Hybrid electric propulsion system, hybrid electric power pack and method of optimizing duty cycle

• US 20050139399A1
• Filed: 12/27/2004
• Published: 06/30/2005
• Est. Priority Date: 12/30/2003
• Status: Abandoned Application

• Current Assignee: Hydrogenics Corporation (Cummins Incorporated)
• Original Assignee: Hydrogenics Corporation (Cummins Incorporated)
• Inventors: Gopal, Ravi B.
• Application Number:
  US11/020,187
• Publication Number:
  US 20050139399A1
• Time in Patent Office: Days
• US Class Current: 180/65.100
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 58/33 by cooling
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• 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 8/04604 Power, energy, capacity or load
• 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: H02J 2300/30 The power source being a fuel cell
• CPC Class Codes: H02J 7/345 using capacitors as storage or buffering devices
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• 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

Abstract

A fuel cell powered vehicle includes a fuel cell power module having at least one fuel cell electrically connected to a drive unit for delivering power to the drive unit, a battery pack having at least one battery electrically connected to the drive unit for independently delivering power to the drive unit, and an ultra-capacitor pack having at least one ultra-capacitor electrically connected to the drive unit for independently delivering power to the drive unit. When the power requirement is low, only the fuel cell power module delivers electric power to the drive unit. The battery pack supplements the power to the drive unit for medium power requirements. The ultra-capacitor pack supplements the power to the drive unit for high power requirements. The ultra-capacitor pack can be recharged by regenerative braking.

Claims

I_We. I/We claim:

1. A fuel cell powered vehicle comprising:

a drive unit for receiving electric power and converting the electric power into a propulsive force to displace the vehicle;

a fuel cell power module having at least one fuel cell electrically connected to the drive unit for delivering power to the drive unit;

a battery pack having at least one battery electrically connected to the drive unit for independently delivering supplemental power to the drive unit; and

an ultra-capacitor pack having at least one ultra-capacitor electrically connected to the drive unit for independently delivering supplemental power to the drive unit.

2. The vehicle as claimed in claim 1 wherein the fuel cell power module is electrically connected to the battery pack for charging the battery pack.

3. The vehicle as claimed in claim 1 wherein the fuel cell power module is electrically connected to both the battery pack and the ultra-capacitor pack for recharging both the battery pack and the ultra-capacitor pack.

4. The vehicle as claimed in claim 1 wherein the drive unit is further connected to the ultra-capacitor pack via a recharge circuit adapted to recharge the ultra-capacitor pack during regenerative braking of the vehicle.

5. The vehicle as claimed in claim 2 wherein the drive unit is further connected to the ultra-capacitor pack via a recharge circuit adapted to recharge the ultra-capacitor pack during regenerative braking of the vehicle.

6. The vehicle as claimed in claim 3 wherein the drive unit is further connected to the ultra-capacitor pack via a recharge circuit adapted to recharge the ultra-capacitor pack during regenerative braking of the vehicle.

7. The vehicle as claimed in claim 1 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller having control logic for efficiently coordinating the fuel cell power module, battery pack and ultra-capacitor pack in response to the power requirement signal.

8. The vehicle as claimed in claim 1 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

9. The vehicle as claimed in claim 2 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

10. The vehicle as claimed in claim 3 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

11. The vehicle as claimed in claim 4 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

12. The vehicle as claimed in claim 5 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

13. The vehicle as claimed in claim 6 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement of the vehicle, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

14. A method of powering a vehicle having a fuel cell power module having at least one fuel cell, the fuel cell power module being selectively supplemented by a battery pack having at least one battery and an ultra-capacitor pack having at least one ultra-capacitor, the method comprising the steps of:

receiving a power requirement signal representing an instantaneous power requirement of the vehicle;

processing the power requirement signal to determine whether the instantaneous power requirement of the vehicle can be satisfied by the fuel cell power module alone, by the fuel cell power module supplemented by the battery pack, or by the fuel cell power module supplemented by both the battery pack and the ultra-capacitor pack;

supplying electric power to a drive unit of the vehicle from the fuel cell power module;

supplementing the electric power delivered to the drive unit by also independently delivering power from the battery pack when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module; and

supplementing the electric power delivered to the drive unit by also independently delivering power from the ultra-capacitor pack when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

15. The method as claimed in claim 14 further comprising the step of charging the battery pack using current from the fuel cell power module when the power requirement is less than the maximum power output of the fuel cell power module.

16. The method as claimed in claim 14 further comprising the step of simultaneously charging both the battery pack and the ultra-capacitor pack using current from the fuel cell power module when the instantaneous power requirement is less than the maximum power output of the fuel cell power module.

17. The method as claimed in claim 14 further comprising the step of charging the ultra-capacitor pack using current generated by the drive unit during regenerative braking of the vehicle.

