Fuel Cell Separator Temperature Estimation and Cooling Control
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Solution Overview
Problem
Current fuel cell cooling systems face challenges in accurately estimating the internal temperature of the fuel cell stack, leading to inefficient coolant flow and increased power consumption, as they rely on indirect temperature measurement and struggle to rapidly adjust to temperature changes.
Innovation Solution
A cooling control system that estimates the temperature of the fuel cell stack based on heat exchange between the separator and coolant, using temperature sensors and a heat exchange device to adjust the coolant flow rate and pump speed, allowing for precise temperature control and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If indirect temperature estimation using coolant temperature is used, then the cooling system can be implemented, but the temperature estimation accuracy is insufficient and cannot rapidly reflect temperature changes
Solution Approach 1:
The patent introduces a separator temperature as an intermediary parameter to estimate the fuel cell stack temperature. By measuring the temperature of the separator (which is in direct thermal contact with the fuel cell stack) and combining it with coolant temperature data, the system achieves more accurate and rapid temperature estimation without requiring direct measurement of the stack temperature.
Solution Approach 2:
The patent replaces the conventional direct coolant temperature measurement approach with a combined thermal model that incorporates separator temperature measurements. This substitution allows the system to capture rapid temperature changes more effectively by using the separator's thermal response as an indicator of stack temperature dynamics.
2Reliability
If pump operates continuously to maintain coolant flow, then cooling control is maintained, but power consumption increases and fuel efficiency decreases
Solution Approach 1:
The patent implements dynamic pump control where the pump operation mode (rotation speed or on/off state) is adjusted based on real-time separator temperature estimates. When the separator temperature exceeds a predetermined threshold, the pump operates at higher speed or remains on; when the temperature is within acceptable ranges, the pump speed is reduced or the pump is turned off, thereby reducing power consumption while maintaining cooling reliability.
Solution Approach 2:
The system uses feedback from separator temperature measurements to dynamically adjust pump operation. The controller continuously monitors the estimated separator temperature and adjusts the pump's rotation speed or on/off state accordingly, creating a closed-loop control system that optimizes power consumption based on actual thermal conditions.
3Temperature
If coolant flow rate is increased to improve cooling, then temperature control is enhanced, but power consumption of the system increases
Solution Approach 1:
The patent dynamically changes the coolant flow rate parameter based on the estimated separator temperature. Instead of maintaining a constant high flow rate, the system adjusts the flow rate to match the actual thermal demand of the fuel cell stack, thereby improving temperature control efficiency while reducing unnecessary energy losses associated with excessive coolant circulation.
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 approach enables rapid and accurate estimation of the fuel cell stack temperature, optimizing coolant flow and reducing power consumption, thereby improving fuel efficiency and maintaining the fuel cell within a suitable temperature range.
Implementation Method 1
a heat exchange device disposed on the cooling line to cool the coolant in the cooling line through heat exchange with the outside
Implementation Method 2
a temperature estimator configured to estimate a temperature of the separator based on heat exchange between the separator and the coolant flowing through the cooling line between the separators
Data Source
AI summary
A cooling control method of a fuel cell is provided. The method includes estimating a temperature of a separator based on heat exchange between the separator formed between unit cells of a fuel cell stack and coolant flowing through a cooling line between the separators. A ratio of coolant passing through a heat exchange device to coolant bypassing the heat exchange device is adjusted based on the estimated temperature of the separator. Additionally, a rotation speed of a pump for circulating coolant for cooling the fuel cell stack is adjusted based on the estimated temperature of the separator.