Reactive compressor surge mitigation strategy for a fuel cell power system

• US 8,846,262 B2
• Filed: 10/25/2012
• Issued: 09/30/2014
• Est. Priority Date: 10/25/2012
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Mussro, Joseph, Zhang, Yanyan
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): COLUCCI RIOS, JOSE A
• Application Number:
  US13/660,083
• Publication Number:
  US 20140120447A1
• Time in Patent Office: 705 Days
• Field of Search: None
• US Class Current: 429/444
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04B 51/00 Testing machines, pumps, or pumping installations
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/04395 of cathode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04425 at auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/04776 at auxiliary devices, e.g. reformer, compressor, burner
• 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

Systems and methods to mitigate surge conditions in a compressor of a vehicle fuel cell system. A first surge mitigation strategy regulates a cathode backpressure valve, if the compressor is operating at or above a threshold speed. A second surge mitigation strategy regulates a recirculation valve if the compressor is operating below the threshold speed. In one form, a feedback-based control may be used as part of a larger feedforward-based control strategy such that the mitigation is part of a reactive control strategy. The strategy may additionally be implemented in a processor-based controller.

Claims

1. A method for avoiding surge in a vehicular fuel cell system compressor, said method comprising:

maintaining, within a memory, a compressor map corresponding to the operation of the compressor;

controlling the compressor using a default strategy such that its operation approaches a setpoint within the compressor map;

sensing a surge condition within the compressor;

determining if an operating speed of the compressor is at or above a threshold value or below the threshold value;

controlling the surge condition with a first surge mitigation strategy if the operating speed of the compressor is at or above the threshold value or a second surge mitigation strategy if the operating speed of the compressor is below the threshold value;

regulating a cathode backpressure valve with the first surge mitigation strategy; and

regulating a recirculation valve with the second mitigation strategy.

2. The method of claim 1, wherein the cathode backpressure valve is regulated by generating a cathode backpressure valve control command that causes the cathode backpressure valve to open.

3. The method of claim 1, further comprising maintaining, within the memory, a surge distance setpoint indicative of the distance between the setpoint and a surge line of the compressor map.

4. The method of claim 3, wherein the recirculation valve is regulated by adjusting the setpoint by adding a surge mitigation distance value to the surge distance setpoint.

5. The method of claim 4, further comprising generating a recirculation valve control command that causes the recirculation valve to open.

6. The method of claim 1, further comprising:

detecting an end to the surge condition; and

returning control of the compressor to the default strategy.

7. The method of claim 1, wherein at least one of the cathode backpressure valve and the recirculation valve is regulated to remain in an open position if the surge condition exceeds a time limit, further comprising providing an alert to an interface device.

8. A controller for a vehicle fuel cell system comprising:

at least one processor; and

a non-transitory memory in communication with the at least one processor, wherein the memory stores machine instructions that, when executed by the at least one processor, cause the at least one processor to;

maintain a compressor map corresponding to the operation of a compressor of the vehicle fuel cell system,

control the compressor using a default strategy such that its operation approaches a setpoint within the compressor map,

detect the presence of a surge condition within the compressor,

determine if an operating speed of the compressor is at or above a threshold value or if the speed of the compressor is below the threshold value;

control the surge condition with a first surge mitigation strategy if the operating speed of the compressor is at or above the threshold value or a second surge mitigation strategy if the operating speed of the compressor is below the threshold value,

regulate a cathode backpressure valve with the first surge mitigation strategy, and

regulate a recirculation valve with the second mitigation strategy.

9. The controller of claim 8, wherein the instructions further cause the at least one processor to generate a cathode backpressure valve control command that opens the cathode backpressure valve as part of the first surge mitigation strategy.

10. The controller of claim 8, wherein the instructions further cause the at least one processor to maintain a surge distance setpoint indicative of the distance between the setpoint and a surge line of the compressor map.

11. The controller of claim 10, wherein instructions further cause the at least one processor to adjust the setpoint by adding a surge mitigation distance value to the surge distance setpoint as part of the second surge mitigation strategy.

12. The controller of claim 11, wherein the instructions further cause the at least one processor to generate a recirculation valve control command that opens the recirculation valve as part of the second surge mitigation strategy.

13. The controller of claim 8, wherein the instructions further cause the at least one processor to detect an end to the surge condition and to control the compressor using the default strategy in the event the surge condition is detected.

14. The controller of claim 8, wherein the instructions further cause the at least one processor to control at least one of the cathode backpressure valve and the recirculation valve to remain open and provide an alert to an interface device if the surge condition exceeds a time limit.

15. A vehicle fuel cell system comprising;

a fuel cell stack;

a compressor operatively connected to the fuel cell stack to provide compressed gas thereto;

a recirculation valve operatively connected to an inlet and outlet of the compressor;

a backpressure valve operatively connected to an outlet of the fuel cell stack; and

a controller in communication with the recirculation valve, the compressor and the backpressure valve, the controller comprising at least one processor and a non-transitory memory in signal communication therewith such that instructions stored in the memory cause the at least one processor to;

maintain a compressor map corresponding to the operation of the compressor,

control the compressor using a default strategy such that the operation of the compressor approaches a setpoint within the compressor map,

detect the presence of a surge condition within the compressor,

determine if an operating speed of the compressor is at or above a threshold value or if the speed of the compressor is below the threshold value;

control the surge condition with a first surge mitigation strategy if the operating speed of the compressor is at or above a threshold value or a second surge mitigation strategy if the operating speed of the compressor is below the threshold value,

regulate a cathode backpressure valve with the first surge mitigation strategy, and

regulate a recirculation valve with the second mitigation strategy.

16. The controller of claim 15, wherein the instructions further cause the at least one processor to generate a cathode backpressure valve control command that opens the cathode backpressure valve as part of the first surge mitigation strategy.

17. The controller of claim 15, wherein the instructions further cause the at least one processor to maintain a surge distance setpoint indicative of the distance between the setpoint and a surge line of the compressor map.

18. The controller of claim 17, wherein instructions further cause the at least one processor to adjust the setpoint by adding a surge mitigation distance value to the surge distance setpoint as part of the second surge mitigation strategy.

19. The controller of claim 18, wherein the instructions further cause the at least one processor to generate a recirculation valve control command that opens the recirculation valve as part of the second surge mitigation strategy.

20. The controller of claim 15, wherein the instructions further cause the at least one processor to detect an end to the surge condition and to control the compressor using the default strategy.