Fuel cell chemical filter monitoring system and method

Abstract

[0003] Embodiments herein relate to a chemical filter monitoring system for use with a fuel cell system. One embodiment includes a fuel cell chemical filter monitoring system having a processing unit and a sensor package. The sensor package can include one or more sensors. The sensor package can be configured to interface with an air flow path of the fuel cell system upstream of the chemical filter and detect an amount of a compound in the air flow path. The sensor package can be operably connected to the processing unit. The processing unit can be configured to track the total exposure of the chemical filter to the compound. The processing unit can be configured to estimate the remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data related to the total capacity of the chemical filter. Other embodiments are also included herein.

Description

[Technical Field]

[0001] This application was filed as a PCT international application on September 27, 2023, with Donaldson Company Inc., a U.S. corporation, as applicant for all designations, and Qinghui Yuan, a U.S. national, Poonam Sehrawat, a national of India, and Gerald E. Weinech, a U.S. national, as inventors for all designations, and claims priority to U.S. Provisional Application No. 63 / 411,364, filed September 29, 2022, and U.S. Application No. 18 / 373,061, filed September 26, 2023, the contents of which are incorporated herein by reference in their entireties.

[0002] Technical Field SUMMARY OF THE INVENTION Embodiments herein relate to a monitoring system for a chemical filter used with a fuel cell system. [Background technology]

[0003] A fuel cell is an electrical power generating device that consumes hydrogen in a chemical reaction with oxygen, producing water as a waste by-product. Fuel cells have two electrodes, an anode and a cathode. Fuel cells can be of various designs, including alkaline fuel cells, polymer electrolyte membrane fuel cells, phosphoric acid fuel cells, molten carbonate fuel cells, and solid oxide fuel cells. Fuel cells generally use catalysts, including those made of platinum, nickel, cobalt, iron, manganese, and other materials.

[0004] Many fuel cells are susceptible to damage from certain chemicals. For example, the catalysts used in various fuel cells are susceptible to catalyst poisoning by certain chemicals. Therefore, it is desirable to filter certain chemical species, such as SO2, H2S, NO2, NH3, and various volatile organic compounds (VOCs). However, most chemical filters have a finite capacity, and if that capacity is exceeded, potentially harmful chemical species may enter the fuel cell. Summary of the Invention [Problem to be solved by the invention]

[0005]

[0003] Embodiments herein relate to a chemical filter monitoring system for use with a fuel cell system. In a first aspect, the system may include a fuel cell chemical filter monitoring system having a processing unit and a sensor package. The sensor package may include one or more sensors. The sensor package may be configured to interface with an air flow path of the fuel cell system upstream of the chemical filter and detect an amount of a compound in the air flow path. The sensor package may be operably connected to the processing unit. The processing unit may be configured to track a total exposure of the chemical filter to the compound. The processing unit may be configured to estimate a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data related to the total capacity of the chemical filter.

[0006] In a second aspect, in addition to one or more of the above or below aspects, or as an alternative for some aspects, the compound can comprise at least one selected from the group consisting of an acid species, a base species, and a volatile organic compound.

[0007] In a third aspect, in addition to one or more of the above or below aspects, or as an alternative for some aspects, the compound can include at least one selected from the group consisting of SO2, H2S, NO2, NH3, and a volatile organic compound.

[0008] In a fourth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the sensor can include at least one selected from the group consisting of an acid sensor, a base sensor, and a volatile organic compound (VOC) sensor.

[0009] In a fifth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the sensor can include at least one selected from the group consisting of a SO sensor, a H2S sensor, a NO sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor.

[0010] In a sixth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system receives data regarding total capacity from a remote system.

[0011] In a seventh aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system receives data regarding total capacity from the chemical filter itself.

[0012] In an eighth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to transmit data regarding at least one of the total tracked exposure and the estimated remaining filter life.

[0013] In a ninth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the data can be transmitted to a vehicle control system.

[0014] In a tenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the data may be transmitted to a vehicle CANbus system.

[0015] In an eleventh aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the data may be transmitted to a remote monitoring system.

[0016] In a twelfth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the sensor package may further include at least one selected from the group consisting of a temperature sensor, a relative humidity sensor, and a pressure sensor.

[0017] In a thirteenth aspect, in addition to one or more of the above or below aspects, or in the alternative to some aspects, the sensor package may further comprise a flow sensor.

[0018] In a fourteenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can further include a geolocation circuit. In a fifteenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to receive data regarding environmental levels of compounds from a remote system using geolocation data from the geolocation circuit. In a sixteenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to receive data regarding environmental levels of compounds from a remote system.

[0019] In a seventeenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to calibrate one or more sensors using the received data. In an eighteenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to modulate an estimation calculation regarding the remaining life of the chemical filter using the received data.

[0020] In a nineteenth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the processing unit may be configured to receive input regarding a filter replacement event.

[0021] In a twentieth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the input may be a user input.

[0022] In a twenty-first aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the input may be received from another sensor or system.

[0023] In a twenty-second aspect, in addition to one or more of the above or below aspects, or in the alternative to some aspects, the processing unit can be configured to receive data from a vehicle data system.

[0024] In a twenty-third aspect, in addition to one or more of the above or below aspects, or in the alternative to some aspects, the processing unit can be configured to receive data regarding power output from the fuel cell.

[0025] In a 24th aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the processing unit can be configured to use data regarding the power output to modulate an estimation calculation regarding the remaining life of the chemical filter.

[0026] In a twenty-fifth aspect, in addition to one or more of the above or below aspects or in the alternative to some aspects, the vehicle data system can include a CANbus system.

