrical architectures that implement fuel cell stack sensing, safety systems, power conversion, power distribution, and control hardware designed to manage the operation of peripheral devices. Examples include interchangeable stack sensing modules designed to meet the core control data requirements of corresponding fuel cell systems and subsystems. Stack sensing modules can be integrated into non-repetitive hardware within the corresponding fuel cell stack and can be configured to have different levels of sensing robustness based on application requirements.

[0179] Examples also include modular safety systems with system isolation sensing, stacked discharge mechanisms, high-voltage disconnection, and pyrotechnic or solid-state disconnection. This ensures system safety during unsafe conditions on the electrical bus. In embodiments, the modular safety system is designed to operate independently of the control architecture when needed.

[0180] Examples include power conversion modules that are modular and support both isolated and non-isolated DC / DC and DC / AC converters for power conditioning and distribution. These modules provide flexible power output to energy storage, the grid, and direct DC loads.

[0181] Examples include power distribution systems comprising high-voltage busbars, fuses, and connectors, designed to efficiently and safely deliver power from the fuel cell stack to the application load. These power distribution systems can be reconfigured with minimal impact on major tooling and processes.

[0182] Depending on application requirements, examples include configurable EDC modules that can act as master controllers, domain controllers, and data aggregators. EDC modules support multiple communication protocols (e.g., CAN, Ethernet, etc.) and integrate with fluid and electrical subsystems.

[0183] The examples above offer scalability and flexibility. The disclosed modular architecture allows for customization based on application requirements. For example, different power converters (DC / DC, DC / AC) and safety components can be integrated into the architecture without requiring changes to the design of the power converter or fuel cell stack. This flexibility is particularly useful in systems that need to meet evolving requirements.

[0184] The example also demonstrates ease of integration. The disclosed modular architecture supports multi-channel communication protocols, which ensures that the fuel cell system can be easily integrated into a wide range of applications, including automotive, industrial, and energy sector applications.

[0185] The example also provides improved safety and fault tolerance. The fuel cell system includes built-in high-voltage isolation and stack discharge hardware to ensure safe operation. Modular safety features, including fire disconnect and system isolation sensing, provide robust fault detection and response. This improves overall system reliability through the decoupling of the hardware.

[0186] The examples also provide adaptable sensing and monitoring. The stacked sensing components can be configured to meet a wide range of robustness requirements, ensuring that critical control data is captured while also providing flexibility for different use cases. The examples also offer power conversion flexibility. The fuel cell system supports both non-isolated and isolated power converters, enabling flexible power regulation for applications such as grid output, energy storage, and direct DC use.

[0187] The examples also provide a single platform adaptable to different electrical components and configurations, enabling a more efficient development process and faster deployment for fuel cell applications. The examples include multi-functional control. One or more of the disclosed control modules are designed to be multi-functional and capable of controlling fluids and managing electrical subsystems. This allows the control modules to adapt to various system architectures.

[0188] The example also implements robust safety protocols. The integration of fire disconnect and active / passive discharge hardware enhances safety and prevents potential failures, providing a fail-safe system for high-power applications. The example also demonstrates supply chain robustness. Electrical system functional partitioning enables robust fuel cell power electronics supply chain development, which reduces commercialization costs in the long run.

[0189] The example minimizes the number and size of components while providing modularity for components and modules, increasing design and layout flexibility. The example eliminates the number and length of external cables, conduits, and other components.

[0190] The preceding description is illustrative in nature and is in no way intended to limit this disclosure, its application, or use. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, specification, and appended claims. It should be understood that one or more steps in the method may be performed in different orders (or simultaneously) without altering the principles of this disclosure. Furthermore, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented and / or combined with features of any other embodiment, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments with respect to each other remains within the scope of this disclosure.

[0191] Spatial and functional relationships between components (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “joined,” “linked,” “adjacent,” “right next to,” “on top of,” “above,” “below,” and “set on.” Unless explicitly described as “direct,” when describing the relationship between the first and second components in the foregoing disclosure, the relationship can be a direct relationship in which no other intermediate components exist between the first and second components, or an indirect relationship (spatially or functionally) in which one or more intermediate components exist between the first and second components. As used herein, the phrase “at least one of A, B, and C” should be interpreted as indicating logic using the non-exclusive logic “OR” (A or B or C) and should not be interpreted as indicating “at least one of A, at least one of B, and at least one of C.”

[0192] In the accompanying drawings, the direction of the arrow, as indicated by the arrowhead, typically represents the flow of information (such as data or instructions) of interest in the illustration. For example, when components A and B exchange various types of information, but the information transmitted from component A to component B is relevant to the illustration, the arrow may point from component A to component B. This unidirectional arrow does not imply that no other information is transmitted from component B to component A. Furthermore, for information sent from component A to component B, component B may send a request for the information to component A or receive an acknowledgment.

