Fuel Cell Air Throttle for Hybrid Power Split Without DC/DC Conversion
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Solution Overview
Problem
Current fuel cell power plants for heavy-duty applications are inefficient due to the need for a DC/DC converter, which adds volume, weight, and cost, and results in significant power loss, making it impractical for large vehicles.
Innovation Solution
A hybrid power system that decouples the air flow system from the water management system, allowing the air flow system to actively regulate the power split between the fuel cell and energy storage systems without a DC/DC converter, using hybrid bipolar plates with internal coolant passages and porous sub-plates for effective water management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a DC/DC converter is used to manage power between fuel cell and energy storage systems, then power control is achieved, but system volume, weight, cost increase and power loss occurs
Solution Approach 1:
The patent removes the DC/DC converter from the system by decoupling the air flow system from water management. The air flow system directly controls the power split between fuel cell and energy storage systems through active regulation of air utilization, eliminating the need for power conversion hardware and its associated losses.
Solution Approach 2:
The air flow system is given multiple functions: it continues its traditional role in water management while simultaneously serving as the active power regulator. By controlling air utilization, the same system manages both water balance and power distribution, eliminating the need for separate DC/DC conversion equipment.
2Adaptability or versatility
If air flow system is coupled with water management system, then water balance is maintained, but power split control is limited
Solution Approach 1:
The patent segments the control functions by decoupling air flow control from water management. The air flow system independently regulates power split through air utilization control, while water management handles liquid water balance. This functional segmentation enables versatile power control without compromising water management.
Solution Approach 2:
The system implements dynamic control where the air flow system actively adjusts air utilization to regulate power split in real-time. This dynamic regulation allows the system to adapt to varying power demands while maintaining proper water balance through the decoupled architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient power management by varying air utilization over a wide range, reducing the need for a DC/DC converter, minimizing power loss, and improving system efficiency, while maintaining proper water balance within the fuel cell stack.
Implementation Method 1
hybrid bipolar plates with internal coolant passages and porous sub-plates for effective water management
Data Source
AI summary
A fuel cell power plant includes an energy storage system connected in parallel with a fuel cell system. The fuel cell system includes a controller, a fuel flow system, an air flow system, and an internal water management system. The controller is operable to receive, as inputs, the energy storage system state of charge and the power demand from an electric load. The controller is further operable to determine a power split set point and execute commands, as output, to control operation of the air flow system, wherein the air flow system actively regulates the proportion of current flow between the fuel cell system and the energy storage system to meet the power demand of the electric load.