Fuel cell power systems and methods of controlling a fuel cell power system

• US 6,773,839 B2
• Filed: 11/23/2001
• Issued: 08/10/2004
• Est. Priority Date: 11/20/1997
• Status: Expired due to Term

• Current Assignee: Emergent Power Inc. (Plug Power Inc.)
• Original Assignee: Relion Incorporated (Plug Power Inc.)
• Inventors: Lott, David R., Bayyuk, Shiblihanna I., Lloyd, Greg, Devries, Peter D., Fuglevand, William A., Scartozzi, John P.
• Primary Examiner(s): Kalafut, Stephen J.
• Application Number:
  US09/990,318
• Publication Number:
  US 20020031692A1
• Time in Patent Office: 991 Days
• Field of Search: 429/9, 429/22, 429/23, 429/24, 429/25, 429/30
• US Class Current: 429/430
• CPC Class Codes: H01M 16/006 of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 8/04007 related to heat exchange
• CPC Class Codes: H01M 8/04014 Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/04097 with recycling of the reactants H01M8/04119, H01M8/04104 take precedence
• CPC Class Codes: H01M 8/04225 during start-up
• CPC Class Codes: H01M 8/04228 during shut-down
• CPC Class Codes: H01M 8/04231 Purging of the reactants
• CPC Class Codes: H01M 8/04291 Arrangements for managing water in solid electrolyte fuel cell systems H01M8/04119 takes precedence
• CPC Class Codes: H01M 8/04302 applied during start-up
• CPC Class Codes: H01M 8/04303 applied during shut-down
• CPC Class Codes: H01M 8/0432 Temperature; Ambient temperature
• CPC Class Codes: H01M 8/04335 of cathode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04343 of anode exhausts
• CPC Class Codes: H01M 8/0444 Concentration; Density H01M8/04492 takes precedence
• CPC Class Codes: H01M 8/04574 Current
• CPC Class Codes: H01M 8/04626 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04664 Failure or abnormal function
• CPC Class Codes: H01M 8/04701 : Temperature
• CPC Class Codes: H01M 8/04753 : of fuel cell reactants
• CPC Class Codes: H01M 8/04768 : of the coolant
• 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: H01M 8/1004 : characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/241 : with solid or matrix-supported electrolytes
• CPC Class Codes: H01M 8/2457 : with both reactants being gaseous or vaporised
• CPC Class Codes: H01M 8/247 : Arrangements for tightening a stack, for accommodation of a stack in a tank or for assembling different tanks
• CPC Class Codes: H01M 8/2483 : characterised by internal manifolds
• CPC Class Codes: H01M 8/249 : comprising two or more groupings of fuel cells, e.g. modular assemblies
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

Fuel cell power systems and methods of controlling a fuel cell power system are provided. According to one aspect, a fuel cell power system includes a plurality of fuel cells electrically coupled with plural terminals and individually configured to convert chemical energy into electricity; and a digital control system configured to at least one of control and monitor an operation of the fuel cells. Another aspect provides a method of controlling a fuel cell power system including providing a plurality of fuel cells individually configured to convert chemical energy into electricity; electrically coupling the plurality of fuel cells; providing a first terminal coupled with the fuel cells; providing a second terminal coupled with the fuel cells; and coupling a digital control system with the fuel cells to at least one of monitor and control an operation of the fuel cells.

Claims

1. A fuel cell power system comprising:

a housing;

a plurality of terminals;

at least one fuel cell within the housing and electrically coupled with the terminals and configured to convert chemical energy into electricity;

a control system configured to monitor an electrical output condition of the at least one fuel cell and to control an operational parameter of at least one of the fuel cells, and wherein the control system comprises a plurality of distributed controllers; and

an operator interface coupled with the control system to indicate the electrical condition monitored by the control system.

2. The fuel cell power system according to claim 1 wherein the at least one fuel cell comprises a plurality of polymer electrolyte membrane fuel Cells.

