Method and system for controlling power distribution in a hybrid fuel cell vehicle

• US 6,792,341 B2
• Filed: 04/16/2003
• Issued: 09/14/2004
• Est. Priority Date: 10/23/2002
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Spiteri, Raymond, Hunt, Thomas Howard
• Primary Examiner(s): Camby, Richard M.
• Application Number:
  US10/249,521
• Publication Number:
  US 20040083039A1
• Time in Patent Office: 517 Days
• Field of Search: 701/1, 701/22, 701/36, 701/99, 318/139, 429/12, 429/17, 429/19, 429/22, 320/124, 320/132, 320/136, 320/137, 322/15, 322/16, 180/65.1, 180/65.3, 180/65.8, 700/297
• US Class Current: 701/22
• 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: 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 power distribution control system for a hybrid fuel cell vehicle is provided. The system includes a high voltage energy converter (HVEC) for providing current from an electrical bus to the battery, or from the battery to the bus. As a vehicle load increases, the HVEC temporarily provides current to the bus from the battery. A feedforward signal is input into a fuel cell subsystem so that the fuel cell begins to generate additional current. As additional fuel cell current becomes available, an HVEC controller reduces the amount of current the HVEC provides to the bus from the battery, until there is a zero net current flow to and from the battery. At this point, a state of equilibrium is reached and the fuel cell provides all the current required by the vehicle loads.

Claims

1. A power distribution control system for a vehicle having a fuel cell and a second power source connected to an electrical bus, the control system comprising:

a voltage regulator configured to control voltage on the bus;

a first controller for controlling the voltage regulator;

a computer programmed and configured with fuel cell characteristics for relating fuel cell voltage to fuel cell current, the computer being further programmed and configured to receive a current request at least partly based on vehicle loads, and to determine a first voltage related to the current request using the fuel cell characteristics; and

a second controller configured to receive a voltage signal from the computer and to provide a current command to the first controller, the voltage signal being at least partly based on the first voltage and a measured voltage.

2. The control system of claim 1, wherein the second power source is one of a nickel metal hydride battery, a lead acid battery, and an ultra-capacitor.

3. The control system of claim 1, further comprising a third controller for controlling the fuel cell.

4. The control system of claim 1, wherein the computer is further programmed and configured to execute control algorithms, the control algorithms including the first controller, the second controller, and the third controller.

5. The control system of claim 1, wherein the voltage regulator and the fuel cell are disposed on the bus such that all vehicle electrical loads connect to the bus between the voltage regulator and the fuel cell.

6. The control system of claim 1, wherein the fuel cell characteristics comprise a plurality of fuel cell polarization curves.

7. The control system of claim 1, wherein the voltage signal received by the second controller is a voltage error, the voltage error being the difference between the first voltage and a measured voltage.

8. The control system of claim 1, wherein the second controller is further configured to provide current commands to the first controller to achieve a target current flow for the second power source.

9. The control system of claim 7, wherein the target current flow for the second power source is a predetermined constant.

11. The method of claim 9, wherein the equilibrium point is reached when the current flow of the second power source is a predetermined constant.

12. The method of claim 9, wherein the first current command is generated at least partly based on a voltage error, the voltage error being the difference between the first voltage and the measured voltage.

13. The method of claim 9, wherein the continuous adjustment of the current flow occurs at a predetermined rate, the predetermined rate being based on calibrated fuel cell current output.

14. The method of claim 9, wherein the first voltage is generated by applying a current request to a fuel cell polarization curve.

15. The method of claim 14, wherein the fuel cell polarization curve is chosen from a family of curves based on fuel cell operating conditions.

16. The method of claim 9, wherein the current command is partly based on a disturbance voltage.

10. A method of controlling the power distribution in a vehicle having a fuel cell and a second power source, the method comprising:

generating a first voltage based on a vehicle electrical load change;

generating a first current command at least partly based on the first voltage and a measured voltage;

adjusting current flow of the second power source at least partly based on the current command;

adjusting available fuel cell current at least partly based on the vehicle electrical load change;

continuously adjusting current flow of the second power source at least partly based on additional current commands until an equilibrium point is reached.

17. A vehicle having a fuel cell and a second power source connected to an electrical bus, and a power distribution system for controlling the distribution of power in the vehicle, the power distribution system comprising:

a voltage regulator configured to control voltage on the bus;

a first controller for controlling the voltage regulator;

a computer programmed and configured with fuel cell characteristics for relating fuel cell voltage to fuel cell current, the computer being further programmed and configured to receive a current request at least partly based on vehicle loads, and to determine a first voltage related to the current request using the fuel cell characteristics; and

a second controller configured to receive a voltage signal from the computer and to provide a current command to the first controller, the voltage signal being at least partly based on the first voltage and a measured voltage.

18. The vehicle of claim 17, wherein the fuel cell characteristics comprise a plurality of fuel cell polarization curves.

19. A controller for controlling the power distribution system in a vehicle, the vehicle having a fuel cell and a second power source, the controller comprising:

an algorithm for generating a first voltage at least partly based on vehicle electrical loads, for generating a current command at least partly based on the first voltage and a measured voltage, for adjusting current flow of the second power source at least partly based on the current command, for adjusting available fuel cell current at least partly based on the vehicle electrical loads, and for continuously adjusting the current flow of the second power source until an equilibrium point is reached.

20. The controller of claim 19, wherein the equilibrium point is reached when the current flow of the second power source is a predetermined constant.