Fuel Cell Power Assembly Control for Predictive Shutdown Timing

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Solution Overview

Problem

Fuel cell systems experience degradation due to frequent start-up and shutdown, and excess power generation is often dissipated or stored inefficiently, leading to reduced durability and energy waste.

Innovation Solution

A method for controlling a power assembly with a fuel cell unit and an electric energy storage system, predicting power demand and state-of-charge to identify periods where the fuel cell can be shut down, minimizing degradation by maintaining operation with the fuel cell off during time periods exceeding a threshold, ensuring efficient power delivery from the energy storage system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the fuel cell system is turned off when the battery SoC is high and power demand is low, then energy dissipation is avoided, but the fuel cell degradation increases due to frequent start-up and shutdown

Engineering Contradiction:
Improveenergy dissipationVSAvoidfuel cell durability
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The control strategy performs preliminary action by predicting future power demand and battery SoC evolution before making the shutdown decision. The controller forecasts whether the battery will reach maximum SoC within a prediction horizon, and only shuts down the fuel cell if the predicted time period is sufficient to avoid degradation. This anticipatory approach prevents both energy dissipation and unnecessary shutdowns.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the fuel cell shutdown decision based on real-time conditions and predictions. The controller continuously monitors battery SoC, power demand, and predicted evolution, adapting the shutdown strategy to current system state. This dynamic approach allows optimal balancing between energy efficiency and fuel cell durability under varying operating conditions.

Inventive Principle:
Principle #15Dynamics

2Reliability

If the fuel cell operates at higher power to avoid low current density degradation, then fuel cell durability is improved, but excess power is generated that must be dissipated or stored

Engineering Contradiction:
Improvefuel cell durabilityVSAvoidexcess power dissipation
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The controller predicts future power demand and battery SoC evolution in advance to determine the optimal operating power of the fuel cell. By forecasting whether excess power will be needed later or if the battery will reach maximum SoC, the system adjusts fuel cell power proactively, maintaining durability while minimizing energy dissipation through informed advance planning.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The control strategy uses feedback from real-time monitoring of battery SoC and power demand to continuously adjust fuel cell operating power. The controller compares actual system state with predicted evolution, dynamically optimizing fuel cell power output to balance durability requirements with excess power generation, ensuring energy is utilized efficiently based on forecasted needs.

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

Reduces fuel cell degradation and improves energy efficiency by optimizing fuel cell operation, allowing the power assembly to meet power demands with minimal fuel cell usage, thus extending its lifespan and enhancing energy utilization.

Implementation Method 1

a fuel cell unit and an electric energy storage system for storing excess electric energy produced by the fuel cell unit

Methodology Applied
Scientific EffectElectrochemical reaction: Fuel Cell

Data Source

PatentUS12447868B2Method for controlling a power assembly
Publication Date: 2025.10.21 VOLVO TRUCK CORP
  • US12447868B2 patent drawing
  • US12447868B2 patent drawing
  • US12447868B2 patent drawing

AI summary

A method for controlling a power assembly comprising a fuel cell unit and an electric energy storage system for storing excess electric energy produced by the fuel cell unit. The method comprises predicting a power demand from the power assembly over a prediction time horizon, obtaining a state-of-charge and/or power capability of the electric energy storage system, based on the predicted power demand and the obtained SoC and/or power capability, identifying a time period during which the power assembly is expected to be able to deliver power in accordance with the predicted power demand with the fuel cell unit shut down, or is at least expected to be able to deliver power at a minimum power level determined with respect to the predicted power demand, controlling the power assembly to shut down the fuel cell unit during at least a part of the identified time period in response to the identified time period being larger than a time threshold.