[0193] In this application, including the following definitions, the term "module" or "controller" may be replaced by the term "circuit". The term "module" may refer to, be a part of, or include: 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 circuitry (shared, dedicated, or group) that executes code; memory circuitry (shared, dedicated, or group) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality; or some or all of the foregoing, such as in a system-on-a-chip.

[0194] A module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module disclosed herein may be distributed across multiple modules connected via the interface circuits. For example, multiple modules may allow for load balancing. In another example, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0195] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuitry" covers a single processor circuitry that executes some or all of the code from multiple modules. The term "group processor circuitry" covers a processor circuitry that, in conjunction with additional processor circuitry, executes some or all of the code from one or more modules. References to multiple processor circuitry cover multiple processor circuitry on a discrete die, multiple processor circuitry on a single die, multiple cores of a single processor circuitry, multiple threads of a single processor circuitry, or a combination thereof. The term "shared memory circuitry" covers a single memory circuitry that stores some or all of the code from multiple modules. The term "group processor circuitry" covers a memory circuitry that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0196] The term "memory circuit" is a subset of the term "computer-readable medium." As used herein, the term "computer-readable medium" does not cover transient electrical or electromagnetic signals propagated through a medium (such as a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0197] The apparatus and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The function blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a skilled technician or programmer.

[0198] A computer program includes processor-executable instructions stored on at least one non-transitory, tangible, computer-readable medium. A computer program may also include or depend on stored data. A computer program may encompass a basic input / output system (BIOS) that interacts with the hardware of a special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0199] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation), (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code executed by an interpreter, (v) source code compiled and executed by a just-in-time (JIT) compiler, and so on. As an example only, source code may be written using the syntax of languages ​​including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, etc. Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language 5th Edition), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK and

Claims

1. A fuel cell module, comprising: A fuel cell stack, comprising one or more first external interfaces; and Multiple modular power electronic modules (MPEMs), wherein each of the multiple MPEMs includes At least one subsystem module is configured to perform operations relating to the fuel cell stack; and One or more corresponding external interfaces, each of which is standardized and configured to connect to each of the first one or more external interfaces, wherein one or more external interfaces of one of the plurality of MPEMs is configured to connect to other external interfaces of the other MPEMs of the plurality of MPEMs.

2. The fuel cell module according to claim 1, wherein, Each of the first one or more external interfaces and each of the one or more external interfaces of the plurality of MPEMs includes a communication bus terminal and a power supply terminal.

3. The fuel cell module according to claim 2, wherein, Each of the first one or more external interfaces and each of the one or more external interfaces of the plurality of MPEMs includes a cooling channel.

4. The fuel cell module according to claim 2, wherein, The power supply terminals include low-voltage terminals with a voltage of less than or equal to 48V and high-voltage terminals with a voltage of greater than or equal to 50V.

5. The fuel cell module according to claim 1, wherein: Each of the plurality of MPEMs includes a plurality of subsystem modules, the plurality of subsystem modules including at least one subsystem module corresponding to one of the plurality of MPEMs; and Each of the plurality of subsystem modules includes at least one internal interface, which is standardized to connect one of the internal interfaces of the plurality of subsystem modules corresponding to one of the plurality of MPEMs to each other.

6. The fuel cell module according to claim 5, wherein, The plurality of MPEMs include: The first MPEM, which includes or is implemented as a power conversion module (PCM); and The second MPEM is implemented as a power distribution control and safety module (PDCSM).

7. The fuel cell module according to claim 6, wherein, The first MPEM includes at least one of a power conversion module, a sensing module, a high-frequency resistance sensing module, and a filtering module.

8. A means of transport, comprising: One or more of the fuel cell modules according to claim 1, wherein the fuel cell module is configured to generate electrical energy and includes an electrical domain control module; and A vehicle control module is configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and to control the distribution of electrical energy to the vehicle's equipment.

9. A stationary power station, comprising: One or more of the fuel cell modules according to claim 1, wherein the fuel cell module is configured to generate electrical energy and includes an electrical domain control module; and The main control module is configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and control the distribution of electrical energy to loads connected to the stationary power station.

10. A fuel cell module, comprising: A fuel cell stack, comprising one or more first external interfaces; and Multiple modular power electronic modules (MPEMs), wherein each of the multiple MPEMs includes At least one subsystem module is configured to perform operations relating to the fuel cell stack; and One or more corresponding external interfaces, each of which is standardized and configured to connect to each of the first one or more external interfaces, wherein one or more external interfaces of one of the plurality of MPEMs are configured to connect to other external interfaces of the other MPEMs in the plurality of MPEMs. Among them, the plurality of MPEMs include The first MPEM includes a power conversion module and a filtering module, and The second MPEM includes a stacked sensing module, a high-frequency resistance sensing module, a filtering module, an application sensing module, a fuse module, and a pyrotechnics module.

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