3. The fuel cell power system according to claim 1 wherein the at least one fuel cell comprises a plurality of fuel cells.

4. The fuel cell power system according to claim 3 wherein the fuel cells are configured to be individually selectively deactivated and remaining ones of the fuel cells are configured to provide electricity to the terminals with others of the fuel cells deactivated.

5. The fuel cell power system according to claim 1 wherein the operator interface is positioned for observation from the exterior of the housing.

6. The fuel cell power system according to claim 1 wherein the operator interface comprises a display configured to emit a human perceptible signal.

7. The fuel cell power system according to claim 1 wherein the operator interface comprises interface switches configured to receive operator inputs.

8. A fuel cell power system comprising:

a plurality of terminals;

a plurality of fuel cells respectively electrically coupled with the terminals and configured to convert chemical energy into electricity, the fuel cells being configured to be individually selectively deactivated and remaining ones of the fuel cells being configured to provide electricity to the terminals with others of the fuel cells deactivated;

a power supply, different from the fuel cells; and

a control system coupled to the power supply and configured to receive electricity from the power supply at least at some times, and which is further operably coupled with the plurality of fuel cells, the control system being configured to monitor at least one operational condition of the power supply.

9. The fuel cell power system according to claim 8 wherein the control system comprises a plurality of distributed controllers.

10. The fuel cell power system according to claim 8 wherein the at least one fuel cell comprises a plurality of polymer electrolyte membrane fuel cells.

11. The fuel cell power system according to claim 8 wherein the power supply includes a battery.

12. The fuel cell power system according to claim 11 further comprising charge circuitry configured to selectively charge the battery responsive to control from the control system.

13. The fuel cell power system according to claim 8 further comprising an operator interface and the control system is configured to control the operator interface to indicate the at least one operational condition.

14. A fuel cell power system comprising:

a plurality of terminals;

a plurality of fuel cells electrically coupled with the terminals and configured to convert chemical energy into electricity;

a main valve adapted to couple with a fuel source and configured to selectively supply fuel to the fuel cells; and

a control system configured to control the main valve, and wherein the control system comprises a plurality of distributed controllers.

15. The fuel cell power system according to claim 14, and wherein the fuel cells comprise polymer electrolyte membrane fuel cells.

16. The fuel cell power system according to claim 14, and wherein the fuel cells are configured to be individually selectively deactivated and the remaining ones of the fuel cells are configured to provide electricity to the terminals with others of the fuel cells deactivated.

17. The fuel cell power system according to claim 14 further comprising a plurality of auxiliary valves configured to selectively supply fuel to the respective fuel cells.

18. A fuel cell power system comprising:

a housing;

a plurality of terminals;

at least one fuel cell within the housing and which is electrically coupled with the terminals and which is configured to convert chemical energy into electricity, and wherein the at least one fuel cell comprises a plurality of fuel cells provided in a plurality of cartridges;

a bleed valve configured to selectively purge non-fuel diluents from the at least one fuel cell;

a control system configured to control selective positioning of the bleed valve; and

a manifold configured to provide fluid communication of the cartridges with the bleed valve.

19. The system according to claim 18, and further comprising a bleed timer, and wherein the control system is configured to access the bleed timer to control the operation of the valve.

20. The system of claim 18, and further comprising an operator interface coupled to the control system, and wherein the operator interface comprises a display configured to indicate an electrical condition of at least one of the plurality of fuel cells.

21. A fuel cell power system comprising:

a housing;

a plurality of terminals;

a plurality of fuel cells, within the housing, and electrically coupled with the terminals and configured to convert chemical energy into electricity, and wherein the plurality of fuel cells are defined by multiple cartridges removably supported by the housing and that are individually selectively removed from the housing and remaining ones of the fuel cells are configured to provide electricity to terminals with others of the cartridges removed;

a control system configured to monitor an electrical output condition of the at least one of the fuel cell and to control an operational parameter of at least one of the fuel cells; and

an operator interface coupled with the control system to indicate the electrical condition monitored by the control system.

