Solid oxide fuel cell electric control system for preventing performance degradation

Abstract

This invention provides a solid oxide fuel cell electronic control system to prevent performance degradation, comprising a core control unit, a power module, a sensing and detection unit, and an intake drive unit. The intake drive unit has a dual-redundant structure, including an independent first intake branch and a second intake branch, each branch being independently configured with an intake drive fan and an on / off control valve. The sensing and detection unit includes an intake pressure sensor, an energy data sensor, and a core temperature sensor, all electrically connected to the core control unit. The core control unit is configured to acquire the intake pressure and automatically switch the working branch to ensure continuous intake when the intake pressure is lower than a preset minimum threshold. Simultaneously, it acquires the stack operating parameters and adjusts the speed of the intake drive fan in the current working branch in real time according to a pre-stored optimal intake model to match the optimal intake flow rate. This effectively prevents performance degradation caused by gas interruption and intake mismatch.

Description

Technical Field

[0001] This invention relates to the field of solid oxide fuel cell technology, and more particularly to an electronic control system for solid oxide fuel cells that prevents performance degradation. Background Technology

[0002] Solid oxide fuel cells (SOFCs) generate electricity through the electrochemical reaction between fuel and air. The stability and flow matching of the air intake directly affect the operating life and performance of SOFCs.

[0003] Existing SOFC electronic control systems generally suffer from two core defects: First, insufficient air intake stability. Most systems employ a single-entry air intake structure, which can lead to air supply interruptions if problems such as filter blockage, fan failure, or pipeline leakage occur. This can cause irreversible damage to the SOFC stack due to sudden temperature changes and anodizing, resulting in permanent performance degradation. Second, poor air intake matching. The air intake flow rate is often a fixed value or only roughly adjusted according to the fuel flow rate, failing to match the optimal air intake requirements of the SOFC under different operating conditions. Insufficient air intake can lead to incomplete fuel reaction, producing carbon deposits that clog porous electrodes. Excessive air intake can cause a large amount of heat to be carried away by excess air, reducing power generation efficiency and causing thermal stress fatigue. Both of these factors can gradually lead to SOFC performance degradation over long-term operation.

[0004] Therefore, how to prevent performance degradation caused by intake interruption and how to match the optimal intake volume to delay long-term performance degradation are technical problems that urgently need to be solved by those skilled in the art. Summary of the Invention This invention provides a solid oxide fuel cell electronic control system to prevent performance degradation, which can prevent performance degradation caused by air intake interruption and match the optimal air intake to delay long-term performance degradation.

[0005] On one hand, the present invention provides an electronic control system for solid oxide fuel cells to prevent performance degradation, comprising: Core control unit, power module, sensing and detection unit, and intake drive unit; The intake drive unit has a dual-redundant structure, including a first intake branch and a second intake branch that are independent of each other. Each branch is independently equipped with an intake drive fan and an on / off control valve. The sensing and detection unit includes an intake pressure sensor installed in the main intake pipeline, and an energy data sensor and a core temperature sensor installed in the solid oxide fuel cell stack; the intake pressure sensor, the energy data sensor, the core temperature sensor, the on / off control valves of the two branches, and the intake drive fan are all electrically connected to the core control unit. The core control unit is configured to: acquire the intake pressure collected by the intake pressure sensor; when the intake pressure is lower than a preset minimum pressure threshold, automatically switch the working branch to ensure continuous intake; simultaneously, acquire the stack operating parameters collected by the power data sensor and the core temperature sensor, and adjust the speed of the intake drive fan of the current working branch in real time according to the pre-stored optimal intake model to match the optimal intake flow rate under the current operating conditions.

[0006] The solid oxide fuel cell electronic control system provided by this invention for preventing performance degradation employs a dual-redundant structure comprising an independent first and second intake branch, and a core control unit that acquires intake pressure signals in real time. When the intake pressure falls below a preset minimum threshold, the operating branch is automatically switched to prevent performance degradation caused by intake interruption. Simultaneously, the system collects stack operating parameters in real time and adjusts the speed of the intake drive fan in the operating branch according to a pre-stored optimal intake model to match the optimal intake flow rate. This delays long-term performance degradation caused by intake mismatch and improves the stability and service life of the solid oxide fuel cell. Attached Figure Description

[0007] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0008] Figure 1 This is a schematic diagram of the structure of the solid oxide fuel cell electronic control system for preventing performance degradation provided in an embodiment of the present invention; Figure 2 This is the logic control diagram of the solid oxide fuel cell electronic control system of the present invention. Detailed Implementation

[0009] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0010] Figure 1 This is a schematic diagram of the structure of the solid oxide fuel cell electronic control system for preventing performance degradation provided in an embodiment of the present invention. Figure 1As shown, the solid oxide fuel cell electronic control system for preventing performance degradation in this embodiment may include a core control unit 1, a power module 2, a sensing and detection unit 5, and an intake drive unit.

