Fuel Cell Preconditioning Using Route Data

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Fuel cells in electric vehicles face overheating issues due to high power demands from steep uphill grades, which reduces their performance and durability.

Innovation Solution

A power subsystem that includes a fuel cell, a battery, and a controller that predicts future power demands based on route data, reduces the fuel cell's operating temperature through cooling and provides supplemental power from the battery to prevent overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the fuel cell operates at high power demand to meet vehicle needs during steep uphill grades, then the power output is sufficient, but the fuel cell overheats and performance deteriorates

Engineering Contradiction:

Improvepower outputVSAvoidoperating temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The system pre-cools the fuel cell before anticipated high power demand periods by using the battery to power the cooling system during low-demand intervals. This preliminary cooling action ensures the fuel cell is in an optimal temperature state before high power demand occurs, allowing sufficient cooling capacity during critical periods without compromising power output.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The battery acts as an intermediary energy storage device that decouples the cooling system's power consumption from the fuel cell's power output. By using the battery to supply power to the cooling system during low-demand periods, the fuel cell can maintain high power output without being constrained by cooling system power requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the cooling system operates at high capacity to maintain optimal temperature, then the fuel cell temperature is controlled, but the power consumption increases

Engineering Contradiction:

Improvetemperature controlVSAvoidpower consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The cooling system operates periodically rather than continuously, with intensity modulated based on predicted power demand and current temperature conditions. During low-power demand periods, the cooling system operates at reduced capacity or is turned off, while during high-power demand periods, it operates at full capacity. This periodic operation maintains temperature control while significantly reducing average power consumption.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically adjusts cooling system parameters (such as coolant flow rate and compressor speed) based on real-time temperature measurements and predicted power demand. By changing these parameters optimally rather than maintaining fixed high-capacity operation, the system achieves effective temperature control with minimized power consumption.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the fuel cell is cooled down before high power demand, then the performance is maintained, but time is lost in reducing temperature

Engineering Contradiction:

Improveperformance maintenanceVSAvoidcooling time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary cooling actions during periods of low power demand, such as during downhill grades or idle periods, so that the fuel cell is already at optimal temperature when high power demand is anticipated. This advance preparation eliminates the need to lose valuable time during critical high-demand periods, maintaining both performance and responsiveness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses the vehicle's own operational patterns (such as downhill coasting or idle periods) as opportunities to cool the fuel cell without requiring dedicated cooling time. By utilizing naturally occurring low-demand periods for cooling, the system achieves temperature management without sacrificing operational time or performance.

Inventive Principle:

Principle #25Self-service

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 maintains the fuel cell within an optimal temperature range, enhancing its performance and extending its lifespan by preventing overheating during high power demand situations.

Implementation Method 1

reduce an operating temperature of the fuel cell

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11724706B2Preconditioning a fuel cell using route data

Publication Date: 2023.08.15 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC

AI summary

Methods and systems may provide for technology to predict a future increase in power demand on a fuel cell based on route data associated with a vehicle powered by the fuel cell and reduce an operating temperature of the fuel cell prior to the future increase in power demand. The technology may also provide supplemental power from a battery to the vehicle while the operating temperature of the fuel cell is being reduced.