Fuel Cell Stack Cooling via Pump Delta Pressure Sensor
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Solution Overview
Problem
Conventional fuel cell stack cooling systems require six sensors to maintain temperature control, increasing costs and complexity due to the need for precise control of outlet temperature and temperature change across the stack.
Innovation Solution
A pump delta pressure (ΔP) sensor is used in conjunction with a pump map or algorithm to correlate pump speed and ΔP with coolant flow rate, allowing for optimal stack temperature control without the need for coolant inlet temperature, pressure, and volumetric flow sensors, reducing the number of sensors required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If six sensors are used to control stack outlet temperature and stack ΔT, then temperature control precision is improved, but system cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates three sensors (coolant inlet temperature sensor, coolant inlet pressure sensor, and volumetric flow sensor) from the conventional six-sensor configuration. Instead of directly measuring these parameters, the system uses a pump ΔP sensor combined with pump map data to infer coolant flow rate, thereby reducing sensor quantity while maintaining control capability
Solution Approach 2:
The patent introduces pump ΔP as an intermediary measurement parameter. Rather than directly measuring coolant inlet temperature, pressure, and flow rate with dedicated sensors, the system uses pump ΔP sensor readings combined with pump performance characteristics (pump map) to indirectly determine coolant flow rate, serving as a mediator that reduces measurement system complexity
2Manufacturing precision
If six sensors are used for temperature control, then control accuracy is improved, but manufacturing and installation cost increase
Solution Approach 1:
The patent replaces three expensive sensors with a single pump ΔP sensor that leverages existing pump infrastructure. The pump ΔP sensor is positioned to utilize the pump's inherent pressure differential, eliminating the need for separate inlet temperature, pressure, and flow sensors, thereby reducing component costs and assembly complexity
3Temperature
If three temperature sensors, one pressure sensor, valve position sensor, and flow sensor are used, then both outlet temperature and stack ΔT are controlled, but I/O cost and wiring complexity increase
Solution Approach 1:
The pump ΔP sensor serves multiple functions: it provides data for determining coolant flow rate, which is essential for both outlet temperature control and stack ΔT control. By using this single sensor in conjunction with pump map data, the system achieves dual temperature control objectives without requiring separate measurement systems for each parameter
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
This solution significantly reduces sensor-related costs and complexity while maintaining precise control of the fuel cell stack temperature, achieving optimal ΔT control with fewer sensors.
Implementation Method 1
a pump delta pressure (ΔP) sensor to measure the change in pump pressure between an inlet port and an outlet port of the coolant pump
Implementation Method 2
A coolant pump map or algorithm is used to correlate a pump speed of the coolant pump and a change in pump pressure with a rate of coolant flow
Implementation Method 3
maintain temperature control of a fuel cell stack by using a pump delta pressure (ΔP) sensor to correlate pump speed and pump ΔP with a coolant flow rate necessary to maintain optimum stack delta temperature (ΔT) control
Data Source
AI summary
A temperature control system and method for a fuel cell stack cooling system is disclosed. The temperature control system includes a coolant circulation line for circulating a coolant to and from a fuel cell stack. A coolant pump is provided in the coolant circulation line, and a pump ΔP sensor is provided in fluid communication with the coolant circulation line on inlet and outlet sides of the coolant pump. The pump ΔP sensor measures a change in pump pressure between the inlet and outlet sides of the coolant pump. A pump map is provided having correlated values of pump speed, change in pump pressure and coolant flow rate for correlating the coolant flow rate with the pump speed and the change in pump pressure to attain a desired coolant flow rate for optimum fuel stack cooling.