[0027] In a 26th aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the sensor package can further include parallel flow paths, and individual sensors can be disposed within the individual parallel flow paths.

[0028] In a 27th aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to issue an alert when the remaining life of the chemical filter exceeds a threshold.

[0029] In a 28th aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to issue an alert according to a hierarchical severity scheme when the remaining life of the chemical filter exceeds one or more thresholds.

[0030] In a twenty-ninth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the processing unit can be configured to estimate the remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter using a linear equation, a nonlinear equation, a machine learning derived algorithm, a neural network, a simulation, or a digital twin.

[0031] A thirtieth aspect can include a method for monitoring a fuel cell chemical filter, the method can include interfacing with an air flow path of a fuel cell system upstream of the chemical filter, detecting an amount of a compound in the air flow path, tracking a total exposure of the chemical filter to the compound, and estimating a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data related to a total capacity of the chemical filter.

[0032] In a thirty-first aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the method can further include transmitting data regarding at least one of the tracked total exposure and the estimated remaining filter life. In a thirty-second aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the method can further include receiving data regarding the environmental levels of the compound from the remote system. In a thirty-third aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the method can further include transmitting geolocation data to the remote system.

[0033] In a thirty-fourth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the step of receiving data regarding the environmental level of the compound from the remote system may include using the received data to modulate an estimate calculation regarding the remaining life of the chemical filter.

[0034] In a thirty-fifth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the step of receiving data regarding the environmental level of the compound from the remote system may include calibrating one or more sensors using the received data.

[0035] In a thirty-sixth aspect, in addition to one or more of the above or below aspects or in the alternative to some aspects, the method may further include receiving input regarding a filter replacement event.

[0036] In a thirty-seventh aspect, in addition to one or more of the above or below aspects or in the alternative to some aspects, the method may further include receiving data from a vehicle data system.

[0037] In a thirty-eighth aspect, in addition to one or more of the above or below aspects, or in the alternative to some aspects, the method may further include receiving data regarding power output from the fuel cell.

[0038] In a thirty-ninth aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the step of receiving data regarding the power output from the fuel cell may include using the data regarding the power output to modulate an estimation calculation regarding the remaining life of the chemical filter.

[0039] In a 40th aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the method may further include issuing an alert when the remaining life of the chemical filter exceeds a threshold value.

[0040] In a forty-first aspect, in addition to one or more of the above or below aspects, or as an alternative to some aspects, the method may further include issuing an alert according to a hierarchical severity scheme when the remaining life of the chemical filter exceeds one or more thresholds.

[0041] This Summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will become apparent to those skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be construed in a limiting sense. The scope herein is defined by the appended claims and their legal equivalents. [Brief explanation of the drawings]

[0042] Aspects may be more fully understood in connection with the following drawings (FIGS.).

[0043] [Figure 1] 1 is a schematic diagram of a fuel cell chemical filter monitoring system according to various embodiments herein.

[0044] [Figure 2] FIG. 1 is a schematic diagram of components of a fuel cell chemical filter monitoring system according to various embodiments herein.

[0045] [Figure 3] FIG. 1 is a schematic diagram of components of a fuel cell chemical filter monitoring system according to various embodiments herein.

[0046] [Figure 4] FIG. 1 is a schematic diagram of components of a fuel cell chemical filter monitoring system according to various embodiments herein.

[0047] [Figure 5]FIG. 1 is a schematic diagram of a portion of a sensor package according to various embodiments herein.

[0048] [Figure 6] FIG. 1 is a schematic diagram of a portion of a sensor package according to various embodiments herein.

[0049] [Figure 7] FIG. 1 is a schematic diagram of a portion of a sensor package according to various embodiments herein.

[0050] [Figure 8] 1 is a flowchart of operations according to various embodiments herein.

[0051] [Figure 9] 1 is a flowchart of operations according to various embodiments herein.

[0052] [Figure 10] 1 is a flowchart of operations according to various embodiments herein.

[0053] [Figure 11] FIG. 2 is a block diagram of components of a processing unit according to various embodiments herein.

[0054] While the embodiments are susceptible to various modifications and alternative forms, details thereof have been shown by way of example and drawings and will be described in detail. It is to be understood, however, that the scope of the specification is not limited to the particular aspects described. Rather, the intention is to cover modifications, equivalents, and alternatives that are within the spirit and scope of the specification. DETAILED DESCRIPTION OF THE INVENTION

[0055] Many fuel cells are susceptible to damage by certain chemicals. For example, the catalysts used in various fuel cells are susceptible to catalyst poisoning by certain chemicals. Therefore, it is desirable to filter certain chemical species, such as SO2, H2S, NO2, NH3, and various volatile organic compounds (VOCs).

[0056] Various chemical filters have been developed for use with fuel cells to remove chemical species such as SO2, H2S, NO2, NH3, and various volatile organic compounds (VOCs). Generally, they function to have a fixed total capacity for removing such compounds. Therefore, once their capacity is exceeded, the chemical filter can no longer remove such compounds, potentially allowing the compounds to pass into the fuel cell and cause serious damage.

[0057] However, embodiments herein may include a fuel cell chemical filter monitoring system that can accurately track the remaining useful life of a chemical filter for a fuel cell, allowing the chemical filter to be replaced or otherwise serviced in a timely manner to prevent damage to the fuel cell. In various embodiments, the fuel cell chemical filter monitoring system may include a processing unit and a sensor package. The sensor package may include one or more sensors. The sensor package may be configured to interface with an air flow path of the fuel cell system upstream of the chemical filter and detect the amount of a compound in the air flow path. The sensor package may be operably connected to the processing unit. The processing unit may be configured to track the total exposure of the chemical filter to the compound. The processing unit may be configured to estimate the remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter.