[0011] The intake drive unit has a dual-redundant structure, including an independent first intake branch 3 and a second intake branch 4. Each branch is independently equipped with an intake drive fan (first intake drive fan 31 and second intake drive fan 41) and an on / off control valve (first on / off control valve 32 and second on / off control valve 42). The sensing and detection unit 5 includes an intake pressure sensor 51 installed in the main intake pipeline, and an energy data sensor 52 and a core temperature sensor 53 installed in the solid oxide fuel cell stack 7; the intake pressure sensor 51, the energy data sensor 52, the core temperature sensor 53, the on / off control valves of the two branches, and the intake drive fan are all electrically connected to the core control unit 1. The core control unit 1 is configured to: acquire the intake pressure collected by the intake pressure sensor 51; when the intake pressure is lower than a preset minimum pressure threshold, automatically switch the working branch to ensure continuous intake; at the same time, acquire the stack operating parameters collected by the power data sensor 52 and the core temperature sensor 53, and adjust the speed of the intake drive fan 31 or 41 of the current working branch in real time according to the pre-stored optimal intake model to match the optimal intake flow rate under the current operating conditions.

[0012] In detail, such as Figure 1 As shown, the core control unit 1 can adopt an ARM architecture embedded controller. The intake drive unit includes a first intake branch 3 and a second intake branch 4, each branch independently configured with an intake drive fan and an on / off control valve. The outputs of the two branches are combined and connected to the air inlet of the SOFC stack 7. After system startup, the first intake branch 3 is in operation by default, and the second intake branch 4 is in hot standby mode (the second on / off control valve 42 is closed, and the second fan 41 is on standby). The intake pressure sensor 51 is installed on the main intake pipe to detect the supply pressure in real time. The power data sensor and the core temperature sensor 53 are installed on the stack.

[0013] The core control unit 1 internally stores a preset minimum pressure threshold, which is calculated based on the minimum airflow required for the SOFC stack 7 to maintain basic electrochemical reactions, for example, set to 70% of the normal operating pressure. The core control unit 1 periodically reads the value of the intake pressure sensor 51. When the pressure value is higher than the threshold, the system considers the current operating branch normal and does not switch. When the pressure value continues to drop below the threshold, the core control unit 1 determines that the current operating branch has malfunctioned (such as fan failure or filter blockage). At this time, the core control unit 1 immediately outputs a control signal: shutting off the first on / off control valve 32 to stop the first intake drive fan 31; simultaneously opening the second on / off control valve 42 and starting the second intake drive fan 41. The entire switching process is completed within 1 second; although the total pipeline pressure fluctuates briefly, it will not drop to zero, thus ensuring the continuity of air intake.

[0014] During normal power generation, the core control unit 1 continuously collects data from the power data sensor and the core temperature sensor 53 to calculate the real-time output power and core temperature. The pre-stored optimal air intake model is an empirical function or lookup table that can output an optimal air intake flow target value based on the current power and temperature. The core control unit 1 converts this target value into a PWM signal to adjust the speed of the air intake drive fan in the current operating branch, ensuring that the actual air intake volume follows the target value in real time. When the power increases or the temperature decreases, the target value increases, and the fan accelerates; conversely, the fan decelerates.

[0015] This embodiment eliminates the risk of gas interruption in single-path air intake through a dual-path redundancy structure and a pressure-triggered automatic switching mechanism; through multi-parameter closed-loop control and an optimal air intake model, it achieves dynamic matching between the air intake volume and the actual operating conditions of the fuel cell stack, avoiding carbon buildup and thermal stress damage, and effectively delaying long-term performance degradation.

[0016] In some embodiments, the core control unit 1 has a built-in optimal air-fuel ratio calibration model as the optimal intake model. The optimal air-fuel ratio calibration model stores the optimal intake flow rate calibration values ​​corresponding to different output powers and different core temperatures. The core control unit 1 queries the optimal air-fuel ratio calibration model to obtain the corresponding optimal intake flow rate calibration value based on the real-time output power and real-time core temperature in the stack operating parameters, and outputs a pulse width modulation speed control signal based on the calibration value to adjust the intake volume of the intake drive fan in the current working branch.

[0017] In detail, the core control unit 1 internal memory contains an optimal air-fuel ratio calibration model. This model stores, in the form of a two-dimensional array, the optimal intake flow rate calibration values, obtained in advance through numerous experiments, under different output power levels (e.g., from 0 to rated power, in 100W intervals) and different core temperature ranges (e.g., 500℃-800℃, in 10℃ intervals). These calibration values ​​ensure that the power generation efficiency of the fuel cell stack is the highest, the carbon deposition rate is the lowest, and the thermal stress is minimized under these operating conditions.

