An integrated hydrogen fuel cell system controller

Abstract

The utility model provides an integration integrated hydrogen fuel cell system controller belongs to fuel cell controller field, including shell, one side of shell is equipped with air cooling heat dissipation fin, is equipped with the heat dissipation fan fixedly on air cooling heat dissipation fin, the inner chamber of shell is equipped with upper layer control panel and lower power board, is equipped with DC converter and temperature acquisition module on lower power board, and DC converter electricity is connected with DC input output power line, is equipped with DC converter control circuit and hydrogen fuel cell system control unit on upper layer control panel, temperature acquisition module and DC converter control circuit, hydrogen fuel cell system control unit electricity is connected, DC converter control circuit and hydrogen fuel cell system control unit electricity are connected, and hydrogen fuel cell system control unit electricity is connected with hydrogen fuel cell system control unit external beam to the system controller of this system. The wide voltage range input output of support is supported, and the power unit of system controller supports water cooling, air cooling two kinds of heat dissipation mode, and the maintenance cost is low, and the service life is long.

Description

Technical Field

[0001] This utility model relates to the field of fuel cell controllers, specifically to an integrated hydrogen fuel cell system controller. Background Technology

[0002] With the increasing demand for clean energy, hydrogen energy has gained widespread attention as an ideal clean energy source. Hydrogen fuel cells are the core means of hydrogen energy application, capable of converting hydrogen into electrical energy of different power levels according to the needs of the scenario. In a hydrogen fuel cell energy system, the energy output by the fuel cell needs to be processed by a power converter before it can be effectively utilized. During the conversion process, a controller needs to adjust system parameters to achieve optimal efficiency. The controller also needs to collect parameters through sensors and adjust key indicators through control components.

[0003] Traditional hydrogen fuel cell systems consist of discrete components such as a power converter, system controller, temperature sensor, pressure sensor, intake valve, exhaust valve, fan, blower, and system power supply module. The power converter is a DC-DC converter based on a DC-DC topology, the system controller is a control device based on an ARM microcontroller (such as the STM32 series) and peripheral circuits, and the system power supply module is an independent step-down converter. All components are connected via wiring harnesses. Traditional hydrogen fuel cell systems have two major problems: First, the discrete components require complex wiring harnesses for information exchange, and wiring space must be reserved during installation, resulting in cumbersome wiring, low space utilization, and large system size, which is not conducive to miniaturization integration and cost control. Second, the compatibility between the components (especially the system controller and the stack and system) is poor, which prevents the full utilization of performance and results in poor system reliability.

[0004] Currently, there is a "fuel cell and system controller integrated" solution: the fuel cell stack and controller are physically integrated, with the controller directly mounted on the side of the fuel cell stack, forming a compact integrated structure. The control board includes a CVM monolithic stack voltage sampling circuit, signal processing circuit, PWM shaping circuit, BOP control circuit, and auxiliary power supply circuit. The power board integrates a synchronous Boost power topology and its drive circuit, enabling power control, status monitoring (voltage, temperature, pressure), and dynamic adjustment of BOP components (intake valve, fan) through the controller. While the "fuel cell and system controller integrated" solution has certain advantages in miniaturization and integration, it has significant limitations: First, the controller is based on a BOOST boost topology, which can only meet boost output requirements, resulting in a narrow range of applications and failing to meet the needs of buck and buck-boost systems. Second, the installation structure is limited by the fuel cell stack, and the controller power unit can only use air cooling, restricting the improvement of system power density. Third, the high integration of the fuel cell stack and controller, coupled with the fact that the fuel cell stack lifespan is much shorter than the controller lifespan, leads to significant disadvantages in overall system lifespan and maintenance costs.

[0005] To address this, we propose an integrated hydrogen fuel cell system controller. Utility Model Content

[0006] The purpose of this invention is to provide an integrated hydrogen fuel cell system controller to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: This utility model provides an integrated hydrogen fuel cell system controller, including a housing. One side of the housing has air-cooled heat dissipation fins, and a cooling fan is fixedly mounted on the fins. The inner cavity of the housing houses an upper control board and a lower power board. Signal pins and power connection studs are provided between the upper control board and the lower power board. Signal transmission between the upper control board and the lower power board is achieved through the signal pins, and power transmission and mechanical fixation are achieved through the power connection studs. The lower power board houses a DC converter and a temperature acquisition module. The DC converter is electrically connected to DC input and output power lines. The upper control board houses a DC converter control circuit and a hydrogen fuel cell system control unit. The temperature acquisition module is electrically connected to the DC converter control circuit and the hydrogen fuel cell system control unit. The DC converter control circuit is electrically connected to the hydrogen fuel cell system control unit. The hydrogen fuel cell system control unit is electrically connected to an external wiring harness.

