FUEL CELL MODULE WITH MODULAR POWER ELECTRONICS MODULES

Abstract

A fuel cell module is disclosed and comprises: a fuel cell stack comprising one or more first outer interfaces; and modular power electronics modules (MPEMs), each MPEM comprising at least one subsystem module configured to perform operations with respect to the fuel cell stack, and one or more outer interfaces, each of which is standardized and configured to couple with each of the first outer interfaces. The outer interfaces of one of the MPEMs are configured to couple with the other outer interfaces of the other MPEMs.

Description

INTRODUCTION

[0001] The present invention relates to fuel cells and in particular to a fuel cell module according to the preamble of claim 1, as is known essentially from DE 10 2021 210 932 A1. Further prior art is described in EP 3 300 943 A1 and US 2004 / 0 217 732 A1.

[0002] A fuel cell receives fuel, including hydrogen and oxygen, and splits the hydrogen into protons and electrons at an anode. The protons pass through an electrolyte membrane to reach a cathode, where they combine with the oxygen atoms and electrons to produce water and electricity. This electricity can be used, for example, to power a vehicle if the fuel cell is installed in a vehicle. Another example is using a fuel cell as a generator to power various loads. SUMMARY

[0003] According to the invention, a fuel cell module is presented which is characterized by the features of claim 1.

[0004] In other features, each of the one or more first outer interfaces and one or more outer interfaces of the MPEMs includes communication bus terminals and power terminals.

[0005] In other features, each of the one or more first outer interfaces and one or more outer interfaces of the MPEMs includes cooling channels.

[0006] Other features include low-voltage terminals, which have voltages of 48 V or less, and high-voltage terminals, which have voltages of 50 V or more.

[0007] In other features, the electrical domain control module controls the operation of the PCM and / or a fluid domain control module.

[0008] In other features, at least one of the MPEMs includes buses and busbars, including communication buses and power busbars, extending between the outer interfaces of the at least one MPEM.

[0009] In other features, one of the MPEMs is implemented as a fluid domain control module and includes hardware drivers, fuses, and a master-local interconnect network.

[0010] In other cases, one or more external interface(s) of the MPEMs couple(s) with an electric air compressor of the fuel cell module, which is driven by an inverter.

[0011] In other features, one of the MPEMs includes: high-voltage interfaces for the plant interfaces, configured to connect pumps; one or more access hatches for accessing the at least one subsystem module of the one of the MPEMs; a low-voltage data and power output interface configured to couple with a load; and a high-voltage output interface configured to couple with a load.

[0012] In other features, the MPEMs are configured to be coupled to each other and to the fuel cell stack in various arrangements.

[0013] In other features, the various arrangements include: a stacked arrangement, wherein a first MPEM is coupled between a second MPEM and the fuel cell stack, the MPEMs comprising the first MPEM and the second MPEM; a centralized arrangement, wherein the first MPEM and the second MPEM are both coupled to the fuel cell stack; and a combination arrangement, wherein two or more of the MPEMs are coupled to the fuel cell stack, and one or more other MPEMs are coupled not to the fuel cell stack but to one of the MPEMs.

[0014] In other respects, the MPEMs are integrated into the unique hardware of the fuel cell stack.

[0015] In other features, the non-multiple hardware includes at least one of: one or more casings; fuel cell ends; and compression hardware.

[0016] Other features disclose a vehicle comprising: one or more fuel cell modules configured to generate electrical current and comprising an electrical domain control module; and a vehicle control module configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and to control the distribution of electrical current to devices of the vehicle.

[0017] Other features disclose a stationary power plant which comprises: one or more fuel cell modules configured to generate electrical current and comprising an electrical domain control module; and a main control module configured to communicate with the electrical domain control module to control the operation of the fuel cell stack and to control the distribution of electrical current to loads connected to the stationary power plant.

[0018] Further applications of the present invention will become apparent from the detailed description, the claims, and the drawings. The detailed description and the specific examples serve only for illustration. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be better understood with reference to the detailed description and the accompanying drawings, wherein: Fig. 1 is a functional block diagram of a vehicle comprising an exemplary fuel cell system according to the present invention; Fig. 2 is a functional block diagram of a stationary power plant comprising an exemplary fuel cell system according to the present invention; Fig. 3 is a functional block diagram of an exemplary control system for multiple fuel cell modules (FCMs) according to the present invention; Fig. 4 is a functional signal and fluid flow diagram of an exemplary fuel cell system according to the present invention; Fig. 5 is a schematic and functional block diagram of a section of an exemplary fuel cell illustrating various different sensors according to the present invention; Fig. 6 is a schematic and functional block diagram of an exemplary FCM according to the present invention; Fig. 7 a functional block diagram of a first exemplary modular power electronics module (MPEM) (also referred to as a power distribution control and safety module) according to the present invention; Fig. 8 is a functional block diagram of a second example of an MPEM (or current conversion module) according to the present invention; Fig. 9 a functional block diagram of a third exemplary MPEM (or fluid domain control module) according to the present invention; Fig. 10 is a functional block diagram of another exemplary MPEM, which is each of the MPEMs of the Fig. 7-9 represent the inner and outer interfaces relative to the subsystem modules according to the present invention; Fig. 11 is a front view of an exemplary external interface according to the present invention; Fig. 12 is a front view of an exemplary internal interface according to the present invention; Fig. 13 is an exemplary subsystem module with a through-flow cooling circuit that provides internal and / or through-flow cooling according to the present invention; Fig. 14 is an exemplary subsystem module with a non-continuous cooling circuit according to the present invention; Fig. 15 an exemplary subsystem module with a low-voltage electrical pass-through circuit according to the present invention; Fig. 16 an exemplary subsystem module with a low-voltage non-transmission electrical circuit according to the present invention; Fig. 17 an exemplary subsystem module with an electrical high-voltage crossing circuit according to the present invention; Fig. 18 an exemplary subsystem module with an electrical high-voltage non-transmission circuit according to the present invention; Fig. 19 a layered representation of an FCM of Fig. 6 according to the present invention; Fig. 20 is a functional block diagram of an exemplary section of an FCM in a first arrangement according to the present invention; Fig. 21 is a functional block diagram of an exemplary section of an FCM in a second arrangement according to the present invention; Fig. 22 a perspective view of a section of an FCM in a third arrangement according to the present invention; Fig. 23 a perspective view of an exemplary section of an FCM in a fourth arrangement according to the present invention; Fig. 24 is a cross-sectional view of an exemplary section of an FCM, which has an arrangement similar to that in Fig. 22 with access flaps according to the present invention; Fig. 25 is a functional block diagram of an exemplary subsystem module according to the present invention; Fig. 26 is a functional block diagram of a further exemplary subsystem module according to the present invention; Fig. 27 is a top view of an exemplary subsystem module (or layer) according to the present invention; Fig. 28 is a top view of an exemplary subsystem module (or layer) according to the present invention; Fig. 29 a top view of the subsystem module of Fig. 28 is the one that is on the subsystem module of Fig. 27 stacked according to the present invention; Fig. 30 is a perspective, representative view of the power bricks of a power conversion module according to the present invention; Fig. 31 is an end view, showing the high-voltage terminals and parallel circuits of the Power Bricks from Fig. 30 in a first arrangement according to the present invention; Fig. Figure 32 is an end view showing the high-voltage terminals of the Power Bricks. Fig. 30 illustrated in a second arrangement according to the present invention; Fig. 33 a cross-sectional view through one of the Power Bricks from Fig. 30 along a sectioning plane AA according to the present invention; Fig. 34 a cross-sectional view through one of the Power Bricks from Fig. 30 along a section plane BB according to the present invention; Fig. 35 a cross-sectional view through one of the Power Bricks from Fig. 30 along a sectioning plane CC according to the present invention; and Fig. 36 a cross-sectional view through one of the Power Bricks from Fig. 30 along a sectioning plane DD according to the present invention.

