Fuel Cell EV Power Strategy for Aggressive Drive Cycles

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Solution Overview

Problem

Traditional control systems for fuel cell electric vehicles do not adequately account for aggressive drive cycles, operator power demand, and varying road conditions, leading to inefficient power management and potential battery damage.

Innovation Solution

A power strategy control system that dynamically adjusts fuel cell and battery power based on battery discharge limits, accelerator pedal requests, and drive conditions to maximize power availability while protecting the battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional rule-based control systems are used to determine fuel cell power set points, then the control system is simple to implement, but the system cannot adequately account for aggressive drive cycles and operator power demand

Engineering Contradiction:
Improveadaptability to aggressive drive cyclesVSAvoidcontrol system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control system transitions from static rule-based algorithms to dynamic control that continuously adapts to varying drive conditions, operator power demand, and battery state. The system dynamically adjusts fuel cell and battery power contributions based on real-time conditions, enabling adequate performance during aggressive drive cycles while maintaining manageable complexity through structured control architecture.

Inventive Principle:
Principle #15Dynamics

2Power

If maximum power is drawn from the battery to fulfill vehicle power demand, then power availability is maximized, but the battery may be damaged or degraded

Engineering Contradiction:
Improvepower availabilityVSAvoidbattery health
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The system dynamically adjusts battery power contribution based on battery state parameters (state of charge, temperature, health status) and drive conditions. By continuously monitoring and adapting power draw parameters, the system maximizes power availability when battery conditions permit while preventing damage through real-time parameter adjustments that keep battery operation within safe boundaries.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The control system incorporates feedback from battery state monitoring to regulate power draw. Battery health metrics and state of charge information feed back into the power management algorithm, which adjusts the battery power contribution accordingly. This closed-loop control ensures power availability is maximized while battery damage is prevented through continuous monitoring and adaptive response.

Inventive Principle:
Principle #23Feedback

3Ease of operation

If the control system accounts for all drive conditions and operator power demand, then drivability is improved, but the control algorithm becomes more complex

Engineering Contradiction:
ImprovedrivabilityVSAvoidcontrol algorithm complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The control algorithm is segmented into distinct functional modules that handle different aspects of power management: fuel cell power determination, battery power optimization, and coordinated control. This modular segmentation enables comprehensive accounting of drive conditions and operator demand while maintaining manageable algorithm complexity through organized, separable control functions.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS20250388094A1Systems and methods to improve drivability in a fuel cell electric vehicle
Publication Date: 2025.12.25 CUMMINS INC
  • US20250388094A1 patent drawing
  • US20250388094A1 patent drawing
  • US20250388094A1 patent drawing

AI summary

A fuel cell electric vehicle includes a fuel cell, a battery, and a power strategy control system communicatively coupled with the fuel cell and the battery. The power strategy control system is configured to maximize a power availability for the fuel cell electric vehicle to fulfill a vehicle power demand.