Fuel Cell Coolant System Cold Weather Startup
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Solution Overview
Problem
Fuel cell systems face challenges in operating and starting up in freezing ambient temperatures due to ice blockages formed from condensed water in the fuel cell stack, which can prevent reactant and byproduct flow and reduce performance.
Innovation Solution
A fuel cell system with a coolant system that circulates coolant through the stack before purging, using a controller to manage coolant flow and temperature to melt ice formations and maintain a uniform temperature, ensuring ice-free conditions for efficient purging and startup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the fuel cell system is exposed to freezing ambient temperatures, then the system can operate in cold climates, but liquid water within the system freezes forming ice blockages that prevent reactant or byproduct flow
Solution Approach 1:
The system performs preliminary heating of the fuel cell stack using the coolant system before the purge operation in cold weather conditions. This preliminary action prevents ice formation that would otherwise block flow channels during the subsequent purge operation, ensuring reliable startup in cold climates.
Solution Approach 2:
The controller activates the coolant system to heat the fuel cell stack before purging in cold conditions, creating a preliminary anti-action against the harmful freezing effect. This counteracts the ice formation tendency by maintaining temperatures above freezing during the critical purge phase.
2Reliability
If the coolant system circulates coolant through the stack before purging, then ice blockages are prevented, but additional energy is consumed for coolant circulation
Solution Approach 1:
The coolant system operation is made dynamic and conditional rather than continuous. The controller activates coolant circulation only when cold weather conditions are detected (below threshold temperature) and only for the specific duration needed before purging, optimizing energy usage while maintaining reliability.
Solution Approach 2:
The system changes the operational parameters of the coolant system based on ambient temperature conditions. In cold weather, the coolant system is activated with specific flow rates and durations to prevent ice formation. In warmer conditions, the system operates normally without these additional cooling cycles, reducing energy consumption.
3Reliability
If the purge operation is delayed to allow uniform temperature distribution, then ice blockages are reduced, but the startup time is increased
Solution Approach 1:
The system performs preliminary temperature equalization by circulating coolant through the stack before the purge operation in cold conditions. This preliminary action ensures uniform temperature distribution throughout the stack, preventing ice formation in cooler regions before the purge begins, thereby maintaining reliability without excessive delay.
Solution Approach 2:
The coolant system leverages the thermal energy already present in the fuel cell stack and coolant to redistribute heat uniformly throughout the system. This self-service approach uses the system's own thermal resources to prevent ice formation rather than requiring external heating sources, minimizing energy input and time delay.
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
The solution effectively prevents ice blockages, allowing for successful fuel cell system startup and operation in freezing conditions by melting ice in the fuel cell stack and ensuring efficient purging of excess water, thus maintaining performance.
Implementation Method 1
a coolant system configured to provide coolant flow through the stack
Implementation Method 2
command the coolant system to circulate coolant through the stack
Implementation Method 3
to melt ice in the fuel cell stack and ensuring efficient purging of excess water
Implementation Method 4
circulate coolant through the stack prior to commanding a purge of the fuel cell stack
Data Source
AI summary
A fuel cell system and a method of controlling the fuel cell system is provided. A fuel cell generates power, and a coolant system provides coolant flow through the stack. A controller is configured to, in response to at least one of an ambient temperature and a coolant temperature being below a threshold value after a vehicle shut down command or event, command the coolant system to circulate coolant through the stack to reduce ice formation in the stack prior to commanding a purge of the fuel cell stack.