Systems and methods for controlling a compressor recirculation valve

• US 9,029,036 B2
• Filed: 10/25/2012
• Issued: 05/12/2015
• 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: Zhang, Yanyan, Mussro, Joseph
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): COLUCCI RIOS, JOSE A
• Application Number:
  US13/660,020
• Publication Number:
  US 20140120444A1
• Time in Patent Office: 929 Days
• US Class Current: 429/444
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• 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 8/04395 of cathode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04656 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/04992 characterised by the implementation of mathematical or computational algorithms, e.g. feedback control loops, fuzzy logic, neural networks or artificial intelligence
• 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 control compressor recirculation of a reactant in a fuel cell system. A recirculation valve flow setpoint value for a gas flow to the recirculation valve is calculated based on a received cathode flow setpoint. A value corresponding to a predicted recirculation valve position is generated, and can be used as a control command for changing the position of the recirculation valve to reduce the valve response time during operational transients of the fuel cell system.

Claims

1. A method for controlling fuel cell system cathode stoichiometry during an operational transient with a compressor recirculation valve, the method comprising:

identifying an operational transient in a fuel cell stack;

receiving a stack cathode flow setpoint for gas flow supplied by an outlet of a compressor to a cathode of said fuel cell stack;

calculating a recirculation valve flow setpoint value for said supplied gas flow using compressor operational data and said stack cathode flow setpoint;

calculating a feedforward term corresponding to a new recirculation valve position by using said recirculation valve flow setpoint value;

generating a feedback term corresponding to said new recirculation valve position through a PID control strategy based on an error between said stack cathode flow setpoint and said feedback term; and

generating a recirculation valve control command based on said feedforward term and said feedback term that causes actuation of said recirculation valve to maintain cathode stoichiometry during said operational transient.

2. The method of claim 1, wherein said operational transient is an operational downtransient.

3. The method of claim 2, wherein a compressor inlet gas flow setpoint is determined from a compressor map.

4. The method of claim 3, wherein said recirculation valve flow value is calculated using a difference between said compressor inlet gas flow setpoint and said cathode flow setpoint.

5. The method of claim 1, further comprising using a controller for at least one of said receiving, calculating and generating.

6. The method of claim 1, further comprising using a controller for said generating said feedback term.

7. The method of claim 1, further comprising opening or closing said recirculation valve in response to said generated recirculation valve control command.

18. The method of claim 1, wherein the compressor recirculation valve is configured to mitigate surge conditions when said fuel cell stack is in a steady-state condition.

8. A vehicular fuel cell system cathode stoichiometry controller comprising:

at least one processor; and

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

identify an operational transient in a vehicle fuel cell stack;

receive a stack cathode flow setpoint for gas flow supplied by an outlet of a compressor to a cathode of said fuel cell stack;

calculate a recirculation valve flow setpoint value for a gas flow to a recirculation valve from said outlet of said compressor using a compressor map and said stack cathode flow setpoint, wherein said recirculation valve fluidly connects said outlet of said compressor to an inlet of said compressor;

calculate a feedforward term corresponding to a new recirculation valve position by using said recirculation valve flow setpoint value;

generate a feedback term corresponding to said new recirculation valve position through a PID control strategy based on an error between said stack cathode flow setpoint and said feedback term; and

generate a recirculation valve control command based on said feedforward term and said feedback term that causes actuation of said recirculation valve to maintain cathode stoichiometry during said operational transient.

9. The controller of claim 8, wherein compressor operational data corresponding to said compressor map is contained within said memory and configured such that a gas flow setpoint for said compressor inlet is determined by said controller.

10. The controller of claim 9, wherein said instructions further cause said at least one processor to calculate a difference between said compressor inlet gas flow setpoint and said stack cathode flow setpoint to determine said recirculation valve flow setpoint value.

11. The controller of claim 9, wherein said changed position of said recirculation valve is determined by a feedforward value and at least one of an integral value and a derivative value within said controller.

12. The controller of claim 8, wherein said recirculation valve control command generated by said controller is in signal communication with said recirculation valve to facilitate repositioning thereof.

19. The controller of claim 8, wherein the compressor recirculation valve is configured to mitigate surge conditions when said vehicle fuel cell stack is in a steady-state condition.

13. A vehicular fuel cell system comprising:

a fuel cell stack comprising a plurality of fuel cells each of which include a cathode;

a compressor having an inlet and an outlet, wherein said outlet is fluidly connected to said stack to provide a reactant gas to said cathodes;

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

a cathode stoichiometry controller comprising at least one processor and a non-transitory memory in signal communication with said at least one processor, wherein said memory stores instructions that, when executed by said at least one processor, cause said at least one processor to;

identify a transition of an output of said fuel cell stack;

receive a stack cathode flow setpoint for gas flow to said cathodes;

calculate a recirculation valve flow setpoint value for a gas flow to said recirculation valve using operational data pertaining to said compressor and said stack cathode flow setpoint; and

generate a recirculation valve control command that causes said recirculation valve to change positions valve to maintain cathode stoichiometry during said operational transient.

14. The system of claim 13, wherein said operational data pertaining to said compressor is based on a compressor map.

15. The system of claim 14, wherein said operational data from said compressor map is used to determine a gas flow setpoint to said compressor inlet.

16. The system of claim 13, wherein said instructions that cause said at least one processor to calculate a recirculation valve flow setpoint value further comprise instructions to have said at least one processor:

calculate a feedforward term corresponding to a new recirculation valve position by using said recirculation valve flow setpoint value; and

generate a feedback term corresponding to said new recirculation valve position through a PID control strategy based on an error between said stack cathode flow setpoint and said feedback term.

17. The system of claim 13, further comprising data communication equipment configured to convey said recirculation valve control command between said controller and said recirculation valve.

20. The system of claim 13, wherein the compressor recirculation valve is configured to mitigate surge conditions when said fuel cell stack is in a steady-state condition.