Fuel Cell Stack Voltage Sensor Diagnostic System
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Solution Overview
Problem
Current hydrogen fuel cell stack voltage sensor systems are cost-intensive due to the high number of sensors required, leading to potential sensor drift or failure going unrecognized, especially when readings fall within normal electrochemical ranges, and there is no effective method to identify faulty sensors within these ranges.
Innovation Solution
A multi-level rationality testing system that evaluates fuel cell stack voltage sensor output by determining if maximum and minimum values are within sensor limits, conducting power mode observations, and performing enhanced reactant concentration tests to differentiate between sensor errors and actual fuel cell issues, using a reduced number of sensors while ensuring accurate diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of voltage sensors is reduced to lower cost, then the quantity of sensors decreases, but the ability to detect sensor drift or failure deteriorates
Solution Approach 1:
The patent combines multiple voltage sensor readings into a single stack voltage measurement, merging the function of multiple sensors into one. This allows cost reduction by using fewer physical sensors while maintaining monitoring capability through mathematical combination of available readings.
Solution Approach 2:
The patent implements a feedback mechanism where sensor readings are continuously monitored against expected ranges and relationships. The system provides feedback on sensor health by comparing actual readings with predicted values, enabling detection of drift or failure even with reduced sensor quantity.
2Ease of manufacture
If fewer voltage sensors are used, then cost is reduced, but measurement precision and fault identification capability worsen
Solution Approach 1:
The patent performs preliminary rationality tests on sensor readings before final evaluation. By pre-screening readings for consistency and合理性, the system ensures measurement precision is maintained even with fewer sensors, as problematic readings are identified and handled before affecting final measurements.
3Reliability
If sensor readings are interpreted as electrochemical phenomena, then normal operation is assumed, but faulty sensors go unrecognized
Solution Approach 1:
The patent applies preliminary anti-action by implementing rationality tests that preemptively identify and flag potentially faulty readings before they are misinterpreted as normal electrochemical phenomena. This prevents loss of fault information by catching anomalies early in the analysis chain.
Solution Approach 2:
The patent introduces an intermediary layer of rationality testing between raw sensor readings and final interpretation. This intermediary process mediates between the sensor output and electrochemical interpretation, preventing direct misinterpretation of faulty readings as normal phenomena.
4Device complexity
If no method is implemented to identify faulty sensors within normal ranges, then system complexity remains low, but diagnostic capability deteriorates
Solution Approach 1:
The patent segments the diagnostic process into distinct levels: first-level rationality tests for basic consistency, second-level tests for relationship validation, and third-level tests for advanced fault detection. This segmentation makes the diagnostic system manageable while progressively improving detection capability without overwhelming complexity.
Solution Approach 2:
The patent implements partial action by applying different levels of diagnostic testing selectively. Not all sensors require all levels of testing at all times, allowing the system to maintain low complexity during normal operation while enabling comprehensive diagnostic capability when needed, thus detecting faulty sensors without constant high complexity.
Data Source
AI summary
A method for evaluating voltage sensor output using a diagnostic system includes: measuring an overall fuel cell stack voltage using a stack voltage sensor; identifying a fuel cell voltage of a first end cell using a first end cell voltage sensor and a second end cell using a second end cell voltage sensor; determining if a maximum value of the overall fuel cell stack voltage, the fuel cell voltage of the first end cell or the second end cell is less than a sensor limit, and if a minimum value of the fuel cell voltages is greater than the sensor limit; performing a test to identify if the maximum value is greater than an average sensor signal value and if the average sensor signal value is greater than the minimum value; and conducting a test to identify if the minimum value is less than a first predetermined threshold.