18. A hybrid electric propulsion system comprising:

a drive unit for receiving electric power and converting the electric power into a propulsive force;

a fuel cell power module having at least one fuel cell electrically connected to the drive unit for delivering power to the drive unit;

a battery pack having at least one battery electrically connected to the drive unit for independently delivering power to the drive unit; and

an ultra-capacitor pack having at least one ultra-capacitor electrically connected to the drive unit for independently delivering power to the drive unit.

19. The propulsion system as claimed in claim 18, wherein the fuel cell power module is electrically connected to the battery pack for charging the battery pack.

20. The propulsion system as claimed in claims 18 wherein the drive unit is further connected to the ultra-capacitor pack via a recharge circuit adapted to recharge the ultra-capacitor pack during regenerative braking of the vehicle.

21. The propulsion system as claimed in claim 18 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement, the controller having control logic for efficiently coordinating the fuel cell power module, battery pack and ultra-capacitor pack in response to the power requirement signal.

22. The propulsion system as claimed in claim 18 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement, the controller causing a battery pack to deliver power to the drive unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the drive unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

23. A hybrid power pack for generating and delivering electric power to equipment having sharply transient power requirements, the power pack comprising:

a power output unit for supplying electric power to the equipment;

a fuel cell power module having at least one fuel cell electrically connected to the power output unit for generating and delivering electric power to the power output unit;

a battery pack having at least one battery electrically connected to the power output unit for selectively and independently delivering electric power to the power output unit; and

an ultra-capacitor pack having at least one ultra-capacitor electrically connected to the power output unit for selectively and independently delivering electric power to the power output unit.

24. The power pack as claimed in claim 23 wherein the fuel cell power module is electrically connected to the battery pack for charging the battery pack.

25. The power pack as claimed in claim 23 wherein the power output unit is an electric motor.

26. The power pack as claimed in claim 25 wherein the electric motor is further connected to the ultra-capacitor pack via a recharge circuit adapted to recharge the ultra-capacitor pack when the electric motor is freely rotating.

27. The power pack as claimed in claim 23 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement, the controller having control logic for efficiently coordinating the fuel cell power module, battery pack and ultra-capacitor pack in response to the power requirement signal.

28. The power pack as claimed in claim 23 further comprising a controller for receiving a power requirement signal representative of an instantaneous power requirement, the controller causing a battery pack to deliver power to the power output unit when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module and further causing an ultra-capacitor pack to deliver power to the power output unit when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

29. The power pack as claimed in claim 23 wherein the equipment is an auxiliary power unit (APU) for providing backup power.

30. A method of outputting electric power in response to a sharply transient power requirement, the method comprising the steps of:

receiving a power requirement signal representing an instantaneous power requirement;

processing the power requirement signal to determine whether the instantaneous power requirement can be satisfied by the fuel cell power module alone, by the fuel cell power module supplemented by the battery pack, or by the fuel cell power module supplemented by both the battery pack and the ultra-capacitor pack;

outputting electric power from the fuel cell power module;

supplementing the electric power delivered by the fuel cell power module by also independently outputting electric power from a battery pack when the instantaneous power requirement exceeds a maximum power output of the fuel cell power module; and

supplementing the electric power delivered by the fuel cell power module and the battery pack by also independently outputting electric power from an ultra-capacitor pack when the instantaneous power requirement exceeds a combined maximum power output of the fuel cell power module and the battery pack.

31. The method as claimed in claim 30 further comprising the step of charging the battery pack using current from the fuel cell power module when the instantaneous power requirement is less than the maximum power output of the fuel cell power module.

32. The method as claimed in claim 30 further comprising the step of simultaneously charging both the battery pack and the ultra-capacitor pack using current from the fuel cell power module when the instantaneous power requirement is less than the maximum power output of the fuel cell power module.

33. The method as claimed in claim 30 further comprising the step of charging the ultra-capacitor pack using current generated by a freely rotating electric motor.

34. The method as claimed in claim 30 further comprising the steps of:

transducing an actual total power output of the fuel cell power module, battery pack and ultra-capacitor pack into a feedback signal;

returning the feedback signal to a controller for comparison with a power setpoint that is set by a user; and

controlling the electric power delivered by the fuel cell power module, battery pack and ultra-capacitor pack in response to a difference between the power setpoint and the feedback signal.

35. The method as claimed in claim 30 further comprising the steps of:

transducing an instantaneous power requirement of a connected load into a feedback signal;

returning the feedback signal to a controller for computation using pre-programmed or dynamically changeable control algorithms and parameters to determine a readiness of the power pack to sustain the instantaneous power requirement; and

controlling the fuel cell power module, battery pack and ultracapacitor pack to deliver electric power in response to a difference between a predetermined power setpoint and the feedback signal.