Fuel Cell DC Current Calculation via Converter Loss Correction
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Solution Overview
Problem
Conventional methods for determining DC current in fuel cell power plants rely on hall effect sensors, which are expensive and unreliable due to moisture-related failures, increasing complexity and cost.
Innovation Solution
A process that determines DC current by correcting measurements from a power electronics converter for losses within the converter, eliminating the need for additional sensors by using a modified conservation of power algorithm and existing measurements from the power conditioning system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hall effect sensors are used to measure DC current, then measurement capability is provided, but cost and reliability deteriorate due to expense and moisture-related failures
Solution Approach 1:
The patent extracts the DC current measurement capability from the hall effect sensor and relocates it to the power electronics converter by utilizing existing current sensing resources within the converter. This eliminates the separate sensor while maintaining measurement functionality.
Solution Approach 2:
The power electronics converter is given the additional function of DC current measurement for fuel cell control, beyond its primary power conversion function. This multi-functionality eliminates the need for dedicated hall effect sensors.
2Measurement precision
If hall effect sensors are used to measure DC current, then measurement capability is provided, but device complexity increases due to additional components
Solution Approach 1:
The patent merges the DC current measurement function with the power electronics converter by integrating the measurement capability into the converter's existing current sensing infrastructure, thereby eliminating separate sensor components and reducing overall system complexity.
Solution Approach 2:
The power electronics converter performs both its primary power conversion function and the additional function of DC current measurement, reducing the total component count and simplifying the power plant architecture.
3Measurement precision
If hall effect sensors are used to measure DC current, then measurement capability is provided, but cost increases due to expensive sensor devices
Solution Approach 1:
The patent extracts the measurement capability from expensive hall effect sensors and implements it using the existing, more cost-effective current sensing resources already present within the power electronics converter.
Solution Approach 2:
The patent replaces expensive hall effect sensors with a software-based calculation approach using existing converter data, effectively using a cheaper methodology to achieve the same measurement function.
Data Source
AI summary
A process for determining the DC current in a fuel cell power plant includes the steps of determining current value from a power electronics converter of a power conditioning system of the power plant; determining a correction factor based upon losses within the converter; and correcting the current value from the converter with the correction factor to determine DC current in the fuel cell. This process also includes determining voltage within the converter and use of the voltage along with the corrected current to determine the desired DC current value.