[0018] During real-time system operation, the core control unit 1 first calculates the instantaneous output power P of the fuel cell stack based on data from the power data sensor and reads the current temperature T from the core temperature sensor 53. Then, using P and T as indices, the core control unit 1 performs a lookup operation in the optimal air-fuel ratio calibration model to find the calibration value Q_opt that is closest to the current P and T. Next, the core control unit 1 converts Q_opt into the corresponding speed command based on the fan characteristic curve and outputs a pulse width modulation signal with the corresponding duty cycle to the intake drive fan of the current working branch. This signal controls the fan speed by changing the average voltage of the fan motor coil, thereby ensuring that the actual intake flow rate is precisely stabilized near Q_opt.

[0019] This embodiment achieves rapid and accurate querying and control of the optimal intake airflow through a pre-calibrated optimal air-fuel ratio model, avoiding complex online calculations, improving the system's real-time performance and control accuracy, and ensuring that the fuel cell stack can obtain the most suitable air supply under various operating conditions, thereby effectively delaying performance degradation.

[0020] In some embodiments, the core control unit 1 is further configured to: During steady-state operation of the system, the core control unit 1 records the current output power, core temperature, actual air intake flow rate, and fluctuation range of the stack output voltage. When the fluctuation of the output voltage exceeds the preset fluctuation threshold, the core control unit 1 determines that the current calibration value deviates from the optimal value, and gradually adjusts the speed of the intake drive fan 31 or 41 with a preset step size until the output voltage fluctuation falls back to within the preset fluctuation threshold. The correspondence between the adjusted intake flow rate and the current output power and core temperature is stored as a new calibration value in the optimal air-fuel ratio calibration model.

[0021] In detail, the core control unit 1 is equipped with an output voltage fluctuation monitoring module. After the system enters steady-state operation (i.e., the output power change rate is less than a certain value and remains so for a certain period of time), this module continuously records the peak-to-peak value or standard deviation of the output voltage as the output voltage fluctuation amplitude. The core control unit 1 also stores a preset fluctuation threshold, such as 2% of the rated voltage.

[0022] When the monitored output voltage fluctuation exceeds the threshold, the core control unit 1 determines that the optimal intake flow rate calibration value obtained from the calibration model has deviated from the true optimal value due to factors such as stack aging, changes in ambient pressure, or fluctuations in fuel composition. At this point, the system initiates an adaptive optimization program. This program starts with the current actual intake flow rate and attempts to increase the intake flow rate in preset small steps (e.g., 1% of the maximum turbine speed). After each adjustment, the system waits a few seconds for the stack to respond and then recalculates the output voltage fluctuation. If the fluctuation decreases, the adjustment continues in the same direction; if the fluctuation increases, the adjustment reverses (i.e., the intake flow rate decreases). This process iterates repeatedly until the output voltage fluctuation decreases to within the preset fluctuation threshold. At this point, the system stores the finally stabilized intake flow rate value, along with the currently recorded output power and core temperature, as a new calibration value triplet in the optimal air-fuel ratio calibration model, overwriting or supplementing the original calibration value.

[0023] This embodiment introduces an online adaptive correction mechanism, enabling the optimal intake model to self-calibrate in response to the slow changes in fuel cell stack performance, thus maintaining optimal control performance and avoiding control deviations caused by model fixation, further delaying performance degradation during long-term operation.

[0024] In some embodiments, the core control unit 1 is further configured to: When it is determined that the intake pressure is lower than the preset minimum pressure threshold and a branch switching is triggered, the pressure difference and pressure change rate between the current intake pressure and the normal operating pressure are calculated. If the pressure difference exceeds a preset pressure difference threshold and the pressure change rate exceeds a preset change rate threshold, it is determined to be a sudden gas outage fault. The switching time is shortened to within a preset rapid switching time, and the faulty branch is locked to prevent automatic recovery.

[0025] In detail, the core control unit 1 stores not only the preset minimum pressure threshold, but also the normal operating pressure value (e.g., rated intake pressure), the preset differential pressure threshold, and the preset rate of change threshold. When the intake pressure falls below the minimum pressure threshold, the core control unit 1 does not immediately perform a standard switch, but first determines the fault type. Specifically, it calculates the difference ΔP between the current pressure and the normal operating pressure, and calculates the rate of pressure drop (i.e., the rate of pressure change) dP / dt.

