Protection circuits for hybrid power systems

• US 7,531,916 B2
• Filed: 05/26/2004
• Issued: 05/12/2009
• Est. Priority Date: 05/26/2004
• Status: Active Grant

• Current Assignee: Altergy Systems
• Original Assignee: Altergy Systems
• Inventors: Oros, James M., Franklin, Jerrold E.
• Primary Examiner(s): Jackson; Stephen W
• Assistant Examiner(s): KAPLAN, HAL IRA
• Application Number:
  US10/855,206
• Publication Number:
  US 20050275983A1
• Time in Patent Office: 1,812 Days
• Field of Search: 307/64, 361/90
• US Class Current: 307/64
• 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 8/04559 of fuel cell stacks
• CPC Class Codes: H01M 8/04567 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04589 of fuel cell stacks
• CPC Class Codes: H01M 8/04604 Power, energy, capacity or load
• CPC Class Codes: H01M 8/04679 of fuel cell stacks
• CPC Class Codes: H01M 8/04686 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/0488 of fuel cell stacks
• CPC Class Codes: H01M 8/0491 of fuel cell stacks
• 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 power management and protection system is provided for a hybrid fuel cell system. The hybridization includes a fuel cell stack and an energy storage device (ESD) having either batteries, ultracapacitors, or both, in parallel with the fuel cell for delivering power to an electrical load. Voltage and current protection is provided to the stack, ESD, and load by use of a two stage control system. The first stage limits the current drawn from the stack and the charging rate of the ESD and provides for the voltage output to be within an adjustable predetermined range to prevent an over-voltage condition on the ESD and the load and an under-voltage condition in the stack. The second stage limits the current delivered to the load to an adjustable predetermined level, prevents an under-voltage condition on the load, and prevents rapid discharge of the ESD in the case of a short circuit.

Claims

1. A system for powering a direct-current electrical load, comprising:

a fuel cell stack configured as a primary power device for producing electrical power in response to the supply of fuel and oxidant;

said fuel cell stack having a cell potential that varies in response to load changes;

a first protection circuit coupled to said fuel cell stack;

a fuel cell output current sensor coupled to said first protection circuit;

a fuel cell output voltage sensor coupled to said first protection circuit;

a first protection circuit output voltage sensor coupled for sensing the output voltage from said first protection circuit;

an energy storage device (ESD) coupled to said first protection circuit and configured for providing current to the load when the fuel cell stack produces less current than the load requires;

wherein said ESD is selected from the group consisting of a supercapacitor, an ultracapacitor, and a battery;

wherein said first protection circuit regulates current supplied to said ESD, and reduces current supplied to said ESD in response to detecting a current level from said fuel cell output current sensor which exceeds an adjustable predetermined threshold;

wherein said first protection circuit ceases conduction in response to said fuel cell output voltage sensor detecting that fuel cell output voltage is below a predetermined threshold;

wherein said first protection circuit limits the voltage applied to said ESD in response to the output of said first protection circuit output voltage sensor;

a second protection circuit coupled to said enemy storage device (ESD) and configured for outputting a fixed voltage driving the electrical load of the system;

an ESD output current sensor coupled to said second protection circuit;

an ESD output voltage sensor coupled to said second protection circuit;

a second protection circuit output voltage sensor coupled for sensing the output voltage from said second protection circuit;

wherein said second protection circuit controls the amount of current being supplied from said ESD to the load in response to detecting current level from said ESD output current sensor;

wherein said second protection circuit ceases conduction in response to the ESD output voltage sensor detecting a low voltage condition below a predetermined threshold;

wherein said second protection circuit limits the voltage applied to the load in response to detecting a low voltage condition from said second protection circuit output voltage sensor.

2. The system according to claim 1, wherein said first and/or second protection circuits comprise regulators.

3. The system according to claim 2, wherein said first and/or second protection circuits incorporates a series element through which current is regulated.

4. A system for powering a direct-current (DC) electrical load comprising:

a fuel cell stack configured as a primary power device;

an energy storage device (ESD) coupled with the primary power device and configured for providing current to the load when the fuel cell stack produces less current than the load requires;

ESD-load protection circuitry coupled with the ESD and the load;

wherein said ESD-load protection circuitry comprises an ESD-load regulating circuit;

wherein said ESD-load protection circuitry additionally comprises a first low threshold voltage error sensor coupled to said ESD-load regulating circuit;

wherein said ESD-load protection circuitry additionally comprises a load current sensor; and

ESD-stack protection circuitry coupled with the fuel cell stack, the ESD, and the ESD-load protection circuitry;

wherein said ESD-stack protection circuitry comprises a first series element, and said ESD-load protection circuitry comprises a second series element.