[0020] Reference symbols can be reused in the drawings to identify similar and / or identical elements. DETAILED DESCRIPTION

[0021] A fuel cell powertrain (or system) may include a fuel cell stack, heaters and / or pumps (e.g., a hydrogen pump and a high-voltage coolant (HVC) pump), an air compressor, valves, converters, one or more heaters, a water separator, a humidifier, a circulating fan, coolant lines (or pipes), low-voltage and high-voltage lines, etc. The aforementioned elements of a fuel cell system are designed, configured, connected, and arranged for a specific application. Fuel cell systems can be implemented in vehicles as well as in other applications, such as stationary power applications. The fuel cell systems disclosed herein may, for example, be implemented in road vehicles, off-road vehicles, locomotives, large and small marine applications, aircraft, stationary power applications, etc.Road vehicles include commercial and private vehicles, medium and heavy-duty trucks (e.g., Class 8), passenger cars, etc. Heavy off-road vehicles include trucks and vehicles for mining, excavation and earthmoving equipment, transport equipment, construction machinery (e.g., cranes, cement mixers, etc.), mobile elevating work platforms, etc. Locomotive applications include auxiliary power units and traction units. Marine applications include auxiliary power and propulsion applications. Aviation applications include aircraft engines, aircraft auxiliary power units, drones, unmanned vehicles, etc. Stationary power applications include installed emergency power generators at commercial sites and other generators and charging stations (e.g., generators and charging stations implemented on trailers).Each of the modular fuel cell systems disclosed herein can be configured and reconfigured to be implemented in any of these applications.

[0022] It can be difficult to make a change to one element and / or part (e.g., the fuel cell stack) without having to change the specifications, bolt patterns, components, coupling arrangements, etc., of other elements and / or parts of the fuel system. For example, a part of the hardware of a fuel cell system is designed to be mechanically, electrically, and fluidically connected to a fuel cell stack and is sized and arranged to fit into a specific space that has spatial limitations for a particular application. This might be the case, for instance, if the power output, and therefore the size of the fuel cell stack, needs to be increased.This change may necessitate the redesign of many other components of the fuel cell system to accommodate the new fuel cell stack and meet the specifications of a current application or the requirements of a different application. For example, the voltage, current, and / or power requirements of the fuel cell stack may increase, requiring a larger size and / or greater number of fuel cell plates. This, in turn, necessitates changes to the specifications, sizes, coupling arrangements, and so on of other components. This can result in time-consuming and costly redesigns, retrofits, and the re-engineering of various components. Consequently, there may be multiple different fuel cell systems and corresponding components for different fuel cell applications.

[0023] The examples described herein include fuel cell systems comprising modular power electronics modules configured for various applications with differing voltage, current, and power requirements, and which can be interconnected in various arrangements. The examples are flexible for different fuel cell systems with different fuel cell stacks exhibiting varying specifications, including different sizes, shapes, voltage and current requirements, power requirements, and cooling requirements.

[0024] The examples provide an electrical architecture for high-power-density fuel cells designed to offer modular flexibility for fuel cell system control, safety, stack sensing, and power conversion. The architecture allows for the integration and replacement of components, including stack sensing elements, power conversion modules, safety systems, and power distribution hardware, without requiring significant modifications to the main design of the fuel cell system.

[0025] The examples provide a scalable and adaptable platform that enables flexible integration based on specific application requirements. These requirements may relate to power conversion, control options, or safety features. The disclosed system modularity improves maintainability, scalability for different current levels, and optimization of fuel cell performance for various use cases, including vehicle applications, energy storage, and grid injection. The adaptable platform is flexible, customizable, and suitable for a multitude of fuel cell applications, ensuring high current density and safety.

[0026] The revealed electrical architecture of the fuel cell is modular and allows for the integration of modular components. For example, the modular design enables the easy replacement and / or upgrade of components (e.g., stack sensing components, power conversion modules, safety hardware, etc.) without requiring major redesigns or modifications to a nuclear fuel cell stack.

[0027] The examples include one or more control modules (e.g., an electric domain control module, a vehicle control module, a main control module, etc.) that are dynamically configurable and perform multiple functions, such as acting as a primary domain controller, a data aggregator, or a general fuel cell controller. This allows the control system to be tailored to specific application needs, regardless of whether the control modules operate independently, for a vehicle application, and / or as part of a larger multi-fuel cell configuration.

[0028] The examples provide multi-channel communication support, including support for a range of communication protocols such as variants of the Local Interconnect Network (LIN), the Controller Area Network (CAN), the serial network (SENT), and Ethernet communication protocols, enabling integration with various systems. The examples also provide reconfigurable power conversion. The power conversion modules within the architecture are modular and can be reconfigured for an isolated or non-isolated topology, depending on the specific application requirements.This reconfigurability allows the system to balance important design trade-offs, such as between isolated conversion, which provides galvanic isolation (desirable for safety in high-voltage systems but generally associated with higher costs and lower efficiency), and non-isolated conversion, which offers higher efficiency and lower costs and is therefore desirable for applications where safety isolation is not critical. This modularity allows system designers to select the appropriate power conversion strategy without having to redesign the entire system, increasing flexibility for applications such as energy storage, grid export, or direct DC power use.

[0029] The examples also provide integrated safety systems. The modular architecture includes a number of safety features, such as pyrotechnic disconnect devices, active / passive discharge hardware, and insulation detection systems. These are implemented in a modular and reconfigurable manner, providing the ability to flag unsafe states and safely disconnect a fuel cell stack from a high-voltage bus without affecting the overall system.

[0030] Fig. Figure 1 represents a host vehicle 100 comprising an exemplary fuel cell system 102. The fuel cell system 102 comprises one or more fuel cell modules (FCMs) 103, fuel sources 104, and a vehicle control module 107. The vehicle control module 107 can simply supply power to the FCMs 103 or, in one embodiment, communicate with the FCMs 103 and control their operation. Each of the FCMs can comprise one or more control modules, as described below. The control modules of the FCMs can be specifically designed to control the operation of the FCMs, or the vehicle control module can control the operation of the FCMs, or a combination thereof. Fuel sources can include hydrogen, oxygen, and / or air sources. Fuel sources can include tanks and pumps. Examples of the FCMs 103 and sections thereof are given in Figure 1. Fig. 2-36 illustrated and described.