22. A fuel cell power system comprising:

a housing;

a temperature sensor supported by the housing to sense temperature in the housing;

a fan supported by the housing to move air inside the housing;

a plurality of terminals;

at least one fuel cell within the housing and electrically coupled with the terminals and configured to convert chemical energy into electricity;

a control system coupled to the temperature sensor and configured to control the fan in response to the sensed temperature;

an operator interface coupled with the control system to indicate the temperature sensed by the control system; and

circuitry electrically coupled to the control system, and configured to at least, at times, determine the output voltage of the at least one fuel cell, and wherein the control system is configured to determine electrical efficiency based upon the output voltage, and wherein the fan is a variable speed fan, and wherein the control system varies the speed of the fan in response to the determined electrical efficiency.

23. The fuel cell power system according to claim 22 and further comprising a plurality of fuel cells, and wherein voltage output determining circuitry is provided for each fuel cell, and wherein the control system is configured to determine the efficiency of each fuel cell by dividing the output voltage of that fuel cell by a theoretical maximum voltage of a single fuel cell.

24. The fuel cell power system according to claim 23, and wherein the control system is configured to determine an average efficiency for the fuel cells, and to control the speed of the fan based upon the average efficiency.

25. The fuel cell power system according to claim 22 and further comprising a temperature sensor supported by the housing to detect temperature outside the housing, and which is electrically coupled to the control system.

26. The fuel cell power system according to claim 25 and further comprising an air passage, supported by the housing and which extends between the inside of the housing and the ambient, and further including a vane which is controllably movable between an open position, and a closed position, and wherein the position of the vane is controlled by the control system at least partially in response to the temperature outside the housing.

27. The fuel cell power system according to claim 22, and wherein the control system comprises a plurality of distributed controllers.

28. The fuel cell power system according to claim 22 and further comprising a plurality of fuel cells, and wherein the fuel cells are configured to be individually selectively deactivated and remaining ones of the fuel cells are configured to provide electricity to the terminals with others of the fuel cells deactivated.

29. The fuel cell power system according to claim 22 and further comprising a plurality of fuel cells, and wherein the fuel cells are defined by multiple cartridges removably supported by the housing and which are further individually selectively removable from the housing and while the remaining fuel cells are configured to provide electricity to the terminals.

30. A fuel cell power system comprising:

a housing;

a plurality of terminals;

at least one fuel cell within the housing and electrically coupled with the terminals and configured to convert chemical energy into electricity;

a bleed valve in fluid communication with the at least one fuel cell to selectively remove waste fluid therefrom;

a control system configured to monitor an electrical output condition of at least one of the fuel cells and to control the bleed valve; and

an operator interface coupled with the control system to indicate the electrical condition monitored by the control system.

31. The fuel cell power system according to claim 30 and further comprising a main valve in fluid communication with the at least one fuel cell and configured to be coupled between a fuel source and the at least one fuel cell, to control the supply of fuel to the at least one fuel cell, and wherein the control system is further configured to control the main valve.

32. The fuel cell power system according to claim 30 and further comprising a fuel gas sensor supported by the housing to detect the concentration of fuel gas inside the housing, and wherein the control system is electrically coupled to the fuel gas sensor.

33. The fuel cell power system according to claim 30 wherein the control system comprises a plurality of distributed controllers.

34. The fuel cell power system according to claim 30 wherein the at least one fuel cell comprises a polymer electrolyte membrane.

35. The fuel cell power system according to claim 30 and comprising a plurality of fuel cells, wherein the fuel cells are configured to be individually selectively deactivated and remaining ones of the fuel cells are configured to provide electricity to the terminals with others of the fuel cells deactivated.