[0008] Furthermore, the housing is provided with output panels at both ends. The DC input and output power lines extend to the outside of the housing through the output panel at one end of the housing, and the external wiring harness of the hydrogen fuel cell system control unit extends to the outside of the housing through the output panel at the other end of the housing.

[0009] Furthermore, the DC converter includes a DC power converter and a DCL converter. The DC power converter is electrically connected to the DC converter control circuit and the hydrogen fuel cell system control unit, and the DCL converter is electrically connected to the DC power converter, the DC converter control circuit, and the hydrogen fuel cell system control unit.

[0010] Furthermore, the DC power converter adopts a synchronous BUCK-BOOST buck-boost topology.

[0011] Furthermore, the DCL converter adopts a synchronous BUCK buck topology.

[0012] Furthermore, the DC converter control circuit includes an MCU21 microcomputer, an ADC data acquisition circuit, and a PWM drive level conversion and floating ground drive circuit. The ADC data acquisition circuit and the PWM drive level conversion and floating ground drive circuit are both electrically connected to the MCU21 microcomputer. The ADC data acquisition circuit is electrically connected to the DC power converter via power terminal blocks. The PWM drive level conversion and floating ground drive circuit is electrically connected to the DC power converter via signal headers. The temperature acquisition module is electrically connected to the MCU21 microcomputer and the hydrogen fuel cell system control unit via signal headers. The MCU21 microcomputer is electrically connected to a buck analog DC control circuit via signal headers. The buck analog DC control circuit is electrically connected to the DCL converter.

[0013] Furthermore, the hydrogen fuel cell system control unit includes an MCU30 microcomputer, a communication circuit, a resistance data acquisition circuit, a fan PWM drive circuit, a fan speed feedback acquisition circuit, a low-side drive circuit, a high-side drive circuit, an ACC and digital I / O interface circuit, a voltage data acquisition circuit, a data exchange circuit, a sampling circuit, a wake-up circuit, and a system wiring harness interface. The communication circuit, resistance data acquisition circuit, fan PWM drive circuit, fan speed feedback acquisition circuit, low-side drive circuit, high-side drive circuit, ACC and digital I / O interface circuit, voltage data acquisition circuit, data exchange circuit, sampling circuit, and wake-up circuit are all electrically connected to the MCU30 microcomputer. The communication circuit, resistance data acquisition circuit, fan PWM drive circuit, fan speed feedback acquisition circuit, low-side drive circuit, high-side drive circuit, ACC and digital I / O interface circuit, voltage data acquisition circuit, and wake-up circuit are all electrically connected to the external wiring harness of the hydrogen fuel cell system control unit through the system wiring harness interface. The MCU30 microcomputer is electrically connected to the MCU21 microcomputer through the data exchange circuit. The MCU30 microcomputer is electrically connected to the DCL converter through the sampling circuit and power terminal blocks.

[0014] Furthermore, the communication circuit includes a CAN communication circuit and a 485 communication circuit.

[0015] Furthermore, the DC input / output power line includes an input lead and an output lead. The positive terminal of the input lead is electrically connected to the positive terminal of the hydrogen fuel cell stack, and the negative terminal of the input lead is electrically connected to the negative terminal of the hydrogen fuel cell stack. The positive terminal of the output lead is electrically connected to the positive terminal of the energy storage battery, and the negative terminal of the output lead is electrically connected to the negative terminal of the energy storage battery.

[0016] Furthermore, the hydrogen fuel cell system control unit includes a three-wire CAN communication interface, a two-wire 485 communication interface, a two-wire high-side drive interface, a two-wire low-side drive interface, a four-wire fan drive interface, a two-wire resistance data acquisition interface, a three-wire voltage data acquisition interface, a single-wire ACC wake-up interface, a single-wire DI digital input interface, and a two-wire DCL power output interface.