[0031] The host vehicle 100 can be a non-autonomous, semi-autonomous, or fully autonomous vehicle. The host vehicle 100 can be an electric vehicle. The vehicle control module 107 controls the operation of the host vehicle 100, a vision (or perception) system 108, which includes object detection sensors 109, other sensors 110 (e.g., temperature and pressure sensors, component and actuator sensors, acceleration and velocity sensors, occupant sensors, etc.), power source(s) 111, an infotainment module 112, and other control modules 113. The power sources 111 include one or more battery packs (one battery pack 114 is shown) and a control circuit 115. The battery packs can be charged via the FCMs 103. The object detection sensors 109 can include cameras, radar sensors, lidar sensors, etc.The other sensors 110 may include temperature sensors, accelerometers, a gyroscope, a steering angle sensor, wheel speed sensors, a vehicle speed sensor, and / or other sensors, some of which are mentioned above. The power sources 111 may include low-voltage power sources (e.g., 5 V, 12 V, or 48 V power sources) and high-voltage power sources (e.g., 240–800 V power sources) for supplying low-voltage and high-voltage loads. The energy is stored and then converted into useful work for low- and high-voltage loads, motive power, auxiliary load(s), etc. The vehicle control module 107 may include an operating mode selection module 117 and a parameter setting module 118.

[0032] Modules 107, 112, 113, 117, and 118 can communicate with each other via one or more buses and / or network interfaces 120 and have access to the memory 119. The network interfaces 120 can include a CAN bus, a LIN bus, an Ethernet network interface, an automatic network communication protocol bus, and / or another network bus.

[0033] The vehicle control module 107 controls the operation of vehicle systems. The mode selection module 117 can select a vehicle operating mode. The parameter setting module 118 can be used to set, obtain, and / or determine parameters of the host vehicle 100, based, for example, on signals from sensors 109, 110, and / or other devices and modules mentioned herein.

[0034] The host vehicle 100 can further include the display 120, an audio system 122, and one or more transceivers 124. The display 120 and / or the audio system 122 can be implemented together with the infotainment module 112 as part of an infotainment system.

[0035] The host vehicle 100 may further include a global positioning system (GPS) receiver 128 and a map module 129. The GPS receiver 128 can provide the vehicle's speed and / or direction (or course) and / or global time information. The GPS receiver 128 can also provide information about the vehicle's location, including lane information. The map module 129 provides map information. This map information may include traffic control objects, routes traveled, and / or routes to be traveled between starting locations (or origin locations) and destinations. The sight detection system 108, the GPS receiver 128, and / or the map module 129 can be used to determine the location of objects and the position of the host vehicle 100 relative to the objects.This information can also be used to determine i) course information of the host vehicle 100 and / or the objects and ii) a relative speed of the host vehicle 100 relative to the objects.

[0036] Memory 119 can store sensor data 130, vehicle parameters 132, and applications 136. The applications 136 can include applications executed by modules 107, 112, and 113. Although memory 119 and the vehicle control module 107 are shown as separate devices, they can be implemented as a single device. Memory 119 can be accessible to a brake control system 141 and / or a steering system 142.

[0037] The vehicle control module 107 can control the operation of systems 141, 142, and a drive system 143, which may include a converter / generator 146, a transmission 148, and / or electric motors 160. This control can be based on parameters set by modules 107, 112, 113, 117, and 118. The vehicle control module 107 can set some of the vehicle parameters 132 based on signals received from sensors 109 and 110. The vehicle control module 107 can receive power from energy sources 111, which can be supplied to the brake control system 141, the converter / generator 146, the transmission 148, the electric motors 160, etc. Some of the vehicle control operations may include starting and running the electric motors 160, supplying power to the systems 102, 141, 142, 143 and / or performing other operations which are further described herein.

[0038] The systems 141, 142, the converter / generator 146, the transmission 148, the brake actuation system 158 and / or the electric motors 160 may include actuators controlled by the vehicle control module 107 to adjust, for example, the airflow, fuel flow, steering angle, speed, acceleration, braking force, etc. This control may be based on the outputs of the sensors 109, 110, the GPS receiver 128, the MAP module 129 and the aforementioned data and information stored in memory 119.The vehicle control module 107 can determine various vehicle parameters, including voltages, currents, vehicle speed, engine speed, engine torque, yaw angle, yaw rate, gear position, accelerometer position, brake pedal position, amount of regenerative (charging) current, understeer coefficient and / or value, oversteer coefficient and / or value, and / or other parameters. These parameters can be stored in memory 119. The drive system 143 can also include one or more axles 164, including one or more differentials 166 of one or more axles 164 of the host vehicle 100. The brake control system 141 can, for example, be a brake-by-wire system, such as an electromechanical or electrohydraulic brake system. The steering system 142 can be an electric power steering system.

[0039] Fig. Figure 2 represents a stationary power plant 200, which includes an exemplary fuel cell system 202. The fuel cell system 202 includes fuel sources 204, FCMs 206, a main control module 208, a load interface 210, a transceiver 212, and a storage device 214. The fuel sources 204 can be hydrogen and oxygen sources. The FCMs 206 can be configured as any of the FCMs mentioned herein. The main control module 208 can request power from the FCMs 206 and / or control the operation of the FCMs 206. The load interface 210 can include low-voltage and / or high-voltage terminals for connecting to one or more loads 230. Fig. The fluid lines (or channels) are designated 220, and the electrical lines are designated 222. Although depicted as a stationary power plant where the loads are separate from the stationary power plant 200, the stationary power plant 200 can be implemented as a machine and include the loads, which include actuators, motors, etc.

[0040] Fig. Figure 3 represents a control system 300 for multiple fuel cell modules (FCMs) 302, 304, which are connected to and / or can be controlled by an application control module 306. Although two FCMs are shown, any number of FCMs can be connected to the application control module 306, which relates to the vehicle control module 107. Fig. 1, the main control module 208 of Fig. 2 refers to, or another application control module. Each of the FCMs 302, 304 includes electrical domain control (EDC) modules 306, 308 and fluidic domain control (FDC) modules 310, 312.

[0041] For example, the 300 control system can be implemented in a truck application. The EDC modules 306 and 308 can contain control code and algorithms and are capable of mediating multiple FCMs and communicating with a system communication gateway. The FDC modules 310 and 312 can drive the anodes and cathodes of fuel cell stacks. Data can be transferred between the EDC modules 306 and 308 and the FDC modules 310 and 312. Data and stimulus signals can be transferred between the application control module 306 and the EDC modules 306 and 308. Control signals can be transferred from the application control module 306 to the EDC modules 306 and 308. Control signals can be transmitted from EDC modules 306 and 308 to FDC modules 310 and 312, which may or may not have been originally generated in EDC modules 306 and 308. In another embodiment, the application control module 306 can include FCM code and algorithms and mediate between multiple FCMs.The EDC modules 306 and 308 can be switched to facilitate algorithm iteration functions and / or include one or more hardware drivers.

