Fuel Cell Air Throttle Control for Hybrid Power Split

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Solution Overview

Problem

Existing fuel cell power plants in large, heavy-duty applications face inefficiencies due to the impracticality and inefficiency of DC/DC converters, which add significant weight, volume, and cost, leading to power loss and limited operational flexibility.

Innovation Solution

Decoupling the air flow system from the water management system in fuel cell power plants, allowing independent control of air flow to regulate power split between the fuel cell and energy storage systems, eliminating the need for a DC/DC converter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a DC/DC converter is used to manage power split between fuel cell and energy storage systems, then power management control is achieved, but system weight, volume, and cost increase significantly

Engineering Contradiction:

Improvepower management controlVSAvoidsystem weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent extracts and removes the DC/DC converter from the power management system, replacing it with direct air flow control to the fuel cell. This eliminates the heavy, expensive power electronic conversion equipment while maintaining power split management capability through aerodynamic control of the fuel cell air supply system.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The air flow control system is given the additional function of power split management beyond its traditional role in fuel cell operation. By controlling air flow to the fuel cell, the system simultaneously manages both the fuel cell's chemical reactions and the power distribution between fuel cell and energy storage systems, eliminating the need for separate DC/DC conversion equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If a DC/DC converter is used for power management, then power conversion and control is achieved, but system volume and cost increase

Engineering Contradiction:

Improvepower conversion controlVSAvoidsystem volume

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

The patent removes the DC/DC converter and its associated power electronics from the system architecture. Power conversion and control functions are achieved instead through the air flow management system, which uses far less space than traditional power electronic conversion equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If DC/DC converter is used in fuel cell power plant, then power management is achieved, but power loss occurs due to conversion inefficiency

Engineering Contradiction:

Improvepower managementVSAvoidpower loss

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent replaces the electrical power conversion system (DC/DC converter) with a pneumatic control system (air flow management). Instead of converting electrical power from fuel cell to battery through power electronics, the system uses air flow control to manage power distribution, eliminating conversion losses associated with electrical power electronics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If DC/DC converter is used for current proportioning, then current split control is achieved, but device complexity increases

Engineering Contradiction:

Improvecurrent split controlVSAvoidsystem complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The air flow control system performs multiple functions simultaneously: it manages fuel cell chemical reactions, controls power output, and manages current split between fuel cell and energy storage systems. This multi-functionality reduces overall system complexity by eliminating separate control systems and power electronic equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12573650B2Method for using fuel cell system air throttle to control hybrid power system

Publication Date: 2026.03.10 NIMBUS POWER SYST LLC

AI summary

A method for operating a fuel cell power plant is provided to deliver power and/or receive power from a load. The fuel cell power plant includes an energy storage system connected in parallel with a fuel cell system. The method for operating includes the steps of calculating and actively proportioning a current split between the fuel cell system and the energy storage system, and controlling the proportioning using fuel cell system air flow. In one embodiment, set point changes in the fuel cell system air flow are operationally independent from a fuel cell water management system that removes product water, humidifies inlet reactant gas, and/or cools the fuel cell stack. In another embodiment, the step of calculating the current split proportion includes the selection of points on a family of V/I curves within a range from 40% fuel cell air utilization to 99% fuel cell air utilization.