[0017] Compared with the prior art, the present invention has the following technical effects: In this invention, the DC power converter adopts a synchronous BUCK-BOOST buck-boost topology. Compared to the BOOST boost topology, it supports a wide voltage range for input and output, is suitable for various fuel cell stack configurations, and is compatible with hydrogen fuel cell systems in various application scenarios such as vehicle power, backup power, and portable power stations, demonstrating broad adaptability. The system controller integrates the DC converter and the hydrogen fuel cell system control unit. In the entire hydrogen fuel cell system, the system controller and the fuel cell stack are two separate components. The installation structure of the system controller is not limited by the fuel cell stack, allowing the system controller power unit to support both water cooling and air cooling. Furthermore, compared to integrated controllers that combine the fuel cell and controller, this system controller has lower maintenance costs and a longer service life. The DC converter control circuit and the hydrogen fuel cell system control unit are two independent control cores with independent control logic. The dual control core architecture has a protection mechanism for critical power signals. If either core fails, the other core can effectively protect the system, avoiding single-point failure risks and preventing catastrophic damage. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the hydrogen fuel cell system controller according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the outer shell of an embodiment of the present utility model; Figure 3 This is a schematic diagram of the structure of the air-cooled heat dissipation fins and the cooling fan in an embodiment of the present utility model; Figure 4 This is a schematic diagram of the lower power board according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the upper control board according to an embodiment of the present invention.

[0019] In the diagram: 1. Outer casing; 2. Air-cooled heat sink fins; 3. Cooling fan; 4. Upper control board; 5. Lower power board; 6. Signal header; 7. Power terminal block; 8. DC input / output power lines; 81. Input lead; 82. Output lead; 9. DC converter control circuit; 10. External wiring harness of the hydrogen fuel cell system control unit; 11. Outlet panel; 12. DC power converter; 13. DCL converter; 14. MCU21 microcomputer; 15. ADC data acquisition circuit; 16. PWM drive level conversion and floating... 17. Ground drive circuit; 18. Step-down analog DC control circuit; 19. MCU30 microcomputer; 10. Communication circuit; 11. CAN communication circuit; 12. 485 communication circuit; 23. Resistance data acquisition circuit; 24. Fan PWM drive circuit; 25. Fan speed feedback acquisition circuit; 26. Low-side drive circuit; 27. High-side drive circuit; 28. ACC and digital I / O interface circuit; 29. ​​Voltage data acquisition circuit; 20. Data exchange circuit; 21. Sampling circuit; 22. System wiring harness interface. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] Please see Figures 1 to 5 This embodiment provides an integrated hydrogen fuel cell system controller, including a housing 1. The housing 1 is manufactured using sheet metal technology. The sheet metal housing 1 can be fitted with heat dissipation fins for air cooling or mounted on a water-cooled plate for water cooling, depending on the specific cooling requirements of the scenario. In this embodiment, one side of the housing 1 is provided with air-cooled heat dissipation fins 2, which are integrally formed with the housing 1. A cooling fan 3 is fixedly mounted on the air-cooled heat dissipation fins 2. The system controller dissipates heat through the air-cooled heat dissipation fins 2 and the cooling fan 3.

[0022] Specifically, the outer casing 1 has cable outlet panels 11 at both ends, which are used for the DC input / output power lines 8 and the external wiring harness 10 of the hydrogen fuel cell system control unit. The inner cavity of the outer casing 1 has an upper control board 4 and a lower power board 5. The upper control board 4 and the lower control board 5 adopt an upper and lower stacked assembly structure. The lower power board 5 is set close to the outer casing 1. The inside of the system controller is filled with thermally conductive potting compound, which, together with the air-cooled heat sink fins 2 and the cooling fan 3, achieves efficient heat dissipation.

[0023] Specifically, a signal pin header 6 and a power connection stud 7 are provided between the upper control board 4 and the lower power board 5. The upper control board 4 and the lower power board 5 transmit signals through the signal pin header 6, and transmit power and fix mechanically through the power connection stud 7.

[0024] Specifically, the lower power board 5 is equipped with a DC converter and a temperature acquisition module. The electronic components of the DC converter and the temperature acquisition module are fixedly mounted on the lower power board 5. The DC converter is electrically connected to DC input and output power lines 8, which extend from the output panel 11 at one end of the housing 1 to the outside of the housing 1. The upper control board 4 is equipped with a DC converter control circuit 9 and a hydrogen fuel cell system control unit. The temperature acquisition module is electrically connected to the DC converter control circuit 9 and the hydrogen fuel cell system control unit. The DC converter control circuit 9 is electrically connected to the hydrogen fuel cell system control unit. The hydrogen fuel cell system control unit is electrically connected to the external wiring harness 10 of the hydrogen fuel cell system control unit, which extends from the output panel 11 at the other end of the housing 1 to the outside of the housing 1.