[0058] Referring now to Figure 1, a schematic diagram of several components of a fuel cell chemical filter monitoring system 108 according to various embodiments herein is shown. Figure 1 illustrates a fuel cell chemical filter monitoring system 108 within a vehicle 102. The vehicle 102 may include a fuel cell system 104 and a chemical filter 106 to be monitored. However, it will be understood that the monitoring systems herein are not limited to fuel cells used with vehicles. Rather, the monitoring systems herein may be used with fuel cells used in any application.

[0059] The monitoring system 108 may be in electronic communication (wired and / or wireless) with various other systems and components to transmit and / or receive data. In some embodiments, wireless communication to a data network may be performed via communications passing through cell towers 120. However, in some embodiments, communications may be passed using other wireless data communication network infrastructures, including, for example, satellite-based architectures or other data networks. In some embodiments, at least some data communications may occur via a wired infrastructure.

[0060] As an example, system 108 may be in data communication with remote computing resources (servers—real or virtual, databases, etc.), such as computing resources in cloud 122 or available through cloud 302. In the example of Figure 1, system 108 may be in data communication with remote system 124, such as one including remote database 126, for the purpose of transmitting and / or receiving data.

[0061] As described below, the sensor package of the system 108 may be configured to interface with the air flow path of the fuel cell system 104. Specifically, the sensor package of the system 108 may be configured to interface with the air flow path of the fuel cell system 104 upstream of the chemical filter 106. The sensor package of the system 108 may detect and record the amount of various chemical compounds in the air flow path. In this manner, the system 108 may track the total amount of chemicals to which the filter 106 is exposed. By subtracting such amount from the known total capacity of the chemical filter 106 to absorb or otherwise sequester such compounds or from the known remaining capacity of the filter, the remaining useful life of the chemical filter 106 may be estimated.

[0062] In one approach, the total starting capacity of the chemical filter 106 can be the starting point for calculations to estimate the remaining useful life of the chemical filter 106. Then, once the amount of chemical is detected using the sensor package, the remaining capacity can be calculated as the starting capacity minus all detected amounts of chemicals collectively observed since the chemical filter 106 was new or serviced. In some embodiments, the rate at which the chemical filter 106 is exposed to the compound can be calculated (in units per period of time), and this rate, along with the total remaining capacity, can then be used to calculate the expected time at which the chemical filter will reach its total capacity (e.g., no remaining useful life).

[0063] However, it will be appreciated that various techniques can be used to calculate and / or estimate the remaining useful life of the chemical filter. In various embodiments, the processing unit can be configured to estimate the remaining useful life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter using linear equations, nonlinear equations, machine learning derived algorithms, neural networks, deep learning models, simulations, or digital twins. For example, in some embodiments, a training set of data relating to detected amounts of compounds of interest and consumption of capacity of the chemical filter can be obtained. The training set of data can be used to train a machine learning model, the output of which can then be used by the system to calculate the consumption of capacity of the chemical filter and the remaining useful life of the chemical filter. For example, a supervised machine learning approach can be used with the training set of data to develop a machine learning model or algorithm that can be used by the systems herein. Other machine learning approaches that can be used include unsupervised machine learning, semi-supervised machine learning, reinforcement learning, etc. The applied algorithms can include nearest neighbor, naive Bayes, decision trees, linear regression, support vector machines, neural networks, etc. Other algorithms that may be applied include k-means clustering, association rules, Q-learning, temporal differences, deep adversarial networks, etc.

[0064] In some embodiments, the data regarding total capacity may be specific to an individual chemical species of interest (e.g., compound "A" has a capacity of 5 "units," compound "B" has a capacity of 7 "units," etc.). In some embodiments, the data regarding total capacity may relate to a particular class of compound. In some embodiments, the data regarding total capacity may represent the collection of all chemical species that the filter element can absorb or otherwise sequester.

[0065] In various embodiments, the total capacity of the chemical filter can be manually entered into the fuel cell chemical filter monitoring system 108 by a system user (located on-site with the vehicle or remotely). In various embodiments, the fuel cell chemical filter monitoring system 108 receives data regarding the total capacity of the chemical filter from a remote system 124. In some embodiments, the fuel cell chemical filter monitoring system 108 receives data regarding the total capacity of the chemical filter from the chemical filter 106 itself. For example, the chemical filter may include a data tag (such as an RFID tag or NFC tag) carrying data thereon, including, for example, the chemical filter model and / or the chemical filter capacity. In some embodiments, the total capacity of the chemical filter can be stored in the memory of the fuel cell chemical filter monitoring system 108 along with data reflecting the amount of chemicals already exposed. In some embodiments, the total capacity of the chemical filter can be estimated based on filter parameters such as the filter geometry, the absorbent materials used and their properties, sizing, etc.