[0042] Fig. Figure 4 presents a signal and fluid flow diagram 400 of an exemplary fuel cell system, such as one of the fuel cell systems mentioned herein. The diagram 400 includes the fuel cell stack's energy generation, stack sensing 404, current conversion 406, high-voltage (HV) distribution and sensing 408, and application load and energy storage 410. A fuel cell stack generates electrical energy, which is sensed by stack sensing 404. Current from the fuel cell stack is converted via current conversion 406, and the resulting current is distributed and sensed via HV current distribution and sensing 408. Power can be supplied to a direct current (DC) to alternating current (AC) converter 420, a DC converter 422, and another DC converter 424, each supplying an air compressor 426, an HVC 428, and a hydrogen pump 430, respectively.During power conversion 406 and / or at converters 420, 422, 424, heat losses can occur, as represented by 426. A Balance of Plant (BOP) 432 can be used to direct fluids, including fuel, air, and coolant, to the fuel cell stack, as shown by arrow 440. Fig. 4. Fluid lines (or channels) are represented by dashed lines 442 and electrical lines by solid lines 444. Control data can be generated during batch acquisition 404 and HV power distribution and acquisition 408, as shown in 446, and can be used to control actuators, valves, pumps, etc.

[0043] Safety systems can be implemented during operations related to 402, 404, 406, 408, and 410. This can include sensing voltages, currents, temperatures, etc., and taking actions to prevent damage to the system and / or components based on the sensed parameters. Low voltages (e.g., 0–350 V) can be used, and low-voltage operations can be performed during fuel cell stack power generation (402), stack sensing (404), and current conversion (406). High voltages (e.g., 400–850 V) can be used, and high-voltage operations can be performed during current conversion (406) and high-voltage power distribution and sensing (408). DC and / or AC power can be delivered to one or more application loads via one or more voltage buses and / or current terminals.DC power can be supplied to an energy storage system, which may include one or more battery packs.

[0044] Fig. Figure 5 presents section 500 of an exemplary fuel cell system and illustrates various sensors. Section 500 comprises a fuel cell stack 502, a first sensing circuit 504, power electronics 506, a second sensing circuit 508, and an application load and energy storage device 510. The fuel cell stack can comprise a stack of plates (e.g., stainless steel plates, graphite plates, composite plates, etc.) and membranes through which air and hydrogen are passed to generate electrical energy, which is converted into usable voltages. The sensing circuits 504 and 508 can be partially or completely connected during stack sensing 504 and / or high-voltage power distribution and sensing 508. Fig. 4 and / or be implemented by one or more MPEMs, examples of which are given in Fig. 6 are shown.

[0045] The first sensing circuit 504 can comprise a high-voltage high-side rail 509, a high-voltage low-side rail 511, current sensors 512, 514, voltage sensors 516, 518, 520, a pyrotechnic discharge device 522, and a switch 524. The current sensor 512 is connected along rail 509 to the fuel cell stack 502 and the power electronics 506. The current sensor 514 is connected along rail 511 to the fuel cell stack 502 and the power electronics 506. The voltage sensor 516 is connected via rails 509, 511 to the current sensors 512, 514. The voltage sensors 518, 520 are connected in series via the rails 509, 511, and the series of 518, 520 is connected in parallel to the voltage sensor 516.The pyrotechnic discharge device 522 is connected in series with the switch 524, and the switched series is connected via the rails 509, 511 and in parallel to the switched series of voltage sensors 518, 520. The voltage sensors 518, 520 and the switch 524 are connected to ground. The switch 524 can be a fault switch for an insulation monitor.

[0046] Current sensor 512 can be a primary DC current sensor for the fuel cell stack. Current sensor 514 can be a secondary DC current sensor for the fuel cell stack. Voltage sensor 516 can be a fuel cell stack HV+-to-HV sensor. Voltage sensor 518 can be a sensor for the HV+ voltage from the fuel cell stack to the chassis. Voltage sensor 520 can be a fuel cell stack-to-HV- voltage sensor. Pyrotechnic discharge device 522 can be a fast fuel cell stack discharge device.

[0047] The second detection circuit 508 can include a high-voltage high-side rail 527, a high-voltage low-side rail 529, voltage sensors 530, 532, 534, current sensors 536, 537, a pyrotechnic isolating device 538, and a pyrotechnic isolating device 540. The voltage sensor 530 is connected via the rails 527 and 529 and can be a sensor for connecting HV+ to HV-. The voltage sensors 532 and 534 are connected in series, via the rails 527 and 529, and to ground. The voltage sensor 532 can be an application HV+ to chassis sensor. The voltage sensor 534 can be a sensor for connecting chassis to HV-. The current sensor 536 is located on the low-side rail 529 and can be a gross FCM DC current sensor. The current sensor 537 is connected along the high-side rail 527 and can be a net FCM DC current sensor. The pyrotechnic disconnect device 538 is connected along the high-side rail 527 and can be intended for an HV+ terminal.The pyrotechnic separation device 540 is connected along the low-side rail and can be designed for an HV clamp.

[0048] Fig. Figure 6 represents an FCM 600, which features a modular and adaptable platform comprising a fuel cell stack 602 and MPEMs 604, 606, 608, a fuel and air circuit 610, a water vapor transfer device 612, an air engine (or air compressor) 614, a hydrogen pump 616, and an HVC pump 618. The MPEM 604 can be a power conversion module (PCM). The MPEM 606 can be a power distribution control and sensing module. The MPEM 608 can be an FDC module.

[0049] The MPEMs 604, 606, and 608 can include subsystem modules. For example, the MPEM 604 can include subsystem modules 620, and the MPEM 606 can include subsystem modules 622. Subsystem modules 620 and 622 can be used to perform various operations, as described below, and can be easily accessed, serviced, connected, activated, replaced, and exchanged for another subsystem module. The components of subsystem modules 620 and 622 can also be easily accessed, serviced, connected, activated, replaced, and exchanged for other components. The MPEMs 604, 606, and 608 can also include one or more communication buses and terminals for communicating with other MPEMs, modules within other MPEMs, and / or other devices. The MPEMs 604, 606, 608 can also include low-voltage and / or high-voltage busbars and terminals, as well as cooling channels.As an example, the MPEM 604 is shown with one or more power buses 630, a communication bus 632, and cooling channels 634 extending over the MPEM 604 and capable of coupling with the MPEM 606 and / or the MPEM 608. In one embodiment, the MPEMs 604, 606, and 608 share common external hardpoints to allow rearrangement of the MPEMs 604, 606, and 608 in various configurations, but have different internal hardware for performing different functional operations.