[0025] Specifically, the DC converter includes a DC power converter 12 and a DCL converter 13. The DC power converter 12 is electrically connected to the DC converter control circuit 9 and the hydrogen fuel cell system control unit through the power wiring stud 7 and the signal header 6. The DCL converter 13 is electrically connected to the DC power converter 12, the DC converter control circuit 9, and the hydrogen fuel cell system control unit.

[0026] Specifically, the DC power converter 12 includes a power transistor (N-type MOSFET), an inductor (high-current power inductor), a filter capacitor, and a sampling resistor. The filter capacitor of the DC power converter 12 is a low equivalent series resistance (ESR) solid-state ceramic capacitor (MLCC). The DC power converter 12 adopts a synchronous BUCK-BOOST buck-boost topology. Based on the synchronous BUCK-BOOST buck-boost topology, the DC power converter 12 has a wide input and output voltage range, is not limited by the voltage relationship of system components, and can achieve wide-range voltage regulation; it supports up to four power conversion units interleaved in parallel to improve system power and meet the power requirements of various scenarios. The specific structure and control logic of the synchronous BUCK-BOOST buck-boost topology are as follows: Topology: The inductor and the input-side switches Q1 and Q2 form a buck converter (the placement of Q1 and Q2 conforms to the switch layout requirements of a standard synchronous buck converter); the inductor and the output-side switches Q3 and Q4 form a boost converter (the placement of Q3 and Q4 conforms to the switch layout requirements of a standard synchronous boost converter).

[0027] Operating modes: When Q1 is on, Q2 is off, and Q3 and Q4 are turned on alternately, the DC power converter 12 operates in BOOST mode; when Q3 is on, Q4 is off, and Q1 and Q2 are turned on alternately, the DC power converter 12 operates in BUCK mode.

[0028] Control method: The on and off of the switching transistor and the working mode of the DC power converter 12 are controlled by the MCU21 microcomputer 14 in the DC converter control circuit 9 (selection includes but is not limited to DSP (such as TMS320F280 series) and ARM single-chip microcomputer (such as STM32F4 series)).

[0029] Specifically, the DCL converter 13 includes a power transistor (N-type MOSFET), an inductor (high-current power inductor), a filter capacitor, and a sampling resistor. The filter capacitor of the DCL converter 13 is an electrolytic capacitor. The DCL converter 13 adopts a synchronous BUCK buck topology. The conversion process is controlled by the DC converter control circuit 9 and the buck analog DC control circuit 17. The buck analog DC control circuit 17 consists of an integrated analog DC control chip (such as LM5116, EG1163, etc.), resistors, and capacitors. This integrated analog DC control chip integrates a high-side bootstrap drive circuit, eliminating the need for an additional PWM drive circuit and simplifying the drive process. The buck analog DC control circuit 17 serves as an auxiliary circuit and is essential for realizing the controllable output of the MCU21 microcomputer 14 in the DC converter control circuit 9. During the conversion process of the DCL converter 13, the MCU21 microcomputer 14 provides the necessary analog and digital signals to achieve the controllable output of the DCL converter 13. The DCL converter 13 is based on a synchronous rectification BUCK buck topology. It draws power from the output bus of the DC power converter 12 and, after adjustment by the hardware feedback voltage divider resistor, can output a variety of configurable voltages such as 12V, 24V, and 48V to power other components and the integrated controller itself.

[0030] Specifically, the DC converter control circuit 9 includes an MCU21 microcomputer 14, an ADC data acquisition circuit 15, and a PWM drive level conversion and floating ground drive circuit 16. Both the ADC data acquisition circuit 15 and the PWM drive level conversion and floating ground drive circuit 16 are electrically connected to the MCU21 microcomputer 14. The ADC data acquisition circuit 15 is electrically connected to the DC power converter 12 via power connection studs 7. Power connection studs 7 are electrically connected to the input terminals (VIN and GND terminals) and output terminals (VOUT and GND terminals) of the DC power converter 12. The output terminal of the DC power converter 12 is electrically connected to the input terminals (VIN and GND terminals) of the DCL converter 13. The PWM drive level conversion and floating ground drive circuit 16 is electrically connected to the DC power converter 12 via signal headers 6. The temperature acquisition module is electrically connected to the MCU21 microcomputer 14 and the hydrogen fuel cell system control unit via signal headers 6. The MCU21 microcomputer 14 is electrically connected to a step-down analog DC control circuit 17 via signal header 6. The step-down analog DC control circuit 17 is electrically connected to the DCL converter 13. The output terminal of the DCL converter 13 (i.e., the VOUT terminal and GND terminal of the DCL converter 13) is electrically connected to the two-wire DCL power output interface via signal header 6.

