Fuel Cell Voltage Control for Startup Deterioration

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Solution Overview

Problem

Fuel cells deteriorate due to non-uniform electric current flow and high resistance when operating under high load conditions, especially at low temperatures, leading to reduced voltage and increased risk of damage during prolonged low-load periods like late-night hours.

Innovation Solution

A fuel cell device with a controller that adjusts the power conditioner to maintain a voltage higher than the maximum output voltage at startup and low temperatures, reducing electric current flow and using a reformer with a catalyst to efficiently manage fuel gas flow and temperature, thereby minimizing fuel cell deterioration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high load is applied to fuel cells at low temperature to meet external power requirements, then power output is improved, but fuel cell deterioration occurs due to non-uniform current flow and concentration

Engineering Contradiction:

Improvepower outputVSAvoidfuel cell durability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The system performs preliminary heating of the fuel cell stack before high-load operation. The control unit activates the heater to raise the temperature of the fuel cell stack to a predetermined temperature before allowing high current flow, thereby preventing deterioration while enabling sufficient power output.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A heater is introduced as an intermediary component between the fuel cell stack and the external load. This heater mediates the temperature condition of the fuel cell stack, ensuring it reaches optimal operating temperature before high-power operation, thus protecting the fuel cells from thermal stress and non-uniform current distribution.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If voltage is reduced to increase current for meeting load requirements, then power output is improved, but fuel cell deterioration accelerates due to increased current flow at low temperature

Engineering Contradiction:

Improvepower outputVSAvoidfuel cell deterioration

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The control unit performs preliminary temperature elevation of the fuel cell stack before high-current operation. By heating the stack to a predetermined temperature first, the system enables subsequent high-current operation without causing deterioration, thus achieving required power output safely.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the temperature parameter of the fuel cell stack from low temperature to a predetermined operating temperature using the heater. This parameter change enables the fuel cells to withstand higher current flows without deterioration, allowing the system to meet load requirements safely.

Inventive Principle:

Principle #35Parameter changes

3Speed

If maximum current is drawn from fuel cells at low temperature, then immediate power availability is improved, but non-uniform current distribution causes concentration and deterioration

Engineering Contradiction:

Improvepower availability speedVSAvoidfuel cell uniformity

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The system performs preliminary heating of the fuel cell stack before high-current operation. By raising the temperature to a predetermined level first, the system enables immediate high-power output while maintaining uniform current distribution across all fuel cell stacks, preventing deterioration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control unit monitors the temperature of the fuel cell stack and uses this feedback to control the heater operation. When the temperature reaches the predetermined level, the control unit activates the fuel cell operation, ensuring optimal conditions for uniform current distribution and preventing deterioration.

Inventive Principle:

Principle #23Feedback

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

The solution effectively suppresses non-uniform current flow and deterioration by maintaining optimal voltage and temperature conditions, ensuring efficient power generation and extending fuel cell lifespan.

Implementation Method 1

a plurality of fuel cells that can generate power using hydrogen-containing gas (fuel gas) and air (oxygen-containing gas)

Methodology Applied

Scientific EffectFuel cell electrochemical reaction: Fuel Cell

Implementation Method 2

a reformer with a catalyst to efficiently manage fuel gas flow and temperature

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9219283B2Method for controlling fuel cell device during power generation start by controlling power conditioner

Publication Date: 2015.12.22 KYOCERA CORP

AI summary

Provided is a fuel cell module and a fuel cell device of which power generation efficiency is improved.A fuel cell device includes a fuel cell module including a housing and a fuel cell stack which is composed of a plurality of fuel cells and is inside the housing, a power conditioner configured to supply electric current generated by the fuel cell stack to an external load, and a controller configured to control the power conditioner such that, at a time of starting power generation, a voltage value of the fuel cells is greater than a voltage value for generating a maximum output in power generation of the fuel cells, and the fuel cell module, the power conditioner and the controller are accommodated in an external case. Accordingly, deterioration of the fuel cells can be suppressed, and the fuel cell device having improved reliability can be obtained.