[0026] If ΔP exceeds a preset differential pressure threshold (e.g., 50% of normal operating pressure) and the absolute value of dP / dt exceeds a preset rate of change threshold (e.g., a 30% drop in rated pressure per second), the core control unit 1 determines that a sudden gas outage fault has occurred, such as a pipeline rupture or a sudden fan jam. At this time, the system enters emergency response mode: the switching time between the on / off control valve 32 or 42 and the fan 31 or 41 is shortened to a preset rapid switching time (e.g., 50 milliseconds), far less than the normal switching time of 1 second, completing the branch switching at maximum speed to minimize the gas outage time. Simultaneously, the core control unit 1 marks the faulty branch as "locked," prohibiting the system from automatically attempting to restore the branch during subsequent operation (e.g., periodic short-term start-up attempts) to prevent instability or secondary damage caused by repeated switching. This locked state can only be released after manual reset or maintenance confirmation.

[0027] This embodiment improves the system's survivability in the event of a sudden severe fault by intelligently judging the fault type and responding differently. The rapid switching protects the fuel cell stack to the maximum extent, while the fault branch locking avoids invalid automatic recovery attempts and improves the system's safety.

[0028] In some embodiments, the core control unit 1 is further connected to an alarm module 6, which is configured to: When the core control unit 1 performs a working branch switching action, the core control unit 1 outputs a maintenance reminder signal containing the fault branch identifier and fault type to the alarm module 6; The system issues an audible and visual alarm based on the maintenance reminder signal and displays the branch information to be maintained on the system's human-machine interface.

[0029] In detail, the core control unit 1 is connected to an alarm module 6 via an I / O interface. The alarm module 6 includes a buzzer, a red LED indicator, and a communication interface with a human-machine interface (e.g., a touchscreen). When the core control unit 1 detects low intake pressure and performs a branch switching, it immediately generates a maintenance reminder signal. This signal is a data packet containing the identifier of the switched-off faulty branch (e.g., "First Intake Branch 3") and a fault type code (e.g., "Low Pressure"). The core control unit 1 sends this signal to the alarm module 6.

[0030] Upon receiving the signal, alarm module 6 performs two actions: First, it activates the buzzer to emit intermittent "beep" sounds and illuminates the red LED indicator, providing an audible and visual alarm to alert on-site operators of a malfunction. Second, alarm module 6 formats the fault information and sends it to the human-machine interface. The corresponding branch icon in the system status diagram on the interface turns red and flashes, while detailed text prompts such as "First intake branch fault, please check the fan and piping" are displayed in the information bar. Maintenance personnel can quickly locate and repair the faulty branch based on the prompts. Once the faulty branch is repaired and manually reset, the alarm is deactivated.

[0031] In some embodiments, the core control unit 1 is further configured to: When the first intake branch 3 is used as the working branch, the on / off control valve 42 and the intake drive fan 41 of the second intake branch 4 are periodically opened for short periods of time, and the air pressure build-up time and fan current of the second intake branch 4 are monitored during the short opening period. If the air pressure build-up time exceeds a preset time threshold, or the fan current exceeds a preset current range, it is determined that there is an abnormality in the second air intake branch 4, and the alarm module 6 outputs a hot standby branch failure warning.

[0032] In detail, when the first intake branch 3 is operating normally, the internal timer of the core control unit 1 will trigger a self-test of the second intake branch 4 at regular intervals (e.g., every hour). The self-test process is as follows: the core control unit 1 briefly opens the second on / off control valve 42 and the second intake drive fan 41 for about 3 seconds. During these 3 seconds, the core control unit 1 monitors two parameters: one is the "air path pressure build-up time" required from the start of the fan until the total intake pipeline pressure reaches the lower limit of normal operating pressure; the other is the real-time operating current of the second intake drive fan 41.

[0033] The core control unit 1 internally stores preset time thresholds (e.g., 2 seconds) and preset current ranges (e.g., 80% to 120% of the fan's rated current). If the monitored air pressure build-up time exceeds 2 seconds, it indicates a serious blockage or leak in the second branch; similarly, if the fan current exceeds the preset range (e.g., excessively high current may indicate a stuck fan or a clogged filter causing a large load, while excessively low current may indicate an open circuit in the fan coil), it also indicates an abnormality in the second branch. If any of these situations occur, the core control unit 1 determines that the second intake branch 4 is unusable. It immediately outputs a "hot standby branch failure warning" through the alarm module 6, prompting operators to promptly check and repair the second branch 4 to avoid having no usable backup branch if the first branch 3 also fails.

[0034] In some embodiments, the first intake branch 3 and the second intake branch 4 share the same intake filter module, or the two branches are each configured with an independent intake filter module; when the two branches are each configured with an independent intake filter module, the core control unit 1 also monitors the pressure difference value before and after the filter module of each branch, and when the pressure difference value exceeds a preset blockage threshold, it provides an early warning that the filter module of the branch needs to be replaced.

