Fuel Cell Thermal Management System Cold Start Control
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Solution Overview
Problem
Fuel cell powertrain systems face challenges in starting up quickly in cold weather conditions due to the need for heating assistance and the complexity of thermal management systems, which often require large radiators and multiple components, leading to increased size and energy consumption.
Innovation Solution
A method and system for controlling the thermal management of fuel cell powertrain systems, involving a system controller that identifies the need for heating, manages coolant temperature, and uses heat exchangers to efficiently warm up the fuel cell systems, including the use of a single heater to warm multiple fuel cell systems and leveraging rejected heat to maintain coolant temperature within tolerance limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal management system with radiators, pumps, fans, and heaters is used to ensure appropriate fuel cell temperature, then the fuel cell system can operate at appropriate temperature, but the system size and number of components increase
Solution Approach 1:
The patent combines multiple thermal management functions into a single integrated thermal management system that serves multiple fuel cell systems. Instead of having separate heating and cooling systems for each fuel cell, the invention uses a shared coolant circulation system with a single radiator, pump, and control unit that can manage temperature for multiple fuel cell systems simultaneously, thereby reducing the overall number of components.
Solution Approach 2:
The thermal management system is designed to perform multiple functions: heating fuel cell systems during cold start, cooling fuel cell systems during operation, and maintaining appropriate temperatures across different operating conditions. The system can switch between heating mode (using heaters) and cooling mode (using radiator and fan) based on temperature requirements, making the same infrastructure serve multiple purposes.
2Reliability
If a heating assist system is used to warm up the fuel cell system in cold conditions, then the fuel cell can start operation, but the time required to heat the system increases
Solution Approach 1:
The system performs preliminary heating actions before the fuel cell system is fully operational. The thermal management system activates heaters and circulates heated coolant through the fuel cell systems during the cold start phase, preparing the systems in advance to reach operational temperature faster. This preliminary thermal conditioning reduces the overall startup time by addressing temperature requirements before full operation begins.
Solution Approach 2:
The thermal management system maintains continuous temperature management throughout the startup process. Rather than using intermittent or discrete heating steps, the system continuously circulates coolant through the fuel cell systems, maintaining steady heat transfer and temperature progression. This continuous thermal management ensures efficient heat distribution and reduces startup time by eliminating thermal gaps or delays.
3Temperature
If multiple heaters are used to warm multiple fuel cell systems, then all systems can be heated simultaneously, but the energy consumption and system complexity increase
Solution Approach 1:
The patent uses a single heater unit that heats a shared coolant reservoir, which then distributes heated coolant to multiple fuel cell systems through a common circulation loop. Instead of having separate heaters for each fuel cell system, the invention combines the heating function into a single point, reducing energy consumption by eliminating redundant heating elements and control systems while still providing thermal management to multiple systems.
Solution Approach 2:
The thermal management system uses the heat generated by one fuel cell system during operation to preheat the coolant for other fuel cell systems that need to be warmed up. This self-service approach allows the system to utilize its own operational heat output to assist with cold starts of other systems, reducing the energy that would otherwise need to be supplied by external heaters.
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 reduces the time required to start up fuel cell systems in cold conditions, simplifies the thermal management system by reducing the number of components, and optimizes energy use by utilizing heat exchangers to efficiently warm the coolant and fuel cell systems.
Implementation Method 1
heating coolant associated with the fuel cell system by a heater
Implementation Method 2
uses heat exchangers to efficiently warm up the fuel cell systems
Data Source
AI summary
The present disclosure generally relates to systems and methods for controlling a thermal management system of a fuel cell powertrain system.