[0031] Specifically, the PWM drive level conversion and floating ground drive circuit 16 is used to drive the switching transistors Q1, Q2, Q3, and Q4 in the synchronous BUCK-BOOST buck-boost topology. Low-side switch driving: Q2 (buck topology) and Q4 (boost topology) are low-side switches and can be directly driven by the driver chip (such as FAN73711) in the PWM drive level conversion and floating ground drive circuit 16. High-side switch driving: Q1 and Q3 are high-side switches and require a floating ground power supply to the output side of the driver chip in the PWM drive level conversion and floating ground drive circuit 16 via an isolated power supply module (such as B1212) before driving.

[0032] Specifically, the ADC data acquisition circuit 15 includes DC voltage sampling and current sampling functions. The circuit structure includes a resistor voltage divider structure, an operational amplifier proportional adjustment structure, a Hall sampling circuit, etc. The specific sampling process is as follows: Voltage sampling: The DC input and output voltages are first divided by resistors, and then the voltage signal is proportionally scaled by the operational amplifier proportional adjustment circuit to adjust it to a voltage signal that matches the range of the ADC port of the MCU21 microcomputer 14 before sampling is completed.

[0033] Current sampling: The DC input and output current signals are first converted into voltage signals by the Hall sampling circuit, and then the voltage signals are proportionally scaled by the operational amplifier proportional adjustment circuit to adjust them to a voltage signal that matches the range of the ADC port of the MCU21 microcomputer 14, and then sampling is completed.

[0034] Specifically, the hydrogen fuel cell system control unit includes an MCU30 microcomputer 18, a communication circuit 19, a resistance data acquisition circuit 20, a fan PWM drive circuit 21, a fan speed feedback acquisition circuit 22, a low-side drive circuit 23, a high-side drive circuit 24, an ACC and digital I / O interface circuit 25, a voltage data acquisition circuit 26, a data exchange circuit 27, a sampling circuit 28, a wake-up circuit, and a system wiring harness interface 29. The communication circuit 19 includes a CAN communication circuit 191 and a 485 communication circuit 192. The MCU30 microcomputer 18 is mainly responsible for completing the system's information acquisition and logic processing functions. The chip function is biased towards communication and peripheral control, and its selection includes, but is not limited to, ARM microcontrollers (such as the STM32F4 series). Communication circuit 19, resistance data acquisition circuit 20, fan PWM drive circuit 21, fan speed feedback acquisition circuit 22, low-side drive circuit 23, high-side drive circuit 24, ACC and digital I / O interface circuit 25, voltage data acquisition circuit 26, data exchange circuit 27, sampling circuit 28, and wake-up circuit are all electrically connected to MCU30 microcomputer 18. Communication circuit 19, resistance data acquisition circuit 20, fan PWM drive circuit 21, fan speed feedback acquisition circuit 22, low-side drive circuit 23, high-side drive circuit 24, ACC and digital I / O interface circuit 25, voltage data acquisition circuit 26, and wake-up circuit are all electrically connected to the external wiring harness 10 of the hydrogen fuel cell system control unit through system wiring harness interface 29. MCU30 microcomputer 18 is electrically connected to MCU21 microcomputer 14 through data exchange circuit 27. MCU30 microcomputer 18 is electrically connected to DCL converter 13 through sampling circuit 28 and power wiring stud 7.

[0035] Specifically, the upper control board 4 is equipped with a DC converter control circuit 9 and a hydrogen fuel cell system control unit. The core functions are realized through the DC converter control circuit 9 and the hydrogen fuel cell system control unit, and the core functions are as follows: Dual cross protection: The MCU30 microcomputer 18 uses a different op-amp ratio adjustment circuit than the ADC data acquisition circuit 15 to convert and process the same signal uploaded by the power connection stud 7, signal header 6 and current sampling Hall, thus achieving dual cross protection together with the MCU21 microcomputer 14.

