Anode leak test implementation

• US 7,942,035 B2
• Filed: 04/09/2008
• Issued: 05/17/2011
• Est. Priority Date: 04/09/2008
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Grimes, Jeffery R., Booden, Valerie Jordan, Milacic, Milos, Sanderson, William F.
• Primary Examiner(s): FITZGERALD, JOHN P
• Application Number:
  US12/099,916
• Publication Number:
  US 20090255326A1
• Time in Patent Office: 1,133 Days
• Field of Search: 73/40, 73/405.R, 73/497
• US Class Current: 73/40.50R
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04097 with recycling of the reactants H01M8/04119, H01M8/04104 take precedence
• CPC Class Codes: H01M 8/04388 of anode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04589 of fuel cell stacks
• CPC Class Codes: H01M 8/04679 of fuel cell stacks
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A system and method is provided for detecting an anode leak of an anode stream in a fuel cell stack. The system comprises a controller that stores at least one first predetermined control value that corresponds to a first pre-selected pressure level. The controller generates at least one first operational control value. The controller controls a pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value. The controller compares the at least one first operational control value to the at least one first predetermined control value. The controller determines the presence of an anode leak in the anode stream based on the comparison of the at least one first operational control value to the at least one first predetermined control value.

Claims

1. A system for detecting an anode leak of an anode stream driven in a fuel cell stack of a vehicle at varying pressure levels by a pressure regulator device, wherein the fuel cell stack generates electrical current in response to the anode stream, the system comprising:

a controller operably coupled to the pressure regulator device and configured to;

store at least one first predetermined control value which is indicative of a first pre-selected pressure level;

generate at least one first operational control value;

control the pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value;

compare the at least one first operational control value to the at least one first predetermined control value; and

determine the presence of an anode leak in the anode stream based on the comparison of the at least one first operational control value to the at least one first predetermined control value.

2. The system of claim 1 wherein the controller is configured to determine the presence of an anode leak in response to the at least one first operational control value not being equal to the at least one first predetermined control value.

3. The system of claim 2 wherein the controller is configured to set a flag in response to the at least one first operational control value not being equal to the at least one first predetermined control value.

4. The system of claim 2 wherein the controller is further configured to calculate a worst case leak size in response to the at least one first operational control value not being equal to the at least one first predetermined control value.

5. The system of claim 1 wherein the controller is further configured to store at least one second predetermined control value that corresponds to a second pre-selected pressure level.

6. The system of claim 5 wherein the controller is further configured to generate at least one second operational control value and to control the pressure regulator device to adjust the pressure of the anode stream to reach the second pre-selected pressure level with the at least one second operational control value.

7. The system of claim 6 wherein the controller is further configured to compare the at least one second operational control value to the at least one second predetermined control value for validating the presence of an anode leak in the anode stream.

8. The system of claim 7 wherein the controller is further configured to calculate a worst case leak size in response to determining that the at least one second operational control value is not equal to the at least one second predetermined control value.

9. The system of claim 1 wherein the controller is further configured to determine whether the fuel cell stack is in an idle state prior to controlling the pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value.

10. The system of claim 9 further comprising a current sensor operably coupled to the fuel cell stack and to the controller, wherein the current sensor measures an amount of current generated by the fuel cell stack and transmits the measured amount of current to the controller.

11. The system of claim 10 wherein the controller is further configured to determine that the fuel cell stack is in the idle state in response to the measured amount of current being below a predetermined current level.

12. A method for detecting an anode leak of an anode stream driven in a fuel cell stack of a vehicle at varying pressure levels by a pressure regulator device, wherein the fuel cell stack generates electrical current in response to the anode stream, the method comprising:

storing at least one first predetermined control value which is indicative of a first pre-selected pressure level;

generating at least one first operational control value;

controlling the pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value;

comparing the at least one first operational control value to the at least one first predetermined control value; and

determining the presence of an anode leak in the anode stream based on the comparison of the at least one first operational control value to the at least one first predetermined control value.

13. The method of claim 12 further comprising calculating a worst case leak size in response to the at least one first operational control value not being equal to the at least one first predetermined control value.

14. The method of claim 12 further comprising determining an amount of current generated by the fuel cell stack to determine if the fuel cell stack is in an idle state prior to controlling the pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value.

15. The method of claim 12 further comprising determining the presence of the anode leak in response to determining that the at least one first operational control value is not equal to the at least one first predetermined control value.

16. The method of claim 15 further comprising storing at least one second predetermined control value that corresponds to a second pre-selected pressure level and controlling the pressure regulator device to adjust the pressure of the anode stream to reach the second pre-selected pressure level with the at least one second operational control value.

17. The method of claim 16 further comprising comparing the at least one second operational control value to the at least one second predetermined control value and to validate the presence of an anode leak in the anode stream.

18. The method of claim 17 further comprising calculating a worst case leak size in response to determining that the at least one second operational control value is not equal to the at least one second predetermined control value.

19. A method for detecting an anode leak of an anode stream that is passed through a fuel cell stack to generate electrical current, wherein the fuel cell stack generates electrical current in response to the anode stream;

the method comprising;

defining a first pre-selected pressure level;

associating at least one first predetermined control value to the first pre-selected pressure level;

generating at least one first operational control value;

controlling a pressure regulator device to adjust the pressure of the anode stream to reach the first pre-selected pressure level with the at least one first operational control value;

comparing the at least one first operational control value to the at least one first predetermined control value; and

determining the presence of an anode leak in the anode stream based on the comparison of the at least one first operational control value to the at least one first predetermined control value.

20. The method of claim 19 further comprising determining the presence of the anode leak in response to determining that the at least one first operational control value is not equal to the at least one first predetermined control value.