[0050] The subsystem modules 620 and 622 can be used to perform various operations, as described below, and can be connected to the power buses 630, the communication bus 632, and / or the cooling channels 634. The power buses 630, the communication bus 632, and the cooling channels 634 can be connected to one or more of the external interfaces 636 and 638 and / or one or more other external interfaces. The power buses 630 can be low-voltage and / or high-voltage DC power buses and / or AC power buses. The external interfaces 636 and 638 can each be connected to the external interfaces 640 and 642 of the MPEMs 608 and 606.

[0051] The MPEM 606 may include an additional external interface 646, which is connected to an external interface 648 of the fuel cell stack housing 650. The external interfaces 642 and 646 may be connected to communication buses and / or voltage busbars 652 and cooling channels 654 of the MPEM 606. The MPEM 606 may include an additional external interface 658, which is connected to an external interface 660 of the air machine (or air compressor) 614. The external interface 658 may be connected to the buses and busbars 652, the cooling channels 654, and / or one of the subsystem modules 622. The modules 604 and 606 may have standardized cooling, such that they have cooling ports of the same shape and size through which the same coolant (or cooling fluid) circulates.

[0052] The outer interfaces 636, 638, 640, 642, 658, and 660 can be configured similarly or identically. An example of this is shown in Fig. 11. The outer interfaces 636, 638, 640, 642, 658, and 660 are standardized to allow a modular arrangement of the MPEMs 604, 606, and 608. Although the MPEMs 604, 606, and 608 are shown with a specific number of outer interfaces, each of the MPEMs 604, 606, and 608 can have any number of outer interfaces, as described, to allow for additional coupling arrangements. Standardized (or common) outer interfaces allow the MPEMs to be moved and coupled in different arrangements.

[0053] The MPEM 606 may further include: a low-voltage data and power output interface 670 for communication and supplying low-voltage loads; one or more access panels 672 to allow access to, maintenance of, and replacement of components of the MPEM 606, including the replacement of the subsystem modules 622 and / or components thereof; a high-voltage output interface 674; a high-voltage BOP interface 676 that supplies the HVC pump 618; and a high-voltage BOP interface 678 that supplies the hydrogen pump 616. Although not in Fig. As shown in Figure 6, each of the subsystem modules 622 can be connected directly or via an internal interface to the external interface 642, the external interface 646, the external interface 658, the low-voltage data and current output interface 670, the high-voltage output interface 674, the HV-BOP interface 676, and the HV-BOP interface 678. The MPEM 608 can also include a low-voltage data and current output interface 680.

[0054] The air machine 614 can include a cooling circuit 690 and a compressor inverter module (CPIM) communication interface 692, which can be connected to the external interface 660.

[0055] Fig. 7 exhibits the modular power electronics module (MPEM) 606 Fig. 6 dar (also referred to as the power distribution control and safety module). The MPEM 606 comprises the subsystem modules 622, the external interfaces 642, 646, 658, the output interfaces 670, 674, the access panels 672, and the HV-BOP interfaces 676, 678. The external interface can be an HV-BOP interface. The HV-BOP interface 658 can be connected via interface 660 to the CPIM communication interface 673 and / or the cooling channels 675. The HV-BOP interface 658 can include cooling and / or low-voltage communication terminals. Each of the subsystem modules 622 comprises corresponding function and / or application modules. For example, the first of the subsystem modules 622 includes an EDC module 710, a stack detection module 712, a high-frequency resistance detection module 714, a filtering module 716, a pyrotechnics module 718 and / or one or more other functional and / or application modules.The EDC module 710 can control operations of the MPEM 606. The MPEM 606 can receive power request signals and / or other command signals from a central control module such as the vehicle control module 107. Fig. 1 or the main control module 208 of Fig. 2. The current request signals request a specific current output from the corresponding fuel cell stack. The stack sensing module 712 monitors the states of the fuel cell stack, such as voltages, currents, power output, and temperatures.

[0056] The HFR detection module 714 identifies one or more HFRs of the fuel cell stack (or its membranes). The filtering module 716 filters the current transformer elements in the PCM 604. The pyrotechnic module 718 can deliver power under certain conditions. For example, if the temperature of the fuel cell stack exceeds a certain threshold, the pyrotechnic module 718 can be used to discharge the fuel cell stack in the event of a stack overvoltage or collision and to disconnect the fuel cell stack from the high-voltage bus in the event of a collision. To control the temperature of the fuel cell stack, the coolant flow is increased, and if the temperature continues to rise, the power is reduced when the temperature reaches a certain threshold.

[0057] The EDC Module 710 can implement the safety control processes described herein, including safety and fault tolerance operations. The EDC Module 710 can control high-voltage disconnection and stack discharge operations, pyrotechnic disconnection operations, and system detection and disconnection operations for fault detection and remediation. The EDC Module 710 can be used in conjunction with one or more of the 604 and 608 modules. Fig. 6 communicate with them, exchange parameters and / or control them. The EDC module 710 can control the operation of the corresponding fuel cell stack or a centralized control module (e.g., the vehicle control module 107 from Fig. 1 or the main control module 208 of Fig. 2) can control the operation of the fuel cell stack by instructing the EDC module 710.

[0058] As another example, a second subsystem module 622 includes an application sensing module 720, a fuse module 722, and / or one or more other function and / or application modules. The application sensing module 720 can include and monitor specific sensors for a particular application. The fuse module 722 can include fuses that can blow under certain conditions. As another example, a third subsystem module 622 includes contactors 724 and inverters 726.

[0059] Fig. 8 represents the MPEM 604 from Fig. 6 (or current conversion module). The MPEM 604 can include subsystem modules 620, the current buses 630, the communication bus 632, the cooling channels 634, and the external interfaces 636, 638. Fig. The MPEM 604 may, for example, include a current conversion module 810, a detection module 812, an HFR (fault) module 814, a filtering module 816, and / or other functional and / or application modules. The current conversion module 810 converts DC current from a suitable fuel cell stack into DC and AC voltages that are output to one or more loads. The stack feeds current from the busbars 652 to the busbars 630, and the busbars 630 distribute the current to one or more current conversion modules. The converted current is then returned to module 606 via an output-side bus (not shown), which may be another current bus located in each of the modules 604 and 606 and connected to the external interfaces 638 and 642. The output bus is then used to distribute the power from module 606 to an application load outside module 606, for example via the HV output 674.The external interfaces 538 and 540 can be used to isolate the fuel cell module from the application load. The DC and AC voltages can be connected to the busbars 652 via busbars 630. Fig. 7 are provided, which can then supply the DC and AC voltages to the LV and HS output interfaces 670 and 674. The sensing module 812 measures voltages, currents, and temperatures of the fuel cell stack and / or other terminals and / or components of the corresponding FCM. The sensors monitored by the sensing module 812 can be separate from the sensors monitored by the stack sensing module 712. Fig. 7 are monitored, and the voltages, currents, and / or temperatures of the same or different terminals and / or components of the FCM are monitored. The sensors monitored by the 812 sensing module and the 712 stack sensing module can be positioned on the fuel cell stack, outside and separate from the fuel cell stack, in the 604, 606 MPEMs, or elsewhere. Modules 814 and 816 can be positioned similarly to modules 714 and 716 of Fig. 7 work.