[0036] Data interaction: Shares operating data with the MCU21 microcomputer 14 through UART communication, SPI communication or shared memory (i.e., data exchange circuit 27).

[0037] Fan control: The PWM digital signal output by the fan PWM drive circuit 21 conforms to the standard TTL level specification (logic 0 is low level, range 0V-0.8V; logic 1 is high level, range 2.0V~5.0V). This signal is first converted from the 3.3V signal output by the MCU30 microcomputer 18 to a 5V signal by a TTL conversion chip (such as SN74LVC2T45), and then used to control the fan speed.

[0038] Fan speed feedback: The fan speed feedback acquisition circuit 22 acquires the square wave PWM signal transmitted by the fan feedback line FG. The input terminal of the acquisition circuit has a pull-up resistor. After the signal is converted by TTL or optocoupler circuit, it is transmitted to the TIM timer input capture channel of the microcomputer 18 of MCU30. The frequency information is obtained through algorithm processing and converted into fan speed.

[0039] Communication and Upgrade: Communication circuit 19 is the main communication interface between the system controller and other components of the hydrogen fuel cell system. The program logic is designed with a program burning function based on the communication port. When the system is equipped with networked central control equipment, remote online upgrades can be achieved through communication circuit 19.

[0040] Low-power wake-up: The system controller has a low-power standby mode. When an external device inputs an ACC signal, the signal is processed by the resistor divider, capacitor filter and voltage regulation protection structure of the ACC wake-up circuit before being transmitted to the MCU detection interface, thereby waking up the entire system.

[0041] Specifically, the DC converter control circuit 9 and the hydrogen fuel cell system control unit are two independent control cores with independent control logic. Each control core has its own independent task allocation and functional domain, and achieves state synchronization and data interaction through inter-core communication. The hydrogen fuel cell system control unit core is responsible for controlling the system's related peripherals, including but not limited to CAN communication interface, 485 communication interface, four-wire fan interface with PWM drive and speed feedback, resistive sampling interface, voltage sampling interface, high-side drive interface, low-side drive interface, digital input / output interface, one-wire interface, and ACC system wake-up interface (all for system auxiliary components). The DC converter control circuit 9 core is responsible for controlling the DC power converter's related functions, including PWM power transistor drive, voltage acquisition, current acquisition, temperature acquisition, relay drive, etc. The dual control cores achieve data interaction through structures such as UART, SPI, or shared memory (i.e., data exchange circuit 27). The DC converter and the hydrogen fuel cell system control unit adopt a modular hardware design to achieve physical isolation between power and signals, and both can be repaired and replaced independently. The core control logic of the hydrogen fuel cell system control unit also supports secondary editing and CAN communication upgrades. The program upgrade process can effectively avoid affecting the power system and prevent system crashes caused by rewriting the program. In addition, the dual control cores are equipped with protection mechanisms for critical power signals. If one core fails, the other core can effectively protect the system and prevent catastrophic damage.

[0042] Specifically, the DC input / output power line 8 includes an input lead 81 and an output lead 82. The input lead 81 is electrically connected to the DC power converter 12, and the output lead 82 is electrically connected to both the DC power converter 12 and the DCL converter 13. The positive terminal of the input lead 81 is electrically connected to the positive terminal of the hydrogen fuel cell stack, and the negative terminal of the input lead 81 is electrically connected to the negative terminal of the hydrogen fuel cell stack. The positive terminal of the output lead 82 is electrically connected to the positive terminal of the energy storage battery, and the negative terminal of the output lead 82 is electrically connected to the negative terminal of the energy storage battery. The unusable electrical energy output from the hydrogen fuel cell is converted into stable and usable electrical energy by the DC converter and then delivered to the energy storage battery through the output lead 82, simultaneously powering the entire hydrogen fuel cell system. The power conversion process is controlled by the DC converter control circuit 9, and the conversion parameters are collected and read in real time by the hydrogen fuel cell system control unit.