[0066] In various embodiments, the fuel cell chemical filter monitoring system 108 can be configured to issue an alert when the remaining useful life of the chemical filter 106 exceeds a threshold value. For example, the fuel cell chemical filter monitoring system 108 can be configured to issue an alert when the remaining useful life of the chemical filter 106 falls below a threshold value. The threshold value can be specified in various ways. In some embodiments, the threshold value is a percentage of the capacity of the chemical filter, such as 30%, 20%, 10%, 5%, 1%, etc., or an amount within any of the above ranges. In some embodiments, the threshold value is an estimated amount of time (based on the current usage rate of the chemical filter) until the chemical filter reaches its capacity, such as 30 minutes, 1 hour, 6 hours, 12 hours, 24 hours, etc., or an amount within any of the above ranges. In some embodiments, the threshold value is an estimated amount of miles the vehicle can travel before the chemical filter reaches its capacity (based on the calculated usage rate per time period and the average speed per time period), such as 10 miles, 50 miles, 100 miles, 200 miles, etc., or a range between any of the above. In various embodiments, the fuel cell chemical filter monitoring system 108 can be configured to issue alerts according to a hierarchical severity scheme when the remaining life of the chemical filter 106 exceeds one or more thresholds. For example, a first alert can be issued when the remaining capacity of the chemical filter falls below 10% of its total capacity, and a second alert, of a higher severity level than the first alert, can be issued when the remaining capacity of the chemical filter falls below 2% of its total capacity. Many different hierarchical alert schemes are contemplated herein.

[0067] In various embodiments, fuel cell chemical filter monitoring system 108 can be configured to transmit data, such as data regarding at least one of tracked total exposure, estimated remaining filter life, alerts, etc., to other systems (co-located with the vehicle and / or remotely located). For example, in various embodiments, fuel cell chemical filter monitoring system 108 can transmit data to a vehicle control system or a vehicle data system. As another example, fuel cell chemical filter monitoring system 108 can transmit data to a vehicle CANbus system. In various embodiments, fuel cell chemical filter monitoring system can transmit data to a remote monitoring system. Similarly, in some embodiments, fuel cell chemical filter monitoring system 108 can receive data from such sources.

[0068] In FIG. 1 , the vehicle 102 is shown with a vehicle geolocation 110. Using various techniques and / or hardware, the system 108 can determine the vehicle geolocation 110, which can be used in a variety of ways. Geolocation data can include latitude / longitude coordinates and / or other location-identifying information, such as the nearest address or nearest landmark. As used herein, the term “geolocation data” includes reference to all location-identifying data, unless the context dictates otherwise. In some cases, the geolocation data can be derived from a satellite-based geolocation system. Such systems can include, but are not limited to, GPS L1 / L2, GLONASS G1 / G2, BeiDou B1 / B2, Galileo E1 / E5b, SBAS, etc. In various embodiments, the system can include geolocation circuitry, which can include an appropriate signal receiver or transceiver for interfacing with satellites, and / or the geolocation circuitry can interface with and / or receive data from a separate device or system that provides geolocation data or derives geolocation data from satellites or other devices. However, it will be understood that geolocation data herein is not limited to only that which may be received from or derived from interfacing with a satellite, but rather geolocation data may also be derived from addresses, beacons, landmarks, various referencing techniques, IP address evaluation, etc.

[0069] The geolocation data can be used by the system in various ways. As one example, the vehicle geolocation 110 can be used to retrieve data from a remote system 124 regarding ambient levels of chemical compounds at the geolocation 110 of the vehicle 102. For example, in some embodiments, the system 108 can be in data communication (e.g., via the cloud 122 or another data network) with an API that serves as a source of data, such as an environmental condition API 130. The environmental condition API 130 can provide data regarding ambient levels of various chemical compounds at a particular geolocation, such as the concentration of one or more of SO, HS, NO, NH, and various volatile organic compounds. Thus, in various embodiments, the fuel cell chemical filter monitoring system can be configured to receive data regarding ambient levels of chemical compounds from a remote system using geolocation data from the geolocation circuitry.

[0070] Such data regarding environmental conditions at the vehicle's geolocation (or fuel cell's location) can be used in a variety of ways. In various embodiments, the fuel cell chemical filter monitoring system 108 can be configured to use the received data to calibrate one or more sensors. This aspect is described below with respect to FIG. 10. In various embodiments, the fuel cell chemical filter monitoring system 108 can be configured to use the received data to modulate an estimation calculation regarding the remaining life of the chemical filter 106. This aspect is described below with respect to FIG. 10.

[0071] 2, a schematic diagram of components of a fuel cell chemical filter monitoring system 108 is shown, in accordance with various embodiments herein. The fuel cell system 104 includes a hydrogen supply tank 202 in fluid communication with a hydrogen supply line 204 that carries hydrogen to the fuel cell. The fuel cell system 104 may include an anode 206 and a cathode 208. The fuel cell system 104 also includes an air supply line 210. Typically, ambient gas 218 is drawn into the air supply line 210. The air provided by the air supply line 210 may be a source of oxygen necessary for the fuel cell to operate.

[0072] The fuel cell chemical filter monitoring system 108 can interface with (and be in fluid communication with) an air supply line 210 upstream of the chemical filter 106. The fuel cell chemical filter monitoring system 108 includes a sensor package 212. The sensor package 212 includes various chemical sensors as described herein. The fuel cell chemical filter monitoring system 108 can also include a processing unit 214. In some embodiments, the sensor package 212 and the processing unit 214 can be physically integrated. In other embodiments, they can be physically separate but can be in wired or wireless communication with each other. FIG. 2 also shows the chemical filter 106. An exemplary chemical filter 106 is described in U.S. Patent No. 7,138,008, the contents of which are incorporated herein by reference. The fuel cell system 104 also includes a waste stream output 216, such as one that carries water and other byproducts from the fuel cell.

[0073] As described above, in various embodiments, the sensor package 212 can be configured to interface with the air flow path or air supply line 210 of the fuel cell system 104 upstream of the chemical filter 106. In various embodiments, the sensor package 212 can be configured to detect the amount of a compound in the air supply line 210. In various embodiments, the compound can include at least one including at least one of an acid species, a base species, and a volatile organic compound. In various embodiments, the compound can include at least one including at least one of SO, HS, NO, NH, and a volatile organic compound.