[0060] Fig. Figure 9 shows the MPEM 608 from Fig. 6 (or Fluid Domain Control Module). The MPEM 608 can include hardware drivers 912, fuses 914, a master LIN 916, and / or other function and / or application modules. The MPEM 608 can control the states of valves, pumps, actuators, pneumatic machines, etc., and monitor various sensors. In one embodiment, this control and monitoring is reduced to a minimum and performed by the EDC module 710. Fig. 7 or a central control module (e.g. the vehicle control module 107 from Fig. 1 or the main control module 208 of Fig. 2) carried out. The MPEM 608 can control the fuel and air circuit 610, the pumps 616, 618 and / or other devices of the FCM 600. Fig. 6 control. The MPEM 608 can include the external interface 640 and the NS data and power interface 680.

[0061] Although each of the subsystem modules of each of the MPEMs 604, 606, 608 of Fig. Figures 7-9, which are shown with specific function and / or application modules, indicate that each of the subsystem modules may include additional or different function and / or application modules. Furthermore, the function and / or application modules shown as implemented by MPEM 604 may also be implemented by MPEM 606, and vice versa. MPEMs 604, 606, and 608 of Fig. Figures 7-9 are shown without internal interfaces and do not depict any external interfaces connected to the subsystem modules. MPEMs 604, 606, and 608 may include external interfaces and may include and / or be connected to internal interfaces. Examples of these interfaces are shown in Fig. Figures 11-12 illustrate. In one embodiment, the function and / or application modules of each of the MPEMs 604, 606, 608 comprise the same types of internal and / or external interfaces, so that the function and / or application modules can be arranged in different sequences and connected differently for different applications.

[0062] Fig. 10 represents an MPEM 1000, which can be used to create any of the MPEMs 604, 606, 608 from Fig. Figures 6-9 can represent the internal and external interfaces relative to the subsystem modules. The MPEM 1000 comprises subsystem modules 1002, which include internal interfaces 1004 and external interfaces 1006. The external interfaces can be represented similarly to external interfaces 636, 638, 640, 642, 646, and 658 of Fig. 6. The subsystem modules 1002 can include all the function and / or application modules mentioned herein.

[0063] Fig. 11 represents an outer interface 1100, which is any outer interface of Fig. 6-10 can represent. The external interface 1100 can include: a communication connector 1102 with communication signal connectors 1103 (e.g., current or voltage signals) and current terminals 1104; hot and cold cooling channels 1105; and positive and negative high-voltage busbars 1106 and corresponding terminals.

[0064] Fig. 12 represents an exemplary internal interface 1200, which is one of the internal interfaces of Fig. 10 represents. The internal interface 1200 can include: a communication plug 1202 with communication signal plugs 1203 (e.g. current or voltage signals) and current terminals 1204; and positive and negative high-voltage busbars 1206 and corresponding terminals.

[0065] The aforementioned subsystem modules can be configured similarly to the subsystem modules of Fig. 13-18, wherein the internal interfaces may include all of the connectors, terminals and / or busbars listed below.

[0066] Fig. 13 represents a subsystem module 1300 with a through-flow cooling circuit comprising input channels 1302 and output channels 1304, providing internal and / or through-flow cooling. Fig. Figure 14 represents an example of a subsystem module 1400 with a non-pass cooling circuit comprising an input channel 1402 and an output channel 1404. Fig. Figure 15 presents an example of a subsystem module 1500 with a low-voltage electrical pass-through circuit comprising an input connector 1502 and an output connector 1504. The terminals of the input connector 1502 can be connected to components within the subsystem module 1500 and to the terminals of the output connector 1504. The terminals of connectors 1502 and 1504 can include communication and power terminals.

[0067] Fig. Figure 16 presents an example of a subsystem module 1600 with a low-voltage non-transmission electrical circuit comprising a connector 1602 which may include input and / or output terminals including communication terminals and power terminals. Fig. Figure 17 represents an example of a subsystem module 1700 with a high-voltage electrical crossover circuit comprising terminals 1702 which may be connected to one or more first busbars and terminals 1704 which may be connected to one or more second busbars. Fig. Figure 18 represents an example of a subsystem module 1800 with a high-voltage non-transmission electrical circuit which may include one or more input terminals 1802 and one or more output terminals 1804.

[0068] Fig. Figure 19 represents a layered representation of the FCM 600 from 1900. Fig. Figure 6 shows that the MPEMs of an FCM can be implemented as layers stacked on a fuel cell stack 1902. The layers can be implemented in one or more sideboxes that are physically connected to a box (or housing) of the fuel cell stack 1902. For example, each layer can have four sidewalls and open ends. The sidewalls of each layer are then stacked, and the components of the layers are connected to each other. The resulting single- or multi-layer stacks of layers are attached to the housing of the fuel cell stack 1902. Several exemplary layers are shown and can include a cooling layer 1904, a stack HV layer 1906, a control board layer with substructure housing 1908, and an application voltage layer 1910. A safety and service layer 1912 can be connected to layers 1906, 1908, and 1910.Layers 1904, 1906, 1908, and 1910 can be arranged between an FCM boundary stack side 1914 and an FCM boundary 1916. Integrated HV modules 1920 for an HVC pump and a hydrogen pump can be connected to the application voltage layer 1910 and the FCM boundary 1916. The FCM boundary stack side 1914 can include connection points 1922 and 1924. The FCM boundary 1916 can include HV connection points 1926 and an access hatch 1928. A cooling layer 1930 can be connected to layers 1908 and 1910.

[0069] Although layers 1904, 1906, 1908, 1910, 1912, and 1930 are shown stacked in a specific arrangement and sequence, they can also be arranged and / or stacked in a different sequence. In one embodiment, layers 1904, 1906, 1908, 1910, 1912, and 1930 have standardized interfaces, such as the external and internal interfaces mentioned herein, to allow the layers to be connected to each other in various arrangements.

[0070] Fig. Figure 20 represents a functional block diagram of section 2000 of an FCM in a first (or centralized) arrangement. Section 2000 comprises a power conversion module (PCM) 2002, a power distribution control and sensing module (PDCSM) 2004, a fuel cell stack 2006, a compressor inverter module 2008, an air compressor 2010, an HVC pump 2012, and a hydrogen pump 2014. In this example, the PCM 2002 and the PDCSM 2004 are coupled to the fuel cell stack 2006 and to each other via external interfaces (in Fig. 20 not shown, but may be configured in a similar way to any other external interface disclosed herein).