[0043] Specifically, the external wiring harness 10 of the hydrogen fuel cell system control unit is used to connect to the auxiliary control equipment in the hydrogen fuel cell system. The wiring harness interface types include a three-wire CAN communication interface (CAN_H, CAN_L, GND), a two-wire 485 communication interface (485_A, 485_B), a two-wire high-side drive interface (drive positive, drive negative), a two-wire low-side drive interface (drive positive, drive negative), a four-wire fan drive interface (power positive, power negative, drive PWM, speed feedback FG), a two-wire resistance data acquisition interface (lead A, lead B), a three-wire voltage data acquisition interface (power positive, voltage signal, power negative), a single-wire ACC wake-up interface, a single-wire DI digital input interface, and a two-wire DCL power output interface. The wiring harness includes the following interfaces: a two-wire high-side drive interface for connecting valves such as the hydrogen inlet valve and hydrogen outlet valve in the hydrogen fuel cell system; a two-wire low-side drive interface for connecting devices such as the heating membrane; a four-wire fan drive interface for connecting devices such as the cooling fan and blower of the hydrogen fuel cell stack; a two-wire resistance data acquisition interface for connecting the resistance-type temperature sampling device in the hydrogen fuel cell system; a three-wire voltage data acquisition interface for connecting devices such as the hydrogen tank pressure sensor and the ambient gas concentration sensor; a single-wire ACC wake-up interface for connecting the central control wake-up signal line of the hydrogen fuel cell system; a single-wire DI digital input interface for communicating with the energy storage battery to obtain its SOC data and other external data; and a two-wire DCL power output interface for connecting other devices in the hydrogen fuel cell system that require power. All of the above wiring harness interfaces are standardized according to the equipment requirements of the hydrogen fuel cell system. The number of each interface can be expanded, and the effectiveness of the interface function is controlled by the hydrogen fuel cell system control unit, maximizing adaptability to different hydrogen fuel cell system structures and effectively reducing wiring complexity.

[0044] Specifically, the DC power converter 12 adopts a synchronous BUCK-BOOST buck-boost topology. Compared with the BOOST boost topology, it supports a wide voltage range for input and output, is suitable for various fuel cell stack configurations, and is compatible with hydrogen fuel cell systems in various application scenarios such as vehicle power, backup power, and portable power stations, demonstrating broad adaptability. The system controller integrates the DC converter and the hydrogen fuel cell system control unit. In the entire hydrogen fuel cell system, the system controller and the fuel cell stack are two separate components. The installation structure of the system controller is not limited by the fuel cell stack, allowing the system controller power unit to support both water cooling and air cooling. In addition, compared with integrated controllers for fuel cells and controllers, the system controller has lower maintenance costs and a longer service life. The DC converter control circuit 9 and the hydrogen fuel cell system control unit have independent functions, and their control logic does not interfere with each other. The dual control core architecture has a protection mechanism for critical power signals. If either core fails, the other core can effectively protect the system, avoiding single-point failure risks and preventing catastrophic damage.

[0045] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An integrated hydrogen fuel cell system controller, characterized in that, The system includes an outer casing (1), one side of which is provided with air-cooled heat dissipation fins (2), and a cooling fan (3) is fixedly mounted on the air-cooled heat dissipation fins (2). The inner cavity of the outer casing (1) is provided with an upper control board (4) and a lower power board (5). Signal pin headers (6) and power connection studs (7) are provided between the upper control board (4) and the lower power board (5). Signal transmission between the upper control board (4) and the lower power board (5) is achieved through the signal pin headers (6), and power transmission between the upper control board (4) and the lower power board (5) is achieved through the power connection studs (7). The lower power board (5) is equipped with a DC converter and a temperature acquisition module. The DC converter is electrically connected to DC input and output power lines (8). The upper control board (4) is equipped with a DC converter control circuit (9) and a hydrogen fuel cell system control unit. The temperature acquisition module is electrically connected to the DC converter control circuit (9) and the hydrogen fuel cell system control unit. The DC converter control circuit (9) is electrically connected to the hydrogen fuel cell system control unit. The hydrogen fuel cell system control unit is electrically connected to the external wiring harness (10) of the hydrogen fuel cell system control unit.

2. The integrated hydrogen fuel cell system controller according to claim 1, characterized in that, The outer casing (1) has a cable outlet panel (11) at both ends. The DC input and output power line (8) extends from the cable outlet panel (11) at one end of the outer casing (1) to the outside of the outer casing (1). The external wiring harness (10) of the hydrogen fuel cell system control unit extends from the cable outlet panel (11) at the other end of the outer casing (1) to the outside of the outer casing (1).