[0074] Correspondingly, in various embodiments, the sensor package 212 can include at least one sensor selected from the group consisting of a sensor for an acid species, a sensor for a base species, and a sensor for a volatile organic compound. In various embodiments, the sensor package 212 can include at least one sensor selected from the group consisting of a SO sensor, an H2S sensor, a NO sensor, an NH3 sensor, and a volatile organic compound sensor. In various embodiments, the sensor package 212 can be operably connected to the processing unit 214. Other sensors can also be included herein. In various embodiments, the sensor package 212 can also include at least one sensor selected from the group consisting of a temperature sensor, a relative humidity sensor, and a pressure sensor. In some embodiments, the sensor package 212 can also include a flow rate sensor.

[0075] In various embodiments, the processing unit 214 may be configured to receive input regarding a filter replacement event. In various embodiments, the input may be user input. In various embodiments, the input may be received from another sensor or system, such as a sensor attached to the chemical filter configured to detect removal of the chemical filter. When a filter replacement event notification is received or a filter replacement event is otherwise detected, the system may determine the capacity of the new filter (via user input, reference to a database, as pre-programmed, or received from the new filter itself) and then reset the stored remaining capacity data to reflect the total capacity of the new filter element.

[0076] It will be appreciated that the fuel cell chemical filter monitoring system 108 can receive data from and / or transmit data to many different other devices and systems. Referring now to FIG. 3, a schematic diagram of components of the fuel cell chemical filter monitoring system 108 is shown, according to various embodiments herein. FIG. 3 is generally similar to FIG. 2. However, FIG. 3 also shows an ambient condition sensor 306 (such as may be mounted on or within the vehicle), a vehicle CANBus system 304 or other vehicle control system or data network, an environmental condition API 130, and a remote database 126. In various embodiments, the ambient condition sensor 306 may be mounted on or within the vehicle and may detect ambient conditions, including, but not limited to, concentrations of at least one of SO, HS, NO, NH, and various volatile organic compounds, and / or temperature, pressure, relative humidity, etc.

[0077] In some embodiments, the vehicle CANBus system 304 (or a similar data network) can provide information about the fuel cell, such as its power output. Thus, in various embodiments, the system 108 and / or its processing unit 214 can be configured to receive data about the power output (e.g., voltage) from the fuel cell. In various embodiments, the processing unit 214 can be configured to use the data about the power output to modulate an estimated calculation about the remaining life of the chemical filter 106. For example, if a decrease in power output is observed, this may indicate a problem with the fuel cell (or its subunit cells). For example, this may mean that some compounds have entered the fuel cell and caused damage to it. In such a case, the system can make further calculations about the remaining useful capacity on a more conservative basis, as will be further described below with reference to FIG. 9.

[0078] In many embodiments herein, sensing of various chemical species occurs upstream of the chemical filter, although in some embodiments, some sensing can also occur downstream of the chemical filter. Referring now to FIG. 4, a schematic diagram of components of a fuel cell chemical filter monitoring system 108 is shown, according to various embodiments herein. FIG. 4 is generally similar to FIG. 2. However, FIG. 4 also shows a downstream sensor 402. The downstream sensor 402 can be used to sense various compounds mentioned herein. However, in some embodiments, the downstream sensor 402 can be used specifically to detect one or more VOCs.

[0079] The sensor package used herein can take on many different configurations and form factors. In some embodiments, the airflow can be separated into multiple parallel flow paths. Referring now to FIG. 5, a schematic diagram of a portion of a sensor package 212 is shown, in accordance with various embodiments herein. The sensor package 212 includes an inlet channel 502 and an outlet channel 504. The airflow can be split into multiple parallel flow paths. In FIG. 5, the airflow can be split into a first path 506, a second path 510, a third path 514, a fourth path 518, and a fifth path 522. Sensors can be positioned within the flow paths. For example, a first sensor 508 can be positioned within the first path 506. A second sensor 512 can be positioned within the second path 510. A third sensor 516 can be positioned within the third path 514. A fourth sensor 520 can be positioned within the fourth path 518. A fifth sensor 524 can be positioned within the fifth path 522.

[0080] Referring now to Figure 6, a schematic diagram of a portion of the sensor package 212 is shown, according to various embodiments herein. Figure 6 is generally similar to Figure 5. However, Figure 6 also includes a flow sensor 602. In this example, the flow sensor 602 is located in the outlet channel 504. However, the flow sensor 602 could also be located within the housing 502 or in one or more of the parallel flow paths.

[0081] In various embodiments, the sensors may include at least one of a SO sensor, a H2S sensor, a NO sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor. However, in some embodiments, the sensors may include an acid sensor, a base sensor, and a VOC sensor.

[0082] Referring now to FIG. 7, a schematic diagram of a portion of a sensor package 212 is shown, according to various embodiments herein. FIG. 7 is generally similar to FIG. 5. However, in FIG. 7, the parallel flow paths include a first path 506, a second path 510, and a third path 514. Here, the sensor may detect classes of compounds instead of individual compounds. For example, in some embodiments herein, the sensor may detect acids, bases, etc. Thus, in this example, the sensor may include an acid sensor 708 disposed in the first path 506, a base sensor 712 disposed in the second path 510, and a VOC sensor 716 disposed in the third path 514.

