Method of qualifying at least a portion of a fuel cell system and an apparatus employing same

• US 6,774,637 B2
• Filed: 11/30/2000
• Issued: 08/10/2004
• Est. Priority Date: 11/30/2000
• Status: Expired due to Fees

• Current Assignee: Plug Power Inc.
• Original Assignee: Plug Power Inc.
• Inventors: Karuppaiah, Chockkalingam, Comi, Chris, Hallum, Ryan, Haridoss, Prathap, Wu, Yaobang
• Primary Examiner(s): Decady, Albert
• Assistant Examiner(s): KERVEROS, DEMETRIOS C
• Application Number:
  US09/726,839
• Publication Number:
  US 20020064694A1
• Time in Patent Office: 1,349 Days
• Field of Search: 324/433, 324/434, 324/426, 324/443, 324/693, 324/71.1, 429/13, 429/17, 429/19, 429/22, 429/90, 205/337
• US Class Current: 324/433
• CPC Class Codes: H01M 8/04 Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
• CPC Class Codes: H01M 8/04552 of the individual fuel cell
• CPC Class Codes: H01M 8/04708 of fuel cell reactants
• CPC Class Codes: H01M 8/04723 of the coolant
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

The present invention provides a method for enabling qualification of at least a portion of a fuel cell system. The method includes electronically obtaining at least one result of a test of the at least a portion of a fuel cell system and electronically comparing the at least one result to at least one qualifying criteria.

Claims

1. A method for enabling qualification of at least a portion of a fuel cell system, the method comprising:

electronically obtaining at least one result of a test of the at least a portion of a fuel cell system before incubation of the system;

electronically comparing the at least one result to at least one qualifying criteria; and

providing an indication before the incubation of the system that the fuel cell system is not functioning properly in response to the comparison.

2. The method of claim 1 further comprising setting the at least one qualifying criteria for the fuel cell system prior to the test.

3. The method of claim 1 wherein the providing the indication comprises at least one of displaying the indication on a display screen and printing the indication.

4. The method of claim 1 further comprising providing a testing mechanism couplable to the fuel cell system.

5. The method of claim 1 wherein the obtaining comprises obtaining a plurality of results of a plurality of tests of at least a portion of the fuel cell system.

6. The method of claim 5 wherein the comparing comprises comparing the plurality of results to a plurality of qualifying criteria.

7. The method of claim 1 wherein the at least one qualification criteria comprises a range of values.

8. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel processor.

9. The method of claim 1 wherein the at least a portion of a fuel cell system comprises an inverter.

10. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel cell stack.

11. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel cell stack, further comprising providing a supply of reactant gases substantially free of carbon monoxide to a fuel cell stack of the at least a portion of a fuel cell system.

12. The method of claim 11 further comprising regulating a temperature of the supply of reactant gases to the fuel cell stack.

13. The method of claim 11 wherein the test comprises performing an open circuit voltage test on a plurality of fuel cells of the fuel cell stack and wherein the at least one result comprises a measurement of a plurality of voltage drops.

14. The method of claim 13 wherein the comparing comprises comparing the measurement of a plurality of voltage drops to the at least one qualifying criteria.

15. The method of claim 14 further comprising providing at least one of an indication that reactant gases in the fuel cell stack are being distributed to all fuel cells of the fuel cell stack and an indication that the reactant gases are not being distributed to all the fuel cells based on the comparison of the plurality of measurements of voltage drops to the at least one qualifying criteria.

16. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel cell stack, further comprising providing a supply of reactant gases substantially free of carbon monoxide to a fuel cell stack of the at least a portion of a fuel cell system.

17. The method of claim 16 wherein the test comprises applying a load to the fuel cell stack and wherein the at least one result comprises a plurality of measurements of voltage drops across a plurality of fuel cells of the fuel cell stack.

18. The method of claim 17 wherein the comparing comprises comparing the plurality of measurements of voltage drops to the at least one qualifying criteria.

19. The method of claim 18 further comprising providing at least one of an indication that dive through holes in fluid flow plates in the fuel cell stack are properly formed and an indication that dive through holes are improperly formed based on the comparison of the plurality of measurements of voltage drops to the at least one qualifying criteria.

20. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel cell stack, the test comprising providing a supply of reactant gases, including carbon monoxide, to the fuel cell stack, applying a load to the fuel cell stack, and wherein the at least one result comprises a plurality of measurements of voltage drops across a plurality of fuel cells of the fuel cell stack.

21. The method of claim 20 wherein the comparing comprises comparing the plurality of measurements of voltage drops to the at least one qualifying criteria.

22. The method of claim 21 wherein the indication comprises an indication of an unsatisfactory installation of a membrane in at least one fuel cell of the fuel cell stack based on the comparison of the plurality of measurements of voltage drops to the at least one qualifying criteria.