36. The fuel cell power system according to claim 30 and comprising a plurality of fuel cells, wherein the fuel cells are defined by multiple cartridges removably supported by the housing and that are individually selectively removed from the housing and remaining ones of the fuel cells are configured to provide electricity to the terminals with others of the cartridges removed.

37. The fuel cell power system according to claim 30 wherein the operator interface is positioned for observation from the exterior of the housing.

38. A fuel cell power system comprising:

a housing having an inside facing surface defining a cavity, and an outside facing surface and having a plurality of receptacles which are accessible from outside of the housing, the individual receptacles including an electrical connector and a fuel supply connector;

a plurality of cartridges each including a casing supporting at least one fuel cell, the casing being removably received in a receptacle and including a fuel inlet connector which mates with the fuel supply connector of at least one of the receptacles when the casing is received in a receptacle, and an electrical connector which mates with the electrical connector of at least one of the receptacles when the casing is received in a receptacle, each fuel cell being configured to convert chemical energy into electricity;

a power bus inside the housing and electrically coupled to the respective electrical connectors and selectively coupled to a load; and

a control system electrically coupled to the power bus and configured to monitor at least one operational condition of the power bus, and wherein the cartridges can be individually removed from the housing while the remaining cartridges continue to produce electricity.

39. A fuel cell power system in accordance with claim 38, and wherein a plurality of fuel cells are supported by each casing.

40. A fuel cell power system in accordance with claim 38, and wherein a casing is removable from the housing while the fuel cells of the remaining casings continue to supply power to the power bus.

41. A fuel cell power system in accordance with claim 38, and wherein each receptacle further includes a waste connector, and wherein each casing further includes a waste connector which mates with the waste connector of the receptacle when the casing is received in a receptacle.

42. A fuel cell power system in accordance with claim 38, and wherein the locations and configurations of the connectors are selected such that a casing is selectively receivable in any of a number of the receptacles.

43. A fuel cell power system comprising:

a plurality of terminals;

at least one fuel cell electrically coupled with the terminals and configured to convert chemical energy into electricity;

a power supply, different from the fuel cells; and

a control system coupled to the power supply and configured to receive electricity from the power supply at least at some times, and which is further operably coupled with the at least one fuel cell, and wherein the control system is configured to monitor at least one operational condition of the power supply.

44. A fuel cell power method comprising:

providing a housing;

providing a plurality of terminals;

providing at least one fuel cell within the housing and electrically coupling the fuel cell within the terminals;

converting chemical energy into electricity using the at least one fuel cell;

defining a control system using a plurality of distributed controllers; and

controlling a bleed valve using the control system to selectively purge non-fuel diluents from the at least one fuel cell.

45. A fuel cell power method comprising:

providing a housing;

providing a plurality of terminals;

providing a plurality of fuel cells within the housing and electrically coupling the fuel cell with the terminals;

converting chemical energy into electricity using the plurality of fuel cells;

controlling a bleed valve using a control system to selectively purge non-fuel diluents from the at least one fuel cell; and

selectively deactivating one of the fuel cells and providing electricity to the terminals from the remaining fuel cells.

46. The fuel cell power method according to claim 45, and wherein the selective purging further comprises periodically opening the bleed valve using the control system.

47. The fuel cell power method according to claim 45, and wherein each fuel cell has an anode side, and a cathode side and wherein the selective purging comprises draining non-fuel diluents from the anode side of at least one of the plurality of fuel cells.

48. A fuel cell power method comprising:

providing a housing;

providing a plurality of terminals;

providing at least one fuel cell within the housing and electrically coupling the fuel cell with the terminals, and wherein the at least one fuel cell in defined by using a plurality of fuel cells provided in a plurality of cartridges;

converting chemical energy into electricity using the fuel call;

controlling a bleed valve using a control system to selectively purge non-fuel diluents from the at least one fuel cell; and

providing fluid communication between the cartridges and the bleed valve using a manifold.

49. The method according to claim 48, and further comprising controlling the operation of the bleed valve using a bleed timer which is operably coupled to the control system.