[0071] Fig. Figure 21 represents a functional block diagram of section 2100 of an FCM in a second (or stacked) arrangement. Section 2100 comprises a PCM 2102, a PDCSM 2104, a fuel cell stack 2106, a compressor-inverter module 2108, an air compressor 2110, an HVC pump 2112, and a hydrogen pump 2114. In this example, the PCM 2102 is coupled to the fuel cell stack 2106 and between the fuel cell stack 2106 and the PDCSM 2104. The PCM 2102 can be connected to the fuel cell stack 2106 and the PDCSM 2104 via external interfaces (in Fig. 21 (not shown, but can be configured similarly to any other external interface disclosed herein). In another embodiment, the PDCSM 2104 is coupled between the fuel cell stack 2106 and the PCM 2102.

[0072] Fig. Figure 22 describes a section 2200 of an FCM in a third (or centralized) arrangement. The section 2200 comprises a fuel cell stack 2202, a PCM 2204, and a PDCSM 2206. The PCM 2204 is coupled via the fuel cell stack 2202 and the PDCSM 2206. This can be done via the external interfaces disclosed herein. The PDCSM 2206 can, for example, include "cutouts" 2210 that can be removed when additional subsystem modules are added to the PDCSM 2206.

[0073] Fig. Figure 23 represents a section 2300 of an FCM in a fourth (or stacked) arrangement. Section 2300 comprises a fuel cell stack 2302, a PCM 2304, and a PDCSM 2306. The PDCSM 2306 is coupled between the PCM 2304 and the fuel cell stack 2302 and is coupled to the PCM 2304 and the fuel cell stack 2302 via external interfaces, as disclosed herein. The PDCSM 2306 may, for example, include cutouts 2310 that can be removed when additional subsystem modules are added to the PDCSM 2306.

[0074] Fig. 24 represents a section 2400 of an FCM, which has a similar arrangement to that in Fig. Section 2400 comprises a PCM 2410, a PDCSM 2412, and a fuel cell stack 2414. Access panels 2402 and 2404 provide maintenance, service, and tool windows for accessing, servicing, and replacing components and modules of the PCM 2410 and the PDCSM 2412. This allows for easy modification, replacement, and reconfiguration of subsystem modules of the PCM 2410 and the PDCSM 2412. An O-ring 2424 can be positioned between the PCM 2410 and the PDCSM 2412, surrounding an opening 2426 and / or external interfaces of the PCM 2410 and the PDCSM 2412. A convoluted fluid path 2430 can be included in the PDCSM 2412 and between the PCM 2410 and the PDCSM 2412. Several busbars 2432, 2434 are shown, which are connected to subsystem modules of the PCM 2410 and the PDCSM 2412.

[0075] Fig. Figures 25-26 provide examples of subsystem modules with distributed functions. Fig. 25 represents an example of a subsystem module 2500, which includes power rails 2502, a stack detection module 2504, an HFR sensor module 2506, a pyrotechnic module 2508, a filtering module 2510, and an EDC control module 2512. The power rails 2502 and the modules 2504, 2506, 2508, 2510, and 2512 can be configured similarly and function like other similarly named power rails and modules mentioned herein.

[0076] Fig. 26 represents another exemplary subsystem module 2600, which includes a filtering module 2602, an application acquisition module 2604, a safety module 2605, a pyrotechnic module 2606, busbars 2608, and an HV data and power output interface 2610. The modules 2602, 2604, 2605, 2606, and the busbars 2608 can be configured similarly and function like other similarly named busbars and modules mentioned herein.

[0077] Fig. 27 represents an exemplary subsystem module (or layer) 2700, which is an example of the subsystem module 2500 of Fig. Layer 2700 can be 25 and is configured to perform fuel cell stack sensing, busbar cooling, and filtration. Layer 2700 comprises busbars 2702, a connector 2704, sensing, cooling, and filtering components (represented as current sensors 2706), a short-circuiting device (e.g., a pyrotechnic device 2708), an interface 2710, and an internal interface 2712. The interface 2710 can be an external or internal interface. The busbars 2702, the connector 2704, and the sensing, cooling, and filtering components 2706 can be mounted on a substrate 2720. The short-circuiting device 2708 and the interfaces 2710 and 2712 can be mounted on or separate from the substrate 2720. The connector 2704 can be an external interface.

[0078] Fig. 28 represents a subsystem module (or layer) 2800, which is an example of the subsystem module 2600 of Fig. 26. The subsystem module 2800 can include pyrotechnic devices 2802 and detonators 2804, 2806, which are coupled to busbars 2808 and mounted on a substrate 2810, which can include sensors (in Fig. 28 (not shown). The subsystem module 2800 can include: the interface 2710 of Fig. 27 and another internal interface 2810, which can be connected to the busbars 2808 and the pyrotechnic devices 2802; and a plug 2804, which can be an external interface.

[0079] Fig. 29 represents the subsystem module 2800 of Fig. 28 represents, which is based on the subsystem module 2700 of Fig. The subsystem modules 2700 and 2800 can be mounted in and / or on a housing 2910 of non-multiplicative hardware, which may be connected to a fuel cell stack. The housing 2910 of non-multiplicative hardware includes non-multiplicative hardware. This may also include the fuel cell stack hardware for which there are no multipliers. The housing 2910 of non-multiplicative hardware and / or a corresponding cooling layer may include hot and cold cooling channels 2912 and 2914. Fuse 2806 and busbar 2808 are connected to a CPIM interface 2920. Some of the busbars are connected to an HV main connector 2940; others may be connected to an HVC pump and hydrogen pump connector 2942.

[0080] Fig. Figure 30 is a perspective, representative view of Power Bricks 3000, 3002, 3004, 3006 of a PCM. The Power Bricks 3000, 3002, 3004, 3006 can each have one HV+ and one HV- busbar 3010, which can be connected in parallel, as shown in Fig. Figure 31 shows that, for example, each of the Power Bricks 3000, 3002, 3004, 3006 can have an output of 50 kilowatts of electricity. Fig. Figure 31 shows the HV terminals 3012 of the HV+ and HV- busbars 3010 and the parallel connection of the Power Bricks 3000, 3002, 3004, 3006 in a first arrangement. Fig. Figure 32 shows an end view illustrating the 2010 busbars and the high-voltage terminals of the Power Bricks 3000, 3002, 3004, and 3006 in a second arrangement. The 3010 busbars can be connected to a PDCSM 3014.

[0081] Each of the Power Bricks 3000, 3002, 3004, and 3006 can be configured identically. The following, regarding Fig. The examples shown in Figures 33-36 may be included in any of the Power Bricks 3000, 3002, 3004, 3006. Fig. Figure 33 shows a cross-sectional view 3300 through the Power Brick 3000 of Fig. Figure 30, taken in section plane AA. The cross-sectional view 3300 includes a lateral cooling channel 3302, the inductors L1, L2, a heating plate 3304 and a power module 3306. The heating plate 3304 engages with the next module in the Power Brick 3000 for joint cooling.

[0082] Fig. Figure 34 shows a cross-sectional view 3400 through the Power Brick 3002 of Fig. Figure 30 shows the Power Brick 3002 along the section plane BB. The Power Brick 3002 comprises inductors L1 and L2, a central cooling channel 3402, and capacitors 3406. The Power Brick 3002 can include multiple sets of coupled power inductors or single inductors, depending on the design of the current conversion characteristics. In one embodiment, the Power Brick 3002 operates in several of the three current phases to enable hardware conversion between a DC-DC converter and a DC-DC inverter.