[0035] In detail, the first intake branch 3 and the second intake branch 4 can have two filter module configuration schemes. The first scheme is to share the same intake filter module, which is installed at the common intake port before the two branches merge. This scheme is simple in structure and low in cost. The second scheme is to configure each branch with an independent intake filter module, which is installed at the inlet of the first intake branch 3 and the second intake branch 4 respectively. This scheme has higher redundancy, and replacing the filter module of one branch does not affect the standby status of the other branch.

[0036] When using an independent configuration, the core control unit 1 also features filter module clogging monitoring. Specifically, a pressure detection point is set at both ends of the filter module in each branch, and these two pressure signals are connected to the core control unit 1. The core control unit 1 periodically calculates the pressure difference across each filter module. The initial pressure difference of a new filter module is very small, but it gradually increases as dust accumulates during use. The core control unit 1 stores a preset clogging threshold (e.g., 5 times the initial pressure difference). When the pressure difference across a filter module in a branch exceeds this preset clogging threshold, the core control unit 1 determines that the filter module is severely clogged. If it is not replaced, the intake resistance of that branch will be too high, preventing normal flow. At this time, the core control unit 1 issues an early warning through the alarm module 6 or the human-machine interface, prompting the operator that "the filter module of the first branch needs to be replaced." The operator can replace the filter module of that branch at an opportune time without affecting the continuous operation of the system (because the system can still be operated by another branch at this time).

[0037] This embodiment achieves predictive maintenance by independently monitoring and providing early warnings for the filter module, preventing branch performance degradation or failure due to filter module blockage, and further enhancing the redundancy and reliability of the system.

[0038] In some embodiments, the power data sensor 52 includes a current sensor and a voltage sensor, and the core control unit 1 is also electrically connected to the fuel intake control valve and configured to: When the real-time output power of the fuel cell stack, calculated based on the current value collected by the current sensor and the voltage value collected by the voltage sensor, changes, the opening of the fuel intake control valve is adjusted synchronously to change the fuel intake volume; and based on the adjusted fuel intake volume and the pre-stored optimal intake model, the matching air intake volume is recalculated; then, by adjusting the speed of the intake drive fan, the actual air intake volume is matched with the recalculated air intake volume to ensure that the air-fuel ratio remains stable within the preset optimal range.

[0039] In detail, the core control unit 1, in addition to being connected to the intake drive fan, is also electrically connected to the fuel intake control valve via another control port. This fuel intake control valve is an electrically adjustable valve installed on the fuel intake pipeline. During system operation, the core control unit 1 calculates the stack's output power P in real time based on data collected by the power data sensor. When changes in external load cause a change in the stack's power demand, the core control unit 1 detects the change in output power P. For example, an increase in load causes an increase in output power P. The core control unit 1 first calculates the required increase in fuel based on the power change and outputs a control signal to increase the opening of the fuel intake control valve, thereby increasing the fuel intake volume to meet the new power output demand.

[0040] After the fuel intake volume changes, in order to ensure that the stoichiometric ratio (i.e., air-fuel ratio) inside the fuel stack remains stable within the optimal range (e.g., between 1.5 and 2.0), the air intake volume must be adjusted simultaneously. The core control unit 1 uses the adjusted fuel intake volume as an input parameter, calls the pre-stored optimal intake model (which essentially contains the correspondence between fuel quantity and optimal air quantity), and recalculates the target air intake volume value matching the fuel quantity. Then, the core control unit 1 adjusts the speed of the intake drive fan in the current operating branch to ensure that the actual air intake volume accurately reaches the target value. Through these three steps (fuel adjustment, air calculation, and fan adjustment), the air-fuel ratio is ensured to remain stable within the preset optimal range at any power level.

[0041] This embodiment achieves precise coordinated adjustment of the air-fuel ratio by linking air intake control and fuel intake control, ensuring that the fuel cell stack can maintain a high-efficiency and stable operating state under any power output, and avoiding efficiency reduction and performance degradation caused by air-fuel ratio imbalance.

[0042] In some embodiments, the core control unit 1 is further configured to: Using the main pipe pressure collected by the intake pressure sensor 51 as the feedback quantity and the target intake pressure value as the given value, the pressure error value is calculated, and the control quantity is output according to the proportional, integral and derivative components of the pressure error value. The control quantity is superimposed on the speed control signal of the intake drive fan to suppress pressure fluctuations caused by the switching between the first intake branch 3 and the second intake branch 4.

[0043] In detail, the core control unit 1 internally operates a digital PID controller. The controller's inputs are: a setpoint (the target intake pressure value, such as the normal operating pressure) and a feedback value (the main pipe pressure acquired in real time by the intake pressure sensor 51). The core control unit 1 first calculates the pressure error value (the difference between the normal operating pressure and the main pipe pressure). Then, the PID controller performs a linear weighted summation of the proportional, integral, and derivative components of the error value to calculate a control variable. This control variable represents the additional speed adjustment required by the intake fan to eliminate the current pressure deviation.

[0044] During normal operation, this control value is very small. When a branch switch occurs (e.g., from branch 3 to branch 4), the main pipe pressure drops sharply due to the interruption of air supply at the moment of switching, leading to an increase in the pressure error. The PID controller calculates a larger positive control value. The core control unit 1 adds this control value to the basic fan speed control signal originally given by the optimal intake model, forming the final fan drive signal. In this way, at the moment of switching, the fan is commanded to briefly overspeed, quickly replenishing air and thus rapidly suppressing the pressure drop. As the pressure recovers, the pressure error decreases, and the control value gradually returns to zero. In this way, pressure fluctuations are effectively controlled within a small range.

[0045] In some embodiments, the core control unit 1 is further connected to a data storage and remote communication module; The data storage module is configured to continuously record inlet pressure, fan speed, output power, core temperature, and branch switching event logs according to timestamps. The remote communication module is configured to upload real-time and historical data to a remote monitoring platform and receive model update parameters or threshold setting instructions from the remote monitoring platform to remotely update the preset minimum pressure threshold and the optimal intake model.

[0046] In detail, the core control unit 1 is connected to a data storage module and a remote communication module via an internal bus. The data storage module uses non-volatile memory (such as an SD card or EEPROM). The core control unit 1 writes critical operating data to this storage module at fixed timestamp intervals (e.g., once per second). This data includes: inlet pressure, turbine speed of the current operating branch, stack output power, and core temperature. Simultaneously, whenever a branch switching event occurs, the core control unit 1 also appends information such as the event type, switching time, and faulty branch as a log.

[0047] The remote communication module uses a 4G wireless communication module or an Ethernet interface. This module periodically packages and uploads real-time and historical data from the data storage module to a remote monitoring platform (e.g., a cloud server). Maintenance personnel can view all operating parameters and alarm records through the platform. Furthermore, the remote communication module supports receiving downlink commands. For example, if the remote platform analyzes data from multiple systems and finds that the preset minimum pressure threshold at a specific altitude is too low, easily leading to false alarms, maintenance personnel can modify the threshold on the platform and send it over the network. Upon receiving the command, the remote communication module forwards it to the core control unit 1, which then updates the internally stored threshold parameters accordingly. Similarly, optimized intake model parameters (such as calibration table data) can also be remotely uploaded and updated.

[0048] In some embodiments, the core control unit 1 is further configured to: The output voltage decay rate of fuel cell stack 7 is continuously recorded during continuous operation cycles, and the health status factor of the fuel cell stack is calculated based on the decay rate. When the health status factor is lower than a preset health threshold, the core control unit 1 executes a decay suppression strategy, which includes: The preset minimum pressure threshold is adjusted upward by a first correction value to improve the trigger sensitivity of intake redundancy protection. The optimal intake flow rate calibration value in the optimal intake model is adjusted upward by the second correction value to increase the excess air coefficient. The maximum allowable output power of the system is limited to N% of the rated power, where N decreases linearly or stepwise as the health status factor decreases. When the health status factor rises above the preset health threshold, the core control unit 1 gradually restores the preset minimum pressure threshold, the optimal intake model, and the maximum allowable output power to their original values.

[0049] In detail, the core control unit 1 is equipped with a health status assessment module. This module reads historical data from the power data sensor at fixed time intervals (e.g., every 24 hours) and calculates the average output voltage decay rate of the fuel cell stack 7 during the most recent continuous operating cycle (e.g., every 100 hours). The decay rate is calculated as follows: the average voltage at the beginning of the cycle minus the average voltage at the end of the cycle, divided by the cycle duration. The core control unit 1 calculates a health status factor based on this decay rate, for example, health status factor = (current voltage decay rate baseline value) / (measured decay rate), normalized to the range of 0-1, where 1 represents healthy and 0 represents complete failure.

[0050] The core control unit 1 internally stores a preset health threshold, for example, 0.7. When the health status factor falls below 0.7, the core control unit 1 determines that the fuel cell stack 7 has shown significant performance degradation and needs to activate an active degradation suppression strategy. This strategy includes three parallel actions: First, the sensitivity of the intake redundancy protection is improved. The core control unit 1 adjusts the internally stored preset minimum pressure threshold upward by a first correction value, for example, from 70% to 80% of the normal operating pressure. This means that when the health of the fuel cell stack declines, the system has stricter requirements on the intake pressure and triggers branch switching earlier to avoid any possible insufficient air supply causing additional damage to the aging fuel cell stack.