3. The integrated hydrogen fuel cell system controller according to claim 1, characterized in that, The DC converter includes a DC power converter (12) and a DCL converter (13). The DC power converter (12) is electrically connected to the DC converter control circuit (9) and the hydrogen fuel cell system control unit. The DCL converter (13) is electrically connected to the DC power converter (12), the DC converter control circuit (9), and the hydrogen fuel cell system control unit.

4. The integrated hydrogen fuel cell system controller according to claim 3, characterized in that, The DC power converter (12) adopts a synchronous BUCK-BOOST buck-boost topology.

5. The integrated hydrogen fuel cell system controller according to claim 4, characterized in that, The DCL converter (13) adopts a synchronous BUCK buck topology.

6. The integrated hydrogen fuel cell system controller according to claim 3, characterized in that, The DC converter control circuit (9) includes an MCU21 microcomputer (14), an ADC data acquisition circuit (15), and a PWM drive level conversion and floating ground drive circuit (16). The ADC data acquisition circuit (15) and the PWM drive level conversion and floating ground drive circuit (16) are both electrically connected to the MCU21 microcomputer (14). The ADC data acquisition circuit (15) is electrically connected to the DC power converter (12) through a power terminal block (7). The PWM drive level conversion and floating ground drive circuit (16) is electrically connected to the DC power converter (12) through a signal header (6). The temperature acquisition module is electrically connected to the MCU21 microcomputer (14) and the hydrogen fuel cell system control unit through a signal header (6). The MCU21 microcomputer (14) is electrically connected to a step-down analog DC control circuit (17) through a signal header (6). The step-down analog DC control circuit (17) is electrically connected to the DCL converter (13).

7. The integrated hydrogen fuel cell system controller according to claim 6, characterized in that, The hydrogen fuel cell system control unit includes an MCU30 microcomputer (18), a communication circuit (19), a resistance data acquisition circuit (20), a fan PWM drive circuit (21), a fan speed feedback acquisition circuit (22), a low-side drive circuit (23), a high-side drive circuit (24), an ACC and digital I / O interface circuit (25), a voltage data acquisition circuit (26), a data exchange circuit (27), a sampling circuit (28), a wake-up circuit, and a system wiring harness interface (29). The communication circuit (19), resistance data acquisition circuit (20), fan PWM drive circuit (21), fan speed feedback acquisition circuit (22), low-side drive circuit (23), high-side drive circuit (24), ACC and digital I / O interface circuit (25), voltage data acquisition circuit (26), and data exchange circuit are also included. (27) The sampling circuit (28) and the wake-up circuit are all electrically connected to the MCU30 microcomputer (18). The communication circuit (19), the resistance data acquisition circuit (20), the fan PWM drive circuit (21), the fan speed feedback acquisition circuit (22), the low-side drive circuit (23), the high-side drive circuit (24), the ACC and digital IO interface circuit (25), the voltage data acquisition circuit (26), and the wake-up circuit are all electrically connected to the external wiring harness (10) of the hydrogen fuel cell system control unit through the system wiring harness interface (29). The MCU30 microcomputer (18) is electrically connected to the MCU21 microcomputer (14) through the data exchange circuit (27). The MCU30 microcomputer (18) is electrically connected to the DC power converter (12) through the sampling circuit (28) and the power connection stud (7).

8. The integrated hydrogen fuel cell system controller according to claim 7, characterized in that, The communication circuit (19) includes a CAN communication circuit (191) and a 485 communication circuit (192).

9. The integrated hydrogen fuel cell system controller according to claim 1, characterized in that, The DC input / output power line (8) includes an input lead (81) and an output lead (82). The positive terminal of the input lead (81) is electrically connected to the positive terminal of the hydrogen fuel cell stack, and the negative terminal of the input lead (81) is electrically connected to the negative terminal of the hydrogen fuel cell stack. The positive terminal of the output lead (82) is electrically connected to the positive terminal of the energy storage battery, and the negative terminal of the output lead (82) is electrically connected to the negative terminal of the energy storage battery.

10. The integrated hydrogen fuel cell system controller according to claim 1, characterized in that, The hydrogen fuel cell system control unit includes a three-wire CAN communication interface, a two-wire 485 communication interface, a two-wire high-side drive interface, a two-wire low-side drive interface, a four-wire fan drive interface, a two-wire resistance data acquisition interface, a three-wire voltage data acquisition interface, a single-wire ACC wake-up interface, a single-wire DI digital input interface, and a two-wire DCL power output interface on its external wiring harness (10).

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