[0083] Fig. Figure 35 shows a cross-sectional view 3500 through the Power Brick 3004 of Fig. 30 along the section plane CC. The Power Brick 3004 comprises capacitors 3502, a control board 3504, an electromagnetic interference shield 3506 on a plastic housing, and a power module 3508.

[0084] Fig. Figure 36 shows a cross-sectional view 3600 through the Power Brick 3006 of Fig.30 along the section plane DD. The Power Brick 3006 includes capacitors 3602, a control board 3604, coolant lines 3606 and three-phase output terminals 3608 for a three-phase DC-AC system, but could also be a two-terminal DC-DC output.

[0085] The examples described above comprise a modular electric fuel cell architecture in which sensors, safety systems, power conversion, power distribution, and control hardware for managing the plant balance are implemented. Examples include a stack acquisition module that is interchangeable and designed to meet the central control data requirements of the corresponding fuel cell system and subsystems. The stack acquisition module can be integrated into the unique hardware of the corresponding fuel cell stack and can be built with varying levels of acquisition robustness depending on the application requirements.

[0086] Examples also include a modular safety system with system isolation detection, stack discharge mechanisms, high-voltage disconnectors, and pyrotechnic or semiconductor disconnectors. This ensures system safety under unsafe conditions on an electrical bus. In one embodiment, the modular safety system is designed to operate independently of the control architecture when required.

[0087] Examples include modular power conversion modules that support both isolated and non-isolated DC / DC and DC / AC converters for power conditioning and distribution. These modules provide flexible power export to energy storage systems, the grid, and direct DC loads.

[0088] The examples include a power distribution system comprising high-voltage busbars, fuses, and connectors designed to efficiently and safely transfer power from a fuel cell stack to the application loads. The power distribution system can be reconfigured with minimal impact on key tools and processes.

[0089] The examples include a configurable EDC module that can function as a primary controller, domain controller, and data aggregator, depending on the application requirements. The EDC module supports multiple communication protocols (e.g., CAN, Ethernet, etc.) and can be integrated into fluidic and electrical subsystems.

[0090] The examples described above provide scalability and flexibility. The revealed modular architecture allows for adaptation based on application needs. For example, various current transformers (DC / DC, DC / AC) and safety components are integrated into the architecture without requiring changes to a current transformer or the design of a fuel cell stack. This flexibility is particularly useful in systems that must meet changing requirements.

[0091] Furthermore, the examples demonstrate easier integration. The disclosed modular architecture supports multi-channel communication protocols, ensuring that the fuel cell system can be easily integrated into a variety of applications, including those in the automotive, industrial, and energy sectors.

[0092] The examples also provide improved safety and fault tolerance. The fuel cell system includes integrated high-voltage isolation and stack discharge hardware to ensure safe operation. Modular safety features, including pyrotechnic disconnect switches and system isolation sensors, provide robust fault detection and response. This improves the overall system reliability through the decoupled nature of the hardware.

[0093] The examples further provide adaptable data acquisition and monitoring. The batch acquisition components can be configured to meet a wide range of robustness requirements, ensuring that critical control data is captured while offering flexibility for various use cases. The examples also provide flexibility in power conversion. The fuel cell system supports both non-isolated and isolated current transformers, enabling flexible power conditioning for applications such as grid export, energy storage, and direct DC use.

[0094] The examples promote a single platform capable of accommodating various electrical components and configurations, enabling a more efficient development process and faster deployment for fuel cell applications. The examples include versatile controllers. One or more of the disclosed control modules are designed to be multifunctional, capable of controlling both the fluidic and electrical subsystems. This allows the control modules to be adapted to different system architectures.

[0095] Furthermore, robust safety protocols are implemented in the examples. The integration of pyrotechnic disconnect switches and active / passive discharge hardware increases safety and prevents potential failures, providing a fail-safe system for high-performance applications. The examples also demonstrate a robust supply chain. A functional segmentation of the electrical system enables robust supply chain development for fuel cell power electronics, which reduces long-term commercialization costs.

[0096] The examples minimize the number and size of components while simultaneously providing modularity for components and modules, allowing for greater flexibility in design and layout. The examples eliminate the number and length of external cables, conduits, and other components.

Claims

[1] Fuel cell module (600), comprising: a fuel cell stack (602) comprising one or more first outer interfaces (636, 638); and a plurality of modular power electronics modules (MPEMs, modular power electronics modules) (604, 606, 608), each of the plurality of MPEMs (604, 606, 608) comprising: at least one subsystem module (622) configured to perform operations with respect to the fuel cell stack (602); and a respective one or more outer interfaces (646, 658), each of which is standardized and configured to couple with each of the one or more first outer interfaces (636, 638), wherein the one or more outer interfaces (646, 658) of one of the plurality of MPEMs (604, 606, 608) is configured to couple with the other outer interfaces of the other plurality of MPEMs (604, 606, 608); wherein each of the plurality of MPEMs (604, 606, 608) comprises a plurality of subsystem modules (622) which comprise the at least one subsystem module (622) of the corresponding plurality of MPEMs (604, 606, 608); wherein each of the plurality of subsystem modules (622) comprises at least one internal interface (636, 638) which is standardized in such a way that it couples with any other of the internal interfaces of the plurality of subsystem modules (622) of the corresponding plurality of MPEMs (604, 606, 608); and the multitude of MPEMs includes (604, 606, 608): a first MPEM (604) comprising or implemented as a power conversion module (PCM) (810); and a second MPEM (606) implemented as a power distribution control and safety module (PDCSM), characterized by , that the first MPEM (604) comprises at least a current conversion module (810), a sensing module (812), a high-frequency resistance sensing module and a filtering module (816); and / or the PDCSM comprises a stack detection module (712), a high-frequency resistance detection module (714), a filtering module (716), an application detection module (720), a fuse module (722), a pyrotechnic module (718), a contactor module and / or an inverter module; and / or the PDCSM includes an electrical domain control module for controlling the operation of the multiple subsystem modules of the PDCSM and the fuel cell stack (602). [2] Fuel cell module according to claim 1, wherein each of the one or more first outer interfaces (636, 638) and of the one or more outer interfaces (646, 658) of the plurality of MPEMs (604, 606, 608) comprises communication bus terminals and current terminals. [3] Fuel cell module according to claim 2, wherein each of the one or more first outer interfaces (636, 638) and of the one or more outer interfaces (646, 658) of the plurality of MPEMs (604, 606, 608) comprises cooling channels (634). [4] Fuel cell module according to claim 2, wherein the current terminals comprise low voltage terminals having voltages of 48 V or less and high voltage terminals having voltages of 50 V or more. [5] Fuel cell module according to claim 1, wherein the electrical domain control module controls the operation of the PCM (810) and / or a fluid domain control module.

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