5. The system according to claim 4, wherein said ESD-stack protection circuitry additionally comprises an ESD-stack regulating circuit.

6. The system according to claim 5, wherein said ESD-stack protection circuitry additionally comprises a first low threshold voltage error sensor coupled to said ESD-stack regulating circuit.

7. The system according to claim 6, wherein said ESD-stack protection circuitry additionally comprises a stack current sensor.

8. The system according to claim 7, wherein said ESD-stack protection circuitry additionally comprises a high voltage error sensor coupled to said ESD-stack regulating circuit.

9. The system according to claim 8, wherein said ESD-stack protection circuitry additionally comprises a second low threshold voltage error sensor coupled to said ESD-stack regulating circuit.

10. The system according to claim 9, wherein said ESD-stack protection circuitry additionally comprises a reverse current blocking diode.

11. The system according to claim 4, 5, 6, 7, 8, 9, or 10, wherein said ESD-load protection circuitry additionally comprises a second low threshold voltage error sensor coupled to said ESD-load regulating circuit.

12. The system according to claim 4, additionally comprising a regulating circuit for regulating current through the ESD-load protection circuitry in response to one or more of the following:

an energy storage device low voltage threshold error, a load current error;

or a load under-voltage error.

13. The system according to claim 12:

wherein said ESD-stack protection circuitry further comprises an ESD-stack regulating circuit; and

wherein said ESD-stack regulating circuit comprises;

a fuel cell stack high current error detection sensor;

a fuel cell stack low voltage threshold error detection sensor;

an energy storage device over-voltage error detection sensor; and

an energy storage device under-voltage error detection sensor.

14. The system according to claim 4, wherein the first series element comprises a field effect transistor.

15. The system according to claim 4 or claim 14, wherein the second series element comprises a field effect transistor.

16. A system for powering a direct-current (DC) electrical load comprising:

a fuel cell stack configured as a primary power device;

an energy storage device (ESD) configured for providing current to the load when the fuel cell stack produces less current than the load requires, said ESD coupled with the primary power device;

wherein said ESD is selected from the group consisting of a supercapacitor, an ultracapacitor, and a battery;

an ESD-load protection circuitry coupled with the ESD and the load;

wherein said ESD-load protection circuitry comprises an ESD-load regulating circuit;

wherein said ESD-load protection circuitry additionally comprises a first low threshold voltage error sensor coupled to said ESD-load regulating circuit;

wherein said ESD-load protection circuitry additionally comprises a load current sensor;

an ESD-stack protection circuitry coupled with the fuel cell stack, the ESD, and the ESD-load protection circuitry; and

at least one regulating circuit

comprising a microprocessor programmed to regulate the current in the system by;

(a) sensing the fuel cell output current to determine if the current being drawn from the fuel cell stack is higher than the error limit;

(b) sensing the fuel cell stack output voltage to determine if this voltage is above the low threshold error limit;

(c) sensing the voltage applied to the energy storage device to determine an over or under-voltage error condition;

(d) sensing the current being delivered to the load to determine if the load current is higher than the error limit;

(e) sensing the voltage being applied to the load to determine if the voltage is lower than the load low voltage error condition; and

(f) applying a control signal in response to one or more of (a) through (e).

17. A system for powering a direct-current (DC) electrical load comprising:

a fuel cell stack configured as a primary power device;

an energy storage device (ESD) configured for providing current to the load when the fuel cell stack produces less current than the load requires, said ESD coupled with the primary power device;

wherein said ESD is selected from the group consisting of a supercapacitor, an ultracapacitor, and a battery;

first protection circuitry coupled with the fuel cell stack and the ESD; and

second protection circuitry coupled with the ESD, the load, and the first protection circuitry;

wherein said first protection circuitry comprises a first series element, and said second protection circuitry comprises a second series element;

wherein said first protection circuitry additionally comprises a first regulating circuit;

wherein said first protection circuitry additionally comprises a first low threshold voltage error sensor coupled to said first regulating circuit;

wherein said first protection circuitry additionally comprises a stack current sensor;

wherein said first protection circuitry additionally comprises a high voltage error sensor coupled to said first regulating circuit; and

wherein said first protection circuitry additionally comprises a second low threshold voltage error sensor coupled to said first regulating circuit.

18. The system according to claim 17, wherein said first protection circuitry additionally comprises a reverse current blocking diode.