[0083] Referring now to FIG. 8 , a flowchart of operations according to various embodiments herein is shown. Specifically, FIG. 8 illustrates a method 800 for monitoring a fuel cell chemical filter. The method for monitoring a fuel cell chemical filter 800 may include an operation 802 of detecting an amount of a compound in an air flow path. The method for monitoring a fuel cell chemical filter 800 may also include an operation 804 of tracking a total exposure of the chemical filter to the compound. The method for monitoring a fuel cell chemical filter 800 may also include an operation 806 of estimating a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data related to the total capacity of the chemical filter.

[0084] Referring now to FIG. 9 , a flowchart of operations according to various embodiments herein is shown. Method 900 can include operation 902 of calculating a baseline value for a remaining useful filter life (RUL). In some embodiments, the method can further include operation 904 of obtaining a fuel cell voltage output value. In some embodiments, the method can further include operation 906 of calculating an adjusted value for remaining useful filter life taking into account the fuel cell voltage output value. As an example, if a decrease in power output from a fuel cell is observed, this may indicate a problem with the fuel cell (or its subunit cells). This may mean that some compounds have entered the fuel cell, causing damage to and / or a decrease in output from the fuel cell. In such cases, the system can perform further calculations regarding remaining useful capacity on a more conservative basis. For example, the calculated remaining useful life that existed at the time the fuel cell output decreased can be used as a new point from which zero remaining useful life is estimated. Thus, for example, if a baseline calculation of remaining useful life indicates that the remaining useful life is 20% of the total starting capacity, but the fuel cell output has now decreased, further calculations of remaining useful life can be scaled accordingly, such as by multiplying the remaining useful life value by a correction factor.

[0085] 10 , a flowchart of operations according to various embodiments herein is shown. Method 1000 may include operation 1002 of acquiring on-board sensor data, such as from a sensor package. Method 1000 may further include operation 1004 of acquiring a geolocation of the vehicle. Method 1000 may further include operation 1006 of acquiring environmental condition data for a given geolocation. Method 1000 may further include operation 1008 of calibrating sensors and / or adjusting a calculation of remaining useful life. For example, in some embodiments, the environmental condition data may be considered accurate, and a correction factor may be used to adjust data from sensors in the sensor package to accurately reflect the concentrations of chemical species indicated by the environmental condition data. In some embodiments, the calculation of remaining useful life may be adjusted using the environmental condition data. For example, if the environmental condition data indicates high levels of various chemical species of interest, the system may adjust the calculation of remaining useful life to be more conservative (e.g., to reflect that the remaining useful life has been depleted more quickly).

[0086] Various components may be used with the systems herein. Referring now to Figure 11, a block diagram of components of a processing unit 214 is shown, according to various embodiments herein. However, it will be understood that more or fewer components may be included in various embodiments, and this schematic diagram is merely exemplary. The processing unit 214 may include a housing 1102 and control circuitry 1104.

[0087] The control circuitry 1104 may include a variety of electronic components, including, but not limited to, a microprocessor, a microcontroller, an FPGA (Field Programmable Gate Array) chip, an application specific integrated circuit (ASIC), and the like.

[0088] In various embodiments, the processing unit 214 may include a first sensor channel 1120, a second sensor channel 1122, a third sensor channel 1124, a fourth sensor channel 1126, and a fifth sensor channel 1128. The sensor channels may provide an interface with the sensors used and, in various embodiments, may perform various operations on the data / signals from the sensors, including amplification, noise reduction, sampling frequency adjustment, etc. However, it will be understood herein that a greater or lesser number of sensor channels may be used.

[0089] The processing power of the control circuitry 1104 and its components may be sufficient to perform various operations on data from the sensors, including, but not limited to, averaging, time averaging, statistical analysis, normalization, aggregation, sorting, deleting, traversing, transforming, condensing (e.g., removing selected data and / or converting data to a less granular form), compressing (e.g., using a compression algorithm), merging, inserting, time stamping, filtering, discarding outliers, calculating trends and trendlines (e.g., linear, logarithmic, polynomial, power, exponential, moving average), predicting filter RUL (remaining useful life), identifying RUL conditions, predicting performance, predicting the cost of replacing filter elements versus not replacing filter elements, etc.

[0090] Normalization operations performed by control circuitry 1104 may include, but are not limited to, adjusting one or more values ​​based on another value or set of values. By way of example only, on-board sensor data (e.g., data from a sensor in a sensor package) may be normalized based on environmental condition data.

[0091] In various embodiments, the control circuitry can calculate the time for filter / filter element replacement and generate a signal regarding the time for replacement. In various embodiments, the control circuitry can calculate the time for filter element replacement and issue a notification regarding the time for replacement via a user output device. In various embodiments, the control circuitry can calculate the time for filter element replacement based on signals from the sensors herein as well as data regarding the capacitance of the filter / filter element.

[0092] In various embodiments, the control circuitry issues an alert or alarm when a predetermined alarm condition is met, which may include, for example, a maximum value of a signal received from a chemical sensor herein exceeding a threshold value of the remaining useful life of a chemical filter.

[0093] In various embodiments, the processing unit 214 may include a power supply circuit 1132. In some embodiments, the power supply circuit 1132 may include various components including, but not limited to, a battery 1134, a capacitor, a power receiver such as a wireless power receiver, a transformer, a rectifier, etc. In various embodiments, instead of and / or in addition to receiving power from a battery, the power supply circuit 1132 may receive power from a power source within the vehicle itself, such as a DC power source associated with the vehicle (or, in some scenarios, an AC power source).

[0094] In various embodiments, the processing unit 214 may include an output device(s) 1136. The output device(s) 1136 may include various components for visual and / or audio output, including, but not limited to, lights (such as LED lights), display screens, speakers, etc. In some embodiments, the output device(s) may be used to provide notifications or alerts to a system user, such as current system status, indications of problems, required user intervention, appropriate times to perform maintenance actions, etc.

