Apparatus and method for high efficiency operation of fuel cell systems

• US 10,056,630 B2
• Filed: 09/28/2015
• Issued: 08/21/2018
• Est. Priority Date: 12/02/2008
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: King, Robert Dean, Richter, Timothy Gerard
• Primary Examiner(s): Usyatinsky, Alex
• Application Number:
  US14/867,652
• Publication Number:
  US 20160020473A1
• Time in Patent Office: 1,058 Days
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• CPC Class Codes: H01M 16/003 of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 16/006 of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04619 of fuel cell stacks
• CPC Class Codes: H01M 8/0494 of fuel cell stacks
• CPC Class Codes: H01M 8/04947 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/18 Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
• CPC Class Codes: H02J 2300/30 The power source being a fuel cell
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02P 90/40 Fuel cell technologies in production processes
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A drive circuit comprising a DC bus configured to supply power to a load, a first fuel cell coupled to the DC bus and configured to provide a first power output to the DC bus, and a second fuel cell coupled to the DC bus and configured to provide a second power output to the DC bus supplemental to the first fuel cell. The drive circuit further includes an energy storage device coupled to the DC bus and configured to receive energy from the DC bus when a combined output of the first and second fuel cells is greater than a power demand from a load, and provide energy to the DC bus when the combined output of the first and second fuel cells is less than the power demand from the load.

Claims

1. A drive circuit comprising:

a DC bus;

a voltage converter assembly coupled to the DC bus;

a fuel cell coupled to the voltage converter assembly; and

a controller programmed to;

operate the fuel cell to deliver a power output to the voltage converter assembly during a first mode of operation; and

operate the voltage converter assembly to permit charging the fuel cell during a second mode of operation,

wherein the fuel cell comprises a regenerative fuel cell.

2. The drive circuit of claim 1 further comprising an energy storage device coupled to the DC bus via the voltage converter assembly, wherein the controller is further programmed to control the energy storage device to deliver a supplemental power output to the voltage converter assembly.

3. The drive circuit of claim 2 wherein the energy storage device comprises one of a battery, an ultracapacitor, and a flywheel.

4. The drive circuit of claim 1 wherein the voltage converter assembly comprises at least one bi-directional buck/boost converter.

5. A method of operating a fuel cell propulsion system comprising:

causing a fuel cell to deliver a first output to a voltage converter assembly during a first mode of operation;

causing the voltage converter assembly to permit charging of the fuel cell during a second mode of operation; and

causing the voltage converter assembly to boost the first output and supply the boosted output to a DC link,

wherein the fuel cell comprises a regenerative fuel cell.

6. The method of claim 5 further comprising causing an energy storage device to deliver a second output to the voltage converter assembly during the first mode of operation.

7. A fuel cell propulsion system comprising:

a motor;

a DC bus coupled to the motor via an inverter;

a DC-to-DC converter assembly coupled to the DC bus;

a fuel cell arrangement coupled to the DC bus via the DC-to-DC converter assembly; and

a controller programmed to;

operate the fuel cell arrangement to deliver a first power output to the DC-to-DC converter assembly during a high-power-demand operating mode;

operate the fuel cell arrangement to deliver a second power output to the DC-to-DC converter assembly during a low-power-demand operating mode; and

operate the DC-to-DC converter assembly to permit charging the fuel cell arrangement during a regenerative mode of operation,

wherein the fuel cell comprises a regenerative fuel cell.

8. The fuel cell propulsion system of claim 7 further comprising an energy storage unit coupled to the DC-to-DC converter assembly, wherein the controller is further programmed to operate the energy storage unit to supply a power output equal to a difference between a requested operating power of the motor and a power output of the fuel cell arrangement.