Fuel Cell Ignition Control via Gas Composition Estimation

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Solution Overview

Problem

Existing fuel cell systems face issues with ignition methods that do not consider changes in gas composition during shut-off durations, leading to potential hydrogen deficiency, reduced fuel efficiency, safety concerns, and corrosion of the carbon catalyst, which affects the durability of the fuel cell.

Innovation Solution

A method for controlling the fuel cell system by monitoring external and fuel cell temperatures, calculating shut-off duration, estimating gas composition, and setting ignition conditions based on the composition to determine a suitable Purge amount, thereby maintaining constant hydrogen levels and preventing corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If ignition is performed without considering gas composition changes during shut-off, then the ignition process is simple and quick, but the fuel cell may be deteriorated due to local lack of hydrogen or excessive hydrogen exhaustion

Engineering Contradiction:

Improveignition process simplicityVSAvoidfuel cell durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The control unit performs preliminary estimation of gas composition in the fuel cell before ignition based on shut-off duration, temperature conditions, and historical operation data. This preliminary assessment allows the system to determine appropriate ignition parameters in advance, preventing hydrogen deficiency or excessive exhaustion before the ignition event occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors temperature conditions and shut-off duration to dynamically adjust ignition parameters. The control unit uses feedback from temperature sensors and operation history to modify ignition timing, duration, and hydrogen supply rates, ensuring optimal ignition conditions are maintained across varying operational states.

Inventive Principle:

Principle #23Feedback

2Speed

If ignition is performed in state with low hydrogen concentration, then the ignition process is faster, but the fuel cell is deteriorated due to local lack of hydrogen

Engineering Contradiction:

Improveignition speedVSAvoidfuel cell durability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The ignition parameters are made dynamic rather than fixed. The control unit adjusts ignition timing, duration, and hydrogen supply rates based on real-time assessment of gas composition and temperature conditions. This dynamic adjustment ensures ignition speed is optimized without causing local hydrogen deficiency that would damage the fuel cell.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If ignition is performed in state with excessively high hydrogen concentration, then the fuel cell operation is stable, but the fuel efficiency and safety are lowered due to excessive exhaustion of hydrogen

Engineering Contradiction:

Improvefuel cell operation stabilityVSAvoidhydrogen efficiency

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The system changes key parameters including ignition timing, hydrogen supply rate, and ignition duration based on assessed gas composition. When hydrogen concentration is high, the control unit adjusts parameters to reduce hydrogen consumption during ignition, thereby improving overall hydrogen efficiency while maintaining stable fuel cell operation.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If oxygen flows in the fuel cell before ignition during latter shut-off duration, then the gas composition changes, but the carbon catalyst of the air electrode is corroded

Engineering Contradiction:

Improvegas composition adaptationVSAvoidcatalyst corrosion

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The control unit takes preliminary anti-action by detecting oxygen ingress during shut-off duration and preventing corrosive conditions before they damage the carbon catalyst. When oxygen is detected in the fuel cell, the system adjusts ignition parameters to avoid conditions that would accelerate catalyst corrosion, thereby protecting the air electrode while still adapting to gas composition changes.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS9531019B2Fuel cell system and method for controlling the same

Publication Date: 2016.12.27 HYUNDAI MOTOR CO LTD

AI summary

Disclosed is a fuel cell system and a method for controlling the fuel cell system. In the method, an external air temperature and a fuel cell temperature are monitored. When a vehicle having the fuel cell system mounted therein is keyed on, a shut-off duration of the fuel cell system, a maximum external air temperature for the shut-off duration and a maximum fuel cell temperature for the shut-off duration are calculated. A gas composition of a fuel cell at a key-on time is estimated using the shut-off duration, the maximum external air temperature and the maximum fuel cell temperature. An ignition condition of the fuel cell system is set based on the estimated gas composition. Ignition of the fuel cell system is performed based on the set ignition condition.