[0051] Second, the excess air coefficient is increased. The core control unit 1 adjusts the optimal intake flow rate calibration values ​​for all operating conditions in the optimal intake model upwards by a second correction value, for example, by a uniform increase of 10%. This results in the actual air intake volume being higher than the theoretical optimal value. For fuel cell stacks that have already shown slight carbon buildup or electrode aging, a slightly higher excess air coefficient helps to more fully oxidize the fuel, inhibit further carbon buildup, and remove any impurities that may accumulate, thereby delaying performance degradation.

[0052] Third, reduced power operation. The core control unit 1 limits the maximum permissible output power of the system to N% of the rated power. The value of N is dynamically adjusted as the health factor decreases: for example, N=80% when the health factor is 0.7, and N=60% when the health factor is 0.5. By limiting the power output, the thermal stress and chemical reaction intensity of the fuel cell stack are reduced, thereby slowing down the aging rate.

[0053] During subsequent operation, if the health status factor rises above the preset health threshold (e.g., due to a decrease in the attenuation rate after power reduction operation), the core control unit 1 gradually restores all parameters to their original values. The restoration process can be a slow, ramp-like recovery to avoid sudden parameter changes impacting the system.

[0054] This embodiment no longer passively responds to faults, but instead predicts the degradation trend based on changes in the stack's own health and actively adjusts control parameters (increasing redundancy sensitivity, increasing the excess air coefficient, and limiting power output) to slow down the aging process. This strategy directly targets the most fundamental performance degradation mechanism in the long-term operation of SOFCs, significantly improving the stack's lifespan and reducing maintenance costs throughout its entire lifecycle.

[0055] In some embodiments, the control logic of the solid oxide fuel cell electronic control system for preventing performance degradation according to the present invention can be as follows: Figure 2 This is the logic control diagram of the solid oxide fuel cell electronic control system of the present invention, as follows: Figure 2As shown, the core control logic of this solid oxide fuel cell electronic control system is divided into four layers: signal input layer, dual-path redundancy switching logic, optimal intake flow calculation logic, and output and closed-loop logic, as detailed below: First layer: Signal input layer The core control unit collects the following three key signals in real time: Real-time intake pressure P: Collected from the intake pressure sensor installed in the main intake pipe; The output voltage U and current I of the fuel cell stack are collected from voltage and current sensors installed in the solid oxide fuel cell stack. Real-time steady-state temperature T: collected from the core temperature sensor installed in the solid oxide fuel cell stack.

[0056] Second layer: Dual-path redundancy switching logic: The core control unit determines the real-time intake pressure P: If P < preset minimum pressure threshold P_min, then the current working branch is determined to be faulty, and the following operations are performed immediately: Perform redundancy switching: disconnect the on / off control valve and intake drive fan of the current working branch, and at the same time turn on the on / off control valve and intake drive fan of the standby branch. Trigger the alarm module and output a maintenance reminder signal (audio-visual alarm and human-machine interface display) that includes the fault branch identifier and fault type. Update the active working branch to the backup branch, and subsequent control will be based on the new branch.

[0057] If P ≥ P_min, then the state of the currently active working branch is maintained, and no switching is performed.

[0058] Third layer: Optimal intake flow calculation logic: Regardless of whether a switch occurs, the system continues to perform optimal intake flow calculations in parallel: Calculate real-time output power: Based on the collected stack output voltage U and current I, calculate W = U × I; Query the pre-stored optimal intake model: Using the current real-time output power W and real-time steady-state temperature T as indexes, look up the table in the optimal air-fuel ratio calibration model built into the core control unit (which stores the optimal intake flow calibration values ​​corresponding to different output powers and different core temperatures); obtain the optimal intake flow rate Q_opt under the current operating conditions.

[0059] Fourth layer: Output and closed loop: Calculate the target fan speed that matches Q_opt; Output PWM control signal (pulse width modulation speed control signal) to adjust the speed of the intake drive fan of the currently active branch (first intake branch or second intake branch after switching) so that the actual intake volume is close to Q_opt; Feedback: The updated inlet pressure, stack output voltage / current, and core temperature re-enter the first layer, forming a continuous closed-loop control.

[0060] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A solid oxide fuel cell electronic control system for preventing performance degradation, characterized in that, include: Core control unit, power module, sensing and detection unit, and intake drive unit; The intake drive unit has a dual-redundant structure, including a first intake branch and a second intake branch that are independent of each other. Each branch is independently equipped with an intake drive fan and an on / off control valve. The sensing and detection unit includes an intake pressure sensor installed in the main intake pipeline, and an energy data sensor and a core temperature sensor installed in the solid oxide fuel cell stack; the intake pressure sensor, the energy data sensor, the core temperature sensor, the on / off control valves of the two branches, and the intake drive fan are all electrically connected to the core control unit. The core control unit is configured to: acquire the intake pressure collected by the intake pressure sensor; when the intake pressure is lower than a preset minimum pressure threshold, automatically switch the working branch to ensure continuous intake; simultaneously, acquire the stack operating parameters collected by the power data sensor and the core temperature sensor, and adjust the speed of the intake drive fan of the current working branch in real time according to the pre-stored optimal intake model to match the optimal intake flow rate under the current operating conditions.

2. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit has a built-in optimal air-fuel ratio calibration model as the optimal intake model. The optimal air-fuel ratio calibration model stores the optimal intake flow rate calibration values ​​corresponding to different output power and different core temperatures. The core control unit queries the optimal air-fuel ratio calibration model to obtain the corresponding optimal intake flow rate calibration value based on the real-time output power and real-time core temperature in the stack operating parameters, and outputs a pulse width modulation speed control signal based on the calibration value to adjust the intake volume of the intake drive fan in the current working branch.

3. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 2, characterized in that, The core control unit is also configured to: During steady-state operation of the system, the core control unit records the current output power, core temperature, actual air intake flow rate, and fluctuation range of the stack output voltage. When the fluctuation of the output voltage exceeds the preset fluctuation threshold, the core control unit determines that the current calibration value deviates from the optimal value, and gradually adjusts the speed of the intake drive fan with a preset step size until the output voltage fluctuation falls back to within the preset fluctuation threshold. The correspondence between the adjusted intake flow rate and the current output power and core temperature is stored as a new calibration value in the optimal air-fuel ratio calibration model.

4. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit is also configured to: When it is determined that the intake pressure is lower than the preset minimum pressure threshold and a branch switching is triggered, the pressure difference and pressure change rate between the current intake pressure and the normal operating pressure are calculated. If the pressure difference exceeds a preset pressure difference threshold and the pressure change rate exceeds a preset change rate threshold, it is determined to be a sudden gas outage fault. The switching time is shortened to within a preset rapid switching time, and the faulty branch is locked to prevent automatic recovery.

5. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit is also connected to an alarm module, which is configured as follows: When the core control unit performs a working branch switching action, the core control unit outputs a maintenance reminder signal containing the fault branch identifier and fault type to the alarm module; The system issues an audible and visual alarm based on the maintenance reminder signal and displays the branch information to be maintained on the system's human-machine interface.

6. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit is also configured to: When the first intake branch is used as the working branch, the on / off control valve and intake drive fan of the second intake branch are periodically opened for short periods of time, and the air pressure build-up time and fan current of the second intake branch are monitored during the short opening period. If the air pressure build-up time exceeds a preset time threshold, or the fan current exceeds a preset current range, it is determined that there is an abnormality in the second air intake branch, and a hot standby branch failure warning is output through the alarm module.

7. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The first intake branch and the second intake branch share the same intake filter module, or the two branches are each configured with an independent intake filter module. When the two branches are each configured with an independent intake filter module, the core control unit also monitors the pressure difference value before and after the filter module of each branch, and when the pressure difference value exceeds the preset blockage threshold, it provides an early warning that the filter module of that branch needs to be replaced.

8. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The power data sensor includes a voltage sensor and a current sensor; The core control unit is also electrically connected to the fuel intake control valve and is configured to: When the real-time output power of the fuel cell stack, calculated based on the current value collected by the current sensor and the voltage value collected by the voltage sensor, changes, the opening of the fuel intake control valve is adjusted synchronously to change the fuel intake volume; and the matching air intake volume is recalculated based on the adjusted fuel intake volume and the pre-stored optimal intake model. Then, by adjusting the speed of the intake drive fan, the actual air intake volume is matched with the recalculated air intake volume to ensure that the air-fuel ratio remains stable within the preset optimal range.

9. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit is also configured to: Using the main pipe pressure collected by the intake pressure sensor as the feedback quantity and the target intake pressure value as the given value, the pressure error value is calculated, and the control quantity is output according to the proportional, integral and derivative components of the pressure error value. The control quantity is superimposed on the pulse width modulation speed control signal of the intake drive fan to suppress pressure fluctuations caused by the instantaneous switching between the first intake branch and the second intake branch.

10. The solid oxide fuel cell electronic control system for preventing performance degradation according to claim 1, characterized in that, The core control unit is also connected to a data storage and remote communication module; The data storage module is configured to continuously record inlet pressure, fan speed, output power, core temperature, and branch switching event logs according to timestamps. The remote communication module is configured to upload real-time and historical data to a remote monitoring platform and receive model update parameters or threshold setting instructions from the remote monitoring platform to remotely update the preset minimum pressure threshold and the optimal intake model.

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