50. The method of claim 48, and further comprising providing an operator interface having a display;

coupling the operator interface to the control system;

sensing an electrical condition of at least one of the plurality of fuel cells using the control system; and

configuring the operator interface to indicate the electrical condition of the at least one fuel cell which is being sensed.

51. A fuel cell power method comprising:

providing a housing;

providing a plurality of terminals;

providing at least one fuel cell within the housing and electrically coupling the at least one fuel cell with the terminals;

providing a control system, and defining the control system using a plurality of distributed controllers;

coupling the operator interface to the control system;

controlling an operational parameter of the at least one fuel cell using the control system;

converting chemical energy into electricity using the at least one fuel cell;

monitoring an electrical output condition of the at least one fuel cell using the control system; and

indicating the electrical output condition monitored by the control system by utilizing an operator interface.

52. The fuel cell power method according to claim 51, and further comprising defining the at least one fuel cell using a plurality of polymer electrolyte membrane fuel cells.

53. The fuel cell power method according to claim 51, and further comprising defining the at least one fuel cell using a plurality of fuel cells.

54. The fuel cell power method according to claim 53 and further comprising individually selectively deactivating at least one of the fuel cells;

and providing electricity to the terminals with another of the active fuel cells.

55. The fuel cell power method according to claim 51, and further comprising locating the operator interface for observation from a location which is exterior to the housing.

56. The fuel cell power method according to claim 51, and further comprising using the operator interlace to emit a humanly perceptible signal.

57. The fuel cell power method according to claim 51, and further comprising receiving an operator input from the operator interface by way of an interface switch.

58. The method of claim 51, and further comprising defining the at least one fuel cell using a plurality of fuel cells, and wherein the fuel cells are further defined by multiple cartridges removably supported by the housing, and wherein the method further comprises removing selected cartridges from the housing;

and providing electricity to the terminals using the remainder of the cartridges.

59. A fuel cell power method comprising:

providing a plurality of terminals;

providing a plurality of fuel cells and electrically coupling the fuel cells with the terminals;

providing a power supply different from the fuel cells, and defining the power supply using a battery;

providing a control system;

providing charge circuitry which is electrically coupled with at least one of the plurality of fuel cells;

configuring the power supply to selectively supply electricity to the control system at least at some times;

monitoring at least one operational condition of the power supply using the control system;

selectively charging the battery, in response to control from the control system, and utilizing the charge circuitry which is electrically coupled to the at least one fuel cell;

converting chemical energy into electricity using the plurality of fuel cells;

individually selectively deactivating one of the fuel cells while another of the fuel cells actively continues to convert chemical energy into electricity; and

providing electricity to the terminals from the active fuel cells.

60. The fuel cell power method according to claim 59, and further comprising indicating the at least one operational condition using an operator interface which is operably coupled with the control system.

61. The fuel cell power method according to claim 59, and further comprising defining the control system using digital electronics.

62. The fuel cell power method according to claim 59, and further comprising defining the fuel cells, with a plurality of cartridges which are removably supported by a housing.

63. A fuel cell power method comprising:

providing a housing;

providing at least one fuel cell within the housing;

providing a plurality of terminals;

providing a control system;

providing an operator interface and coupling the operator interface to the control system;

electrically coupling the at least one fuel cell with the terminals;

supporting a temperature sensor in the housing to sense a temperature in the housing, and coupling the temperature sensor to the control system;

moving air inside the housing using a fan supported by the housing;

controlling the fan in response to the sensed temperature using the control system;

converting chemical energy into electricity using the at least one fuel cell;

determining an output voltage of the at least one fuel cell;

indicating the temperature sensed by the control system using the operator interface;

determining the electrical efficiency of the at least one fuel cell based on the output voltage using circuitry electrically coupled to the control system; and

varying the speed of the fan in response to the determined electrical efficiency, utilizing the control system.

64. The fuel cell power method according to claim 63 and further comprising defining the at least one fuel cell using a plurality of fuel cells;

determining the output voltage of each of the fuel cells; and

determining the efficiency of each of the fuel cells by dividing the output voltage of the respective fuel cells by a theoretical maximum voltage of a single fuel cell, by using the control system.

65. The fuel cell power method according to claim 64 and further comprising determining an average efficiency for the respective fuel cells using the control system;

and controlling the speed of the fan based upon the average efficiency which has been determined by the control system.

66. The fuel cell power method according to claim 63, and further comprising detecting a temperature outside the housing by using a sensor which is supported by the housing and which is further electrically coupled to the control system.

67. The fuel cell power method according to claim 66 and further comprising providing an air passage supported by the housing and located between the inside of the housing and the ambient;

positioning a selectively moveable vane within the air passage, and wherein the vane is selectively moveable between an open position and a closed position; and

controlling the relative position of the vane at least partially in response to the temperature outside the housing by way of the control system.

68. The fuel cell power method according to claim 63, and further comprising defining the control system by using a plurality of distributed controllers.

69. A fuel cell power method comprising:

providing a housing;

providing a plurality of terminals;

providing at least one fuel cell within the housing;

electrically coupling at least one fuel cell with the terminals;

converting chemical energy into electricity using the at least one fuel cell;

selectively removing waste fluid from the at least one fuel cell using a bleed valve;

monitoring an electrical output condition of the at least one fuel cell and controlling the bleed valve, using a control system;

indicating the electrical condition using an operator interface coupled with the control system;

providing a fuel gas sensor which is positioned within the housing; and

detecting the concentration of a fuel gas inside of the housing by using the fuel gas sensor which is supported by the housing and which is electrically coupled to the control system.

70. The fuel cell power method according to claim 69, and further comprising defining the control system by using a plurality of distributed controllers.

71. A fuel cell power method comprising:

providing a housing having an inside cavity and an outside surface, and having a plurality of receptacles accessible from outside of the housing, the receptacles respectively including an electrical connector and a fuel supply connector;

providing a plurality of cartridges each including a casing supporting at least one fuel cell, and wherein the casing is removably received within a receptacle and further including a fuel inlet connector which mates with the fuel supply connector of at least one of the receptacles when the casing is received in a receptacle, and an electrical connector which mates with the electrical connector of at least one of the receptacles when the casing is received in a receptacle;

selectively coupling respective electrical connectors of a power bus which is positioned inside the housing to a load and electrically coupling the plurality of cartridges having at least one fuel cell to the power bus;

converting chemical energy into electricity using at least one of the fuel cells; and

monitoring at least one operational condition of the power bus using a control system which is electrically coupled to the power bus, and wherein the respective cartridges may be operably removed from the housing while the remaining cartridges continue to produce electricity.

72. A fuel cell power method in accordance with claim 71 and further comprising providing a plurality of fuel cells which are enclosed within each casing.

73. A fuel cell power method in accordance with claim 71 and further comprising selectively removing a casing from the housing while the fuel cells of the remaining casings continue to supply power to the power bus.

74. A fuel cell power method in accordance with claim 71 and further comprising providing respective waste connectors for each receptacle and casing, and wherein the method comprises locating the waste connector of each casing to mate with the waste connector of the receptacle when the casing is received within the receptacle.

75. A fuel cell power method in accordance with claim 71 and further comprising configuring the locations and arrangement of the respective connectors such that a casing is selectively receivable in any one of a number of the respective receptacles.

76. A fuel cell power method comprising:

providing a plurality of terminals;

electrically coupling at least one fuel cell with the terminals;

providing a power supply, different from the fuel cells, and coupling the power supply to a control system, to provide electricity to the control system, and wherein the control system is electrically coupled to the at least one fuel cell;

converting chemical energy into electricity using the at least one fuel cell; and

monitoring at least one operational condition of the power supply using the control system.