Fuel Cell Anode Gas Injector Abnormality Detection
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Solution Overview
Problem
In fuel cell systems, when power demand is less than a prescribed amount, some injectors do not operate, leading to insufficient anode gas supply during abnormality, causing unstable power generation and deterioration of the fuel cell stack.
Innovation Solution
A fuel cell system with a control section that ensures the second valve apparatus operates at least once during system activation to stop, allowing for operational checks and preventing insufficient anode gas supply by using both the main and BP injectors, with pressure monitoring to detect abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second valve apparatus is not operated during low power demand periods, then the system operates efficiently with fewer components active, but the valve apparatus may have undetected abnormalities that lead to insufficient gas supply when needed
Solution Approach 1:
The control section performs an operational check by operating the second valve apparatus at least once during the period from activation to stop, before actual power demand occurs. This preliminary action ensures the valve is functioning normally before it is critically needed, preventing undetected abnormalities from causing supply insufficiency.
Solution Approach 2:
The system uses its own operational cycles (activation to stop period) to perform self-diagnosis of the valve apparatus. The control section leverages the natural operation window to conduct the check without requiring external testing equipment or separate maintenance interventions, making the system self- verifying.
2Reliability
If the second valve apparatus is operated continuously to ensure it functions normally, then abnormality detection is improved, but energy consumption and wear increase
Solution Approach 1:
The operational check is performed preliminarily during the activation to stop period, ensuring the valve is tested before it is critically needed for power generation. This timing allows reliability verification without requiring continuous operation, thus avoiding excessive energy consumption and wear while still ensuring functionality when demanded.
3Reliability
If the operational check is performed only when power demand exceeds the prescribed amount, then the valve is tested under load conditions, but the check may be too late if the valve fails before that point
Solution Approach 1:
The control section performs the operational check during the activation to stop period, which occurs before power demand exceeds the prescribed amount. This preliminary timing ensures the valve is verified to be functioning normally before it is critically needed, detecting abnormalities early enough to prevent supply insufficiency and allowing timely system response.
Solution Approach 2:
The control section uses feedback from the operational check results to determine whether to proceed with normal operation or trigger protective measures. If the valve is judged abnormal, the control section restricts power generation amount, creating a feedback loop that prevents system failure while maintaining operation when the valve is healthy.
Data Source
AI summary
A fuel cell system includes a fuel cell stack, a plurality of injectors capable of adjusting a flow rate of anode gas supplied to the fuel cell stack, and an ECU causing the plurality of injectors to operate. The plurality of injectors include a main injector, and a BP injector that operates when power that exceeds a prescribed power generation amount is generated. The ECU performs an operational check of causing the BP injector to operate at least once and judging whether the BP injector is normal or abnormal, during a period from when the fuel cell system is activated to when the fuel cell system stops.