[0095] In various embodiments, the processing unit 214 may include memory 1138 and / or a memory controller. The memory may include various types of memory components, including dynamic RAM (D-RAM), read-only memory (RAM), static RAM (S-RAM), disk storage, flash memory, EEPROM, battery-backed RAM such as S-RAM and D-RAM, and any other type of digital data storage component. In some embodiments, the electronic circuit or electronic component includes volatile memory. In some embodiments, the electronic circuit or electronic component includes non-volatile memory. In some embodiments, the electronic circuit or electronic component may include transistors interconnected to provide positive feedback that operate as a latch or flip-flop, providing a circuit with two or more metastable states that remain in one of these states until changed by an external input. Data storage may be based on circuits including such flip-flops. Data storage may also be based on the storage of charge in a capacitor or other principles. In some embodiments, the non-volatile memory 1138 may be integrated with the control circuit 1104.

[0096] In various embodiments, the processing unit 214 may include a clock circuit 1140. In some embodiments, the clock circuit 1140 may be integrated with the control circuit 1104. Although not shown in FIG. 11 , it will be understood that various embodiments herein may include a data / communication bus for providing transfer of data between components. In some embodiments, an analog signal interface may be included. In some embodiments, a digital signal interface may be included.

[0097] In various embodiments, the processing unit 214 may include communications circuitry 1142. In various embodiments, the communications circuitry may include components such as an antenna 1144, amplifiers, filters, digital-to-analog and / or analog-to-digital converters. The communications circuitry 1142 may facilitate wired and / or wireless communications to and from the system.

[0098] method Many different methods are contemplated herein, including, but not limited to, methods of manufacture, methods of use, etc. Aspects of system / device operation described elsewhere herein may be implemented as acts of one or more methods, according to various embodiments herein.

[0099] In various embodiments, the operations and method steps described herein may be performed as part of a computer-implemented method executed by one or more processors of one or more computing devices. In various embodiments, the operations and method steps described herein may be implemented in instructions stored on a non-transitory computer-readable medium that, when executed by one or more processors, cause the system to perform the operations and / or steps.

[0100] One embodiment includes a method for monitoring a fuel cell chemical filter. The method can include interfacing with an air flow path of a fuel cell system upstream of the chemical filter. The method can also include detecting an amount of a compound in the air flow path. The method can also include tracking a total exposure of the chemical filter to the compound. The method can also include estimating a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data related to a total capacity of the chemical filter.

[0101] In one embodiment, the method may further include transmitting data regarding at least one of the tracked total exposure and the estimated remaining filter life.

[0102] In one embodiment, the method can further include receiving data regarding the environmental levels of the compound from the remote system. In one embodiment, the method can further include transmitting geolocation data to the remote system to obtain data regarding the environmental levels of the compound specific to the geolocation of the vehicle or other system. In one embodiment of the method, receiving data regarding the environmental levels of the compound from the remote system can further include using the received data to modulate an estimate calculation regarding the remaining life of the chemical filter. In one embodiment of the method, receiving data regarding the environmental levels of the compound from the remote system can include calibrating one or more sensors using the received data.

[0103] In one embodiment, the method may further include receiving input regarding a filter replacement event.

[0104] In one embodiment, the method can further include receiving data from a vehicle data system. In one embodiment, the method can further include receiving data related to power output from the fuel cell. In one embodiment of the method, receiving data related to power output from the fuel cell can include using the data related to power output to modulate an estimation calculation related to remaining life of the chemical filter.

[0105] In one embodiment, the method can further include issuing an alert when the remaining life of the chemical filter exceeds a threshold value. In one embodiment, the method can further include issuing an alert when the remaining life of the chemical filter exceeds one or more threshold values ​​according to a hierarchical severity scheme.

[0106] Sensor Package Various embodiments herein include one or more sensors. Further details regarding sensors are provided below. However, it will be understood that this is provided by way of example only and that further variations are contemplated herein.

[0107] The sensors herein may include, but are not limited to, SO2 sensors, HS sensors, NO2 sensors, NH3 sensors, and volatile organic compound (VOC) sensors. In some embodiments, the sensors herein may be specific to a particular compound. In other embodiments, the sensors herein may be specific to a class or group of compounds. In the latter case, an estimate of the concentration of a particular compound may be generated by multiplying by a correction factor that accounts for the amount of signal associated with that particular compound. For example, if the sensor signal reflects contributions from all bases, a contribution factor can be used to estimate the amount of NH3 reflected in the overall signal. For example, the concentration of NH3 may be calculated as NH3 = base sensor signal * k_base, where k_base is a contribution or correction factor that reflects the ratio of NH3 to all bases in the air sample. The correction factor may be derived through a calibration procedure. The concentration value may be converted to a total exposure by adjusting for flow rate and sampling time. The total exposure may be tracked and subtracted from the total capacity value of the filter to obtain the remaining capacity.

[0108] The sensors herein can operate according to many different operating principles. The sensors herein can include, but are not limited to, electrochemical sensors. In some embodiments, the electrochemical sensors can operate by contacting and / or reacting with a gas sample and generating an electrical signal proportional to the gas concentration of a specific chemical species or class of gas within the gas sample. In some embodiments, the chemical sensors herein can be optical chemical sensors. Other sensor types herein can include, but are not limited to, liquid membrane ion sensors, ion-selective FETs, solid-state membrane ion sensors, semiconductor gas sensors, catalytic combustion gas sensors, polymer gas sensors, capacitance-based sensors, resistance-based sensors, and the like. Exemplary sensors herein include, but are not limited to, ALPHASENSE H2S-B4, ALPHASENSE SO2-B4, ALPHASENSE NO2-B43F, SGX SENSORTECH MiCS-5914, BOSCH BME688, and the like.

