Power converter architecture and method for integrated fuel cell based power supplies

• US 7,449,259 B2
• Filed: 09/04/2003
• Issued: 11/11/2008
• Est. Priority Date: 04/29/2003
• Status: Expired due to Fees

• Current Assignee: NuCellSys GmbH (Mercedes-Benz Group AG)
• Original Assignee: NuCellSys GmbH (Mercedes-Benz Group AG)
• Inventors: Hampo, Richard J., Zhu, Lizhi, Wells, Brian W.
• Primary Examiner(s): Ryan; Patrick
• Assistant Examiner(s): Lee; Cynthia
• Application Number:
  US10/654,872
• Publication Number:
  US 20040219399A1
• Time in Patent Office: 1,895 Days
• Field of Search: 429/12, 429/34, 429/46
• US Class Current: 429/422
• 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 8/0432 Temperature; Ambient temperature
• CPC Class Codes: H01M 8/04388 of anode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04395 of cathode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04604 Power, energy, capacity or load
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/04768 of the coolant
• 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 8/04955 Shut-off or shut-down of 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: H02M 3/28 using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
• 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 based power supply comprises a main power converter and control that allows the fuel cell stack to be electrically shorted from time-to-time to improve performance. Additionally, the power converter may temporarily disconnect the fuel cell stack from the load after shorting, allowing the fuel cell stack to return to an open circuit voltage, and/or provide current limiting during a period after shorting to provide stable operation while the fuel cell stack powers the load and recharges a power storage device.

Claims

1. A method of operating a fuel cell system comprising a main power converter having a first side and a second side, a fuel cell stack electrically coupled to the first side of the main power converter and a load electrically coupled to the second side of the main power converter, the method comprising:

determining when to start a current pulsing operation; and

selectively operating switches in the first side of the main power converter to produce a high current pulse from the fuel cell stack during a current pulsing operation as at least a portion of the current pulsing operation.

2. The method according to claim 1, further comprising:

driving an inductor electrically coupled in series with the fuel cell stack and at least one switch in the first side of the main power converter into saturation during the current pulsing operation.

3. The method of claim 2 wherein said step of selectively operating switches on the first side of the main power converter comprises selectively operating the switches on the first side of the main power converter to electrically short the fuel cell stack during the current pulsing operation.

4. The method of claim 2 wherein said step of determining when to start a current pulsing operation includes at least one of:

determining that a specified interval has passed; and

determining that a voltage across at least a portion of the fuel cell stack has dropped below a threshold voltage.

5. The method of claim 1, further comprising:

selectively operating switches in the second side of the main power converter to electrically isolate the main power converter from the load during at least a portion of the current pulsing operation.

6. The method of claim 1,further comprising:

selectively operating switches in the first side and the second side of the main power converter to stop a current flow out of the second side of the main power converter during a bridge off period following the current pulsing operation.

7. The method of claim 6, further comprising:

selectively operating switches in at least one of the first and the second sides of the main power converter to limit a current flow out of the second side of the main power converter to a defined threshold during a current limiting period following the bridge off period.

8. The method of claim 7, further comprising:

selectively operating switches in at least one of the first and the second sides of the main power converter to boost/convert a current from the fuel cell to the load during a boost/converting period following the current limiting period to enter a normal operation.

9. The method of claim 8, further comprising:

storing energy from the fuel cell stack in a power storage device electrically coupled across the second side of the main power converter during at least a portion of the boost/converting period; and

releasing energy from the power storage device to the load during the current pulsing period.

10. The method of claim 9, further comprising:

selectively operating switches in the second side of the main power converter to electrically isolate the main power converter from the load during at least a portion of the current pulsing period.

11. The method of claim 9, further comprising:

clamping voltage spikes with a voltage spike clamping circuit across the first side of the main power converter.

12. The method according to claim 1, wherein:

said main power converter comprises a bridge circuit which includes a plurality of first switches that are coupled to output terminals of said fuel cell system at said first side of said main power converter, and are operable to cause said power converter to supply power to said load during a boost operation; and

said step of selectively operating switches comprises operating at least some of said first switches to electrically short circuit the output terminals of the fuel cell system during the current pulsing operation.

13. A method of operating a fuel cell system comprising a main power converter having a first side and a second side, a fuel cell stack electrically coupled to the first side of the main power converter and a load electrically coupled to the second side of the main power converter, the method comprising:

determining when to start a current pulsing operation; and

selectively operating switches in the first side of the main power converter to produce a high current pulse from the fuel cell stack during a current pulsing operation as at least a portion of the current pulsing operation;

wherein said step of selectively operating switches in the first side of the main power converter comprises electrically operating a first pair of transistors in said main power converter to electrically couple a first pole of a primary side of a transformer to both a positive and a negative voltage rail and electrically operating a second pair of transistors in said main power converter to electrically couple a second pole of the primary side of a transformer to both the positive and the negative voltage rail.

14. A method of operating a fuel cell system comprising a main power converter having a first side and a second side, a fuel cell stack electrically coupled to the first side of the main power converter and a load electrically coupled to the second side of the main power converter, the method comprising:

determining when to start a current pulsing operation; and

selectively operating switches in the first side of the main power converter to produce a high current pulse from the fuel cell stack during a current pulsing operation as at least a portion of the current pulsing operation;

wherein determining when to start the current pulsing operation includes determining that an interval of between approximately 30 and 600 seconds, inclusive, has elapsed.

15. A method of operating a fuel cell system comprising a main power converter having a first side and a second side, a fuel cell stack electrically coupled to the first side of the main power converter and a load electrically coupled to the second side of the main power converter, the method comprising:

determining when to start a current pulsing operation; and

selectively operating switches in the first side of the main power converter to produce a high current pulse from the fuel cell stack during a current pulsing operation as at least a portion of the current pulsing operation;

wherein said step of selectively operating switches in the first side of the main power converter comprises selectively operating said switches in the first side of the main power converter to produce the high current pulse from the fuel cell stack for between 20 and 300 milliseconds, inclusive.