Fuel Cell Startup Control via Parallel BHDC Boosting

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Solution Overview

Problem

Conventional fuel cell startup processes are time-consuming, requiring 7 to 8 seconds for completion, and expose the fuel cell stack to open circuit voltage, leading to durability issues and energy wastage due to sequential operation and unnecessary air supply.

Innovation Solution

A method and system that parallelize the startup process using a low-voltage battery to boost the Bi-directional high-voltage DC/DC Converter and open the air/hydrogen valve simultaneously, eliminating the need to supply air and check stack voltage, thereby reducing startup time and preventing exposure to open circuit voltage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the conventional sequential startup process is used, then the fuel cell system operates reliably, but the startup time is excessively long (7 to 8 seconds)

Engineering Contradiction:
Improvefuel cell system operation reliabilityVSAvoidstartup time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-charging the low-voltage battery before the startup sequence begins. The battery is charged during vehicle operation or idle periods, so when startup is needed, the voltage boost is already available immediately, eliminating the sequential delay of charging the battery first before proceeding with other startup steps.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent merges multiple sequential operations into a parallel execution model. Specifically, the BHDC boosting operation and the air compressor operation are performed simultaneously using the pre-charged low-voltage battery, rather than waiting for one to complete before starting the other. This parallelization dramatically reduces the overall startup time while maintaining system reliability.

Inventive Principle:
Principle #5Merging (Combining)

2Power

If the air compressor is operated to supply air to the stack during startup, then the fuel cell can generate power, but the stack is exposed to open circuit voltage which negatively affects durability

Engineering Contradiction:
Improvefuel cell power generation capabilityVSAvoidstack durability
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-mixing hydrogen and air in the manifold before the fuel cell stack is activated. The recirculation blower circulates and mixes the gases in advance, so when the stack becomes operational, the mixture is already prepared and can immediately begin generating power without exposing the stack to open circuit voltage conditions.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent skips the problematic intermediate state where the stack would be exposed to open circuit voltage. By pre-mixing the hydrogen and air outside the stack and then rapidly introducing the mixture when the stack is ready, the system rushes through the critical transition period, eliminating the durability-damaging OCV exposure phase entirely.

Inventive Principle:
Principle #21Skipping (Rushing through)

3Stress or pressure

If the BHDC boosting is completed before operating the air compressor, then the voltage is sufficient for compressor operation, but this sequential process increases startup time and causes energy waste

Engineering Contradiction:
Improvevoltage level for compressor operationVSAvoidenergy waste from unnecessary air supply
Core Design Contradiction:
Stress or pressureVSLoss of energy

Solution Approach 1:

The patent merges the BHDC boosting operation and air compressor operation into a parallel execution model. Both operations draw power from the pre-charged low-voltage battery simultaneously, eliminating the sequential wait time. The air compressor starts immediately without waiting for BHDC completion, and both processes complete in parallel, reducing total startup time and preventing energy waste from premature air supply.

Inventive Principle:
Principle #5Merging (Combining)

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 significantly reduces fuel cell startup time, enhances durability by avoiding open circuit voltage exposure, and conserves energy by eliminating unnecessary air supply, allowing the fuel cell output to be available promptly and efficiently.

Implementation Method 1

boosting a Bi-directional high-voltage DC/DC Converter (BHDC) of a main bus stage

Methodology Applied
Scientific EffectElectrical energy transformation: Electromagnetic Induction

Implementation Method 2

opening a valve of an air/hydrogen line together with the boosting of the BHDC; The opening of the valve of the air/hydrogen line may include opening the valve of the air/hydrogen line using charged power of a low-voltage battery

Methodology Applied
Scientific EffectBattery electrical energy storage and release: Battery (electricity)

Implementation Method 3

A fuel cell is a power generation system which directly converts chemical energy of fuel into electrical energy. Hydrogen is supplied to an anode electrode of a unit cell and oxygen is supplied to a cathode electrode thereof, and thus, electricity is generated through a chemical reaction of an ionized material

Methodology Applied
Scientific EffectElectrochemical energy conversion: Fuel Cell

Data Source

PatentUS11296341B2Method and system for controlling startup of fuel cell
Publication Date: 2022.04.05 HYUNDAI MOTOR CO LTD
  • US11296341B2 patent drawing
  • US11296341B2 patent drawing
  • US11296341B2 patent drawing

AI summary

A method and a system for controlling startup of a fuel cell are provided. The method includes sensing a startup request signal and boosting a Bi-directional high-voltage DC/DC Converter (BHDC) of a main bus stage when the startup request signal has been sensed by a controller. A valve of an air/hydrogen line is then opened together with the boosting of the BHDC and the startup of the fuel cell is completed by allowing an output of the fuel cell after the valve of the air/hydrogen line is opened.