[0109] The sensitivity of the sensors herein can vary. In some embodiments, the sensitivity can be 1000 ppm, 500 ppm, 100 ppm, 10 ppm, 5 ppm, 1 ppm, 100 ppb, 50 ppb, 25 ppb, 10 ppb, or 5 ppb, or any range therebetween. While not intending to be bound by theory, configurations herein in which the sensor package is configured to interface with a chemical filter and with an airflow path upstream from the chemical filter are advantageous because sensors with lower sensitivity values ​​can be used. Specifically, upstream of the chemical filter, the concentration of the target chemical species is relatively high compared to downstream of the chemical filter. Therefore, sensors with relatively lower sensitivity can be used herein.

[0110] It should be noted that as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing a "compound" includes a mixture of two or more compounds. It should also be noted that the term "or" is generally used in its sense to include "and / or" unless the content clearly dictates otherwise.

[0111] It should also be noted that, as used in this specification and the appended claims, the phrase "configured to" describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration. The phrase "configured to" can be used interchangeably with other similar phrases, such as arranged and configured, built and deployed, built, manufactured and deployed, etc.

[0112] All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.

[0113] As used herein, the recitation of numerical ranges by endpoints is intended to include all numbers subsumed within that range (e.g., 2 to 8 includes 2.1, 2.8, 5.3, 7, etc.).

[0114] The headings used herein are provided to comply with suggestions under 37 CFR 1.77 and otherwise to provide organizational guidance. These headings should not be construed as limiting or characterizing the invention(s) set forth in any claims that may arise from this disclosure. For example, although a heading refers to a "Field," such claims should not be limited by the language selected under that heading to describe that so-called technical field. Furthermore, the discussion of technology in the "Background" is not an admission that that technology is prior art to any invention(s) in this disclosure. The "Summary" also should not be construed as a characterization of the invention(s) set forth in the claims that will be issued.

[0115] The embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices. Thus, aspects have been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the description.

Claims

1. A fuel cell chemical filter monitoring system, Processing unit and A sensor package comprising, the sensor package including one or more sensors, The sensor package mentioned above is It interfaces with the airflow path of the fuel cell system upstream of the chemical filter. The amount of compound in the air channel is detected. It is configured in such a way, The sensor package is operably connected to the processing unit, The processing unit is configured to track the total exposure of the chemical filter to the compound. The processing unit is configured to estimate the remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data relating to the total capacity of the chemical filter. Fuel cell chemical filter monitoring system.

2. The aforementioned compound comprises at least one selected from the group consisting of acid species, basic species, and volatile organic compounds. The fuel cell chemical filter monitoring system according to claim 1.

3. The aforementioned compound comprises at least one selected from the group consisting of SO2, H2S, NO2, NH3, and volatile organic compounds. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

4. The one or more sensors include at least one selected from the group consisting of an acid sensor, a base sensor, and a volatile organic compound (VOC) sensor. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

5. The one or more sensors include at least one selected from the group consisting of an SO2 sensor, an H2S sensor, an NO2 sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

6. The fuel cell chemical filter monitoring system receives the data relating to the total capacity from the remote system and / or the chemical filter. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

7. The fuel cell chemical filter monitoring system is configured to transmit data relating to at least one of the total exposure amount tracked and the estimated remaining filter life, and this data is transmitted to at least one of the vehicle control system, the vehicle CANbus system, and the remote monitoring system. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

8. The sensor package further includes at least one selected from the group consisting of a temperature sensor, a relative humidity sensor, and a pressure sensor. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

9. The aforementioned sensor package further comprises a flow sensor. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

10. Further equipped with geolocation circuits, A fuel cell chemical filter monitoring system according to either claim 1 or 2.

11. The fuel cell chemical filter monitoring system is configured to receive data on the environmental levels of the compound from a remote system using geolocation data from the geolocation circuit. The fuel cell chemical filter monitoring system according to claim 10.

12. The fuel cell chemical filter monitoring system is configured to receive data on the environmental levels of the compound from a remote system. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

13. The fuel cell chemical filter monitoring system is configured to use the received data to calibrate one or more of the sensors. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

14. The fuel cell chemical filter monitoring system is configured to modulate the estimated remaining lifespan of the chemical filter using the received data. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

15. The processing unit is configured to receive inputs relating to filter replacement events, wherein the inputs are either user inputs or / or inputs received from another sensor or system. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

16. The processing unit is configured to receive data relating to power output from the fuel cell and to modulate an estimation calculation of the remaining life of the chemical filter using the data relating to power output. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

17. The sensor package further comprises parallel channels, and each sensor is arranged within its own parallel channel. A fuel cell chemical filter monitoring system according to either claim 1 or 2.

18. A method for monitoring a fuel cell chemical filter, Steps to interface the chemical filter with the airflow path of the fuel cell system upstream. The steps include detecting the amount of compound in the air passage, A step of tracking the total exposure of the chemical filter to the compound, The steps include: estimating the remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data relating to the total capacity of the chemical filter; Methods that include...

19. The process further includes receiving data on the environmental level of the compound from a remote system and modulating an estimated calculation of the remaining life of the chemical filter using the received data. The method according to claim 18.

20. The further step of receiving data relating to power output from the fuel cell and modulating an estimation calculation relating to the remaining life of the chemical filter using the data relating to power output, The method according to any one of claims 18 and 19.

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