23. The method of claim 1 wherein the at least a portion of a fuel cell system comprises a fuel cell stack, the test comprising providing a minimum flow rate of reactant gases, which are substantially free of carbon monoxide, to allow at least one of a plurality of fuel cells of the fuel cell stack to produce electricity, applying a load to the fuel cell stack, and wherein the at least one result comprises a plurality of measurements of voltage drops across a plurality of fuel cells of the fuel cell stack.

24. The method of claim 23 wherein the comparing comprises comparing the plurality of measurements of voltage drops to the at least one qualifying criteria.

25. The method of claim 24 further comprising providing an indication regarding relative electrical production among the plurality of fuel cells based on the comparison of the plurality of measurements of voltage drops to the at least one qualifying criteria.

26. A method for enabling qualification of a fuel cell stack, the method comprising:

electronically obtaining at least one measurement of voltage drop from an open circuit voltage test on a plurality of fuel cells of the fuel cell stack before incubation of the fuel cell stack;

electronically comparing the at least one measurement of voltage drop to a qualifying criteria; and

providing an indication before incubation of the fuel cell stack that reactant gases in the fuel cell stack are at least one of being distributed to all fuel cells of the fuel cell stack and that the reactant gases are not being distributed to all of the fuel cells, based on the comparison of the at least one measurement of voltage drop to a qualifying criteria.

27. The method of claim 26 further comprising obtaining at least one result of a second test of at least a portion of the fuel cell system, and electronically comparing the at least one result of a second test to at least one second qualifying criteria.

28. The method of claim 27 wherein the first test is different from the second test.

29. The method of claim 28 further comprising providing an indication regarding qualification of the fuel cell system based on the comparison of the at least one result of a second test to the at least one second qualifying criteria.

30. The method of claim 29 wherein the providing the indication comprises at least one of providing an indication that the fuel cell system requires further testing, providing an indication that the fuel cell system is qualified, and providing an indication that the system is not qualified.

31. The method of claim 26 wherein a supply of reactant gases substantially free of carbon monoxide is supplied to the fuel cell stack.

32. A method for enabling qualification of a fuel cell stack, the method comprising:

applying a load to the fuel cell stack;

electronically obtaining at least one measurement of voltage drop from a voltage drop test across a plurality of fuel cells of the fuel cell stack before incubation of the fuel cell stack;

electronically comparing the at least one measurement of voltage drop of the voltage drop test to a qualifying criteria; and

providing at least one of an indication regarding formation of dive through holes in fluid flow plates of the fuel cell stack are properly formed and an indication that the dive through holes are not properly formed, in response to the comparison of the at least one measurement of voltage drop of the voltage drop test to the qualifying criteria.

33. The method of claim 32 wherein a supply of reactant gases substantially free of carbon monoxide is supplied to the fuel cell stack.

34. A method for enabling qualification of a fuel cell stack, the method comprising:

applying a load to the fuel cell stack;

electronically obtaining at least one measurement of voltage drop from a voltage drop test across a plurality of fuel cells of the fuel cell stack;

electronically comparing the at least one measurement of voltage drop of the voltage drop test to a qualifying criteria; and

providing at least one of an indication regarding installation of a membrane in at least one fuel cell of the fuel cell stack such that a cathode portion of the membrane faces a cathode portion of the at least one fuel cell and an anode portion of the membrane faces an anode portion of the at least one fuel cell and an indication that the membrane is improperly installed such that the cathode portion of the membrane does not face the cathode portion of the at least one fuel cell and the anode portion of the membrane does not face the anode portion of the at least one fuel cell, in response to the comparison of the at least one measurement of voltage drop of the voltage drop test to the qualifying criteria.

35. The method of claim 34 further comprising providing a supply of reactant gases including carbon monoxide to the fuel cell stack.

36. A method for enabling qualification of a fuel cell stack, the method comprising:

providing a flow rate of reactant gases to the fuel cell stack to mimic minimum power output for the fuel cell stack to produce electricity;

applying a load to the fuel cell stack to mimic low electrical demand, electronically obtaining at least one measurement of voltage drop from a voltage drop test across a plurality of fuel cells of the fuel cell stack;

electronically comparing the at least one measurement of voltage drop of the voltage drop test to a qualifying criteria; and

providing at least one of an indication that all fuel cells of the fuel cell stack are adequately producing electricity and an indication that all of the fuel cells are not adequately producing electricity, in response to the comparison of the at least one measurement of voltage drop of the voltage drop test to the qualifying criteria.

37. The method of claim 36 further comprising providing a supply of reactant gases substantially free of carbon monoxide.

38. At least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform a method of qualifying at least a portion of a fuel cell system, said method comprising:

electronically obtaining at least one result of a test on the at least a portion of a fuel cell system before incubation of the system;

electronically comparing the at least one result to at least one qualifying criteria; and

electronically indication before the incubation of the system the fuel cell system is not functioning properly in response to the comparison.

39. The at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform a method of qualifying at least a portion of a fuel cell system of claim 38, wherein said method further comprises: