Title of Invention	METHOD FOR MAXIMUM NET POWER CALCULATION FOR FUEL CELL SYSTEM BASED ON ONLINE POLARIZATION CURVE ESTIMATION
Abstract	An algorithm for determining the maximum net power available from a fuel cell stack as the stack degrades over time using an online adaptive estimation of a polarization curve of the stack. The algorithm separates the current density range of the stack into sample regions, and selects a first sample region from the far left of the estimated polarization curve. The algorithm then calculates the cell voltage for that current density sample region, and determines whether the calculated cell voltage is less than or equal to a predetermined cell voltage limit. If the calculated cell voltage is not less than the cell voltage limit, then the algorithm selects the next sample region along the polarization curve. When the calculated cell voltage does reach the cell voltage limit, then the algorithm uses that current density for the sample region being analyzed to calculate the maximum power of the fuel cell stack.

Title of Invention

METHOD FOR MAXIMUM NET POWER CALCULATION FOR FUEL CELL SYSTEM BASED ON ONLINE POLARIZATION CURVE ESTIMATION

Abstract

An algorithm for determining the maximum net power available from a fuel cell stack as the stack degrades over time using an online adaptive estimation of a polarization curve of the stack. The algorithm separates the current density range of the stack into sample regions, and selects a first sample region from the far left of the estimated polarization curve. The algorithm then calculates the cell voltage for that current density sample region, and determines whether the calculated cell voltage is less than or equal to a predetermined cell voltage limit. If the calculated cell voltage is not less than the cell voltage limit, then the algorithm selects the next sample region along the polarization curve. When the calculated cell voltage does reach the cell voltage limit, then the algorithm uses that current density for the sample region being analyzed to calculate the maximum power of the fuel cell stack.

Full Text	METHOD FOR MAXIMUM NET POWER CALCULATION FOR FUEL CELL SYSTEM BASED ON ONLINE POLARIZATION CURVE ESTIMATION BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] This invention relates generally to an algorithm for determining the maximum power available from a fuel cell stack as the stack degrades over time and, more particularly, to an algorithm for determining the maximum power available from a fuel cell stack using an online polarization curve estimation process as the stack degrades over time. 2. Discussion of the Related Art [0002] Hydrogen is a very attractive fuel because it is clean and can be used to efficiently produce electricity in a fuel cell. A hydrogen fuel cell is an electro-chemical device that includes an anode and a cathode with an electrolyte therebetween. The anode receives hydrogen gas and the cathode receives oxygen or air. The hydrogen gas is dissociated in the anode to generate free hydrogen protons and electrons. The hydrogen protons pass through the electrolyte to the cathode. The hydrogen protons react with the oxygen and the electrons in the cathode to generate water. The electrons from the anode cannot pass through the electrolyte, and thus are directed through a load to perform work before being sent to the cathode. [0003] Proton exchange membrane fuel cells (PEMFC) are a popular fuel cell for vehicles. The PEMFC generally includes a solid polymer electrolyte proton conducting membrane, such as a perfluorosulfonic acid membrane. The anode and cathode typically include finely divided catalytic particles, usually platinum (Pt), supported on carbon particles and mixed with an ionomer. The catalytic mixture is deposited on opposing sides of the membrane. The combination of the anode catalytic mixture, the cathode catalytic mixture and the membrane define a membrane electrode assembly (MEA). MEAs are relatively expensive to manufacture and require certain conditions for effective operation. [0004] Several fuel cells are typically combined in a fuel cell stack to generate the desired power. The fuel cell stack receives a cathode input gas, typically a flow of air forced through the stack by a compressor. Not all of the oxygen is consumed by the stack and some of the air is output as a cathode exhaust gas that may include water as a stack by-product. The fuel cell stack also receives an anode hydrogen input gas that flows into the anode side of the stack. [0005] The stack controller needs to know the current/voltage relationship, referred to as a polarization curve, of the fuel cell stack to schedule reactants in accordance with power demands. The relationship between the voltage and the current of the stack is typically difficult to define because it is non-linear, and changes depending on many variables, including stack temperature, stack partial pressures and cathode and anode stoichiometries. Additionally, the relationship between the stack current and voltage changes as the stack degrades over time. Particularly, an older stack will have lower cell voltages, and will need to provide more current to meet the power demands than a new, non-degraded stack. [0006] Fortunately, many fuel cell systems, once they are above a certain temperature, tend to have repeatable operating conditions at a given current density. In those instances, the voltage can be approximately described as a function of stack current density and age. SUMMARY OF THE INVENTION [0007] In accordance with the teachings of the present invention, an algorithm is disclosed for determining the maximum net power available from a fuel cell as the fuel cell stack degrades over time using an online adaptive estimation of a polarization curve of the stack. The algorithm first obtains estimation parameters from the fuel cell system, such as average cell voltage and minimum cell voltage, and estimates a polarization curve for the stack for both an average cell voltage and a minimum cell voltage, respectively. The algorithm then calculates the maximum power available from the stack for both the average cell voltage and the minimum cell voltage from the polarization curve estimation. To do this, the algorithm separates the current density range of the stack into sample regions, and selects a first sample region from the far left of the estimated polarization curve. The algorithm then calculates the cell voltage for that current density sample region, and determines whether the calculated cell voltage is less than or equal to a predetermined cell voltage limit. If the calculated cell voltage is not less than the cell voltage limit, then the algorithm selects the next sample region along the polarization curve. When the calculated cell voltage does reach the cell voltage limit, then the algorithm uses that current density for the sample region being analyzed to calculate the maximum power of the fuel cell stack. The algorithm then selects the lesser of the maximum power for both the average cell voltage and the minimum cell voltage as the maximum fuel cell system output voltage. [0008] Additional features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0009] Figure 1 is a block diagram of a fuel cell system including split stacks and a controller; [0010] Figure 2 is a graph with fuel cell stack current density on the horizontal axis and fuel cell stack voltage on the vertical axis showing a polarization curve for a minimum cell in the fuel cell stack and an average cell in the fuel cell stack; [0011] Figure 3 is a flow chart diagram showing a process for determining the maximum fuel cell stack power at any particular point in time for a fuel cell stack, according to an embodiment of the present invention; and [0012] Figure 4 is a flow chart diagram showing a process for calculating the maximum fuel cell stack power, according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS [0013] The following discussion of the embodiments of the invention directed to an algorithm for determining the maximum net power available from a fuel cell system as the fuel cell stack degrades over time using an online polarization curve estimation process is merely exemplary in nature, and is in no way intended to limit the invention or it's applications or uses. [0014] Many control parameters of a fuel cell system require knowledge of the polarization curve of the fuel cell stack, such as knowing the maximum voltage potential and current draw available from the fuel cell stack. As mentioned above, as the stack ages, the stack polarization curve also changes as a result of stack degradation. U.S. Patent Application serial No. 11/669,898, filed January 31, 2007, titled Algorithm for Online Adaptive Polarization Curve Estimation of a Fuel Cell Stack, assigned to the Assignee of this Application and herein incorporated by reference, discloses an algorithm for calculating the polarization curve of a fuel cell stack online as the fuel cell system is being operated. The algorithm of the '898 application estimates two or more stack parameters from collected data as the stack is being operated, and uses the parameters to calculate the polarization curve. When the fuel cell stack is running and certain data validity criteria have been met, the algorithm goes into a good collection mode where it collects stack data, such as stack current density, average cell voltage and minimum cell voltage. When the stack is shut-down, the algorithm uses a cell voltage model to solve a non-linear least squares problem to estimate predetermined parameters that define the polarization curve. If the estimated parameters satisfy certain termination criteria, then the estimated parameters are stored to be used by a system controller to calculate the polarization curve of the stack for future stack runs. [0015] The present invention proposes an algorithm for determining the maximum net power available from a fuel cell stack using an online polarization curve estimation process, such as that disclosed in the '898 application. The algorithm uses previously saved estimation parameters to generate the polarization curve online, and calculates a maximum net power from the system based on stack health. As the parameters vary with the life of the stack, so does the maximum net power. The algorithm provides the vehicle controller with an estimate of the maximum power available from the stack. It can use this information to change the way it distributes power requests to the battery and the fuel cell stack. [0016] From this, the reliability of the fuel cell system is improved if the vehicle does not request more power from the stack than it can produce. For example, assume a fuel cell module can typically provide 90 kW, but stack voltage has degraded so that it can only provide 80 kW. If 85 kW is requested, the balance of plant set-points will go to 85 kW even though the stack cannot produce that much power. Further, information of predicted maximum power level will be available for service personnel if the stack needs servicing. If the maximum power level is significantly degraded, the fuel cell system can modify set-points to enhance vehicle reliability. During system start-up, the rate at which the stack is initially loaded CAN be reduced as a result of a reduced power output. Although it will take longer for the vehicle to drive away, the risk of failed start-ups is reduced. Further, extra thermal loads can be turned on when the fuel cell system is warming up. A degraded stack often has a reduced ability to manage liquid water. Additional stack warming will quickly reduce the risk of unstable operation. If the stack is heavily degraded, relative humidity set-points can be modified to better manage liquid water. [0017] Figure 1 is a block diagram of a fuel cell system 10 including a first split stack 12, a second split stack 14 and a controller 16. The controller 16 receives information from the split stacks 12 and 14, and controls the split stacks 12 and 14. The controller 16 uses the information to calculate the polarization curve of the stacks 12 and 14 in real time, and provide the maximum net power available from the stacks 12 and 14. [0018] In order to determine the maximum net power from the fuel cell stacks 12 and 14, the present invention uses the average cell voltage of the stacks 12 and 14 and the minimum cell voltage of the stacks 12 and 14. Figure 2 is a graph with current density on the horizontal axis and voltage on the vertical axis. The graph includes two polarization curves, namely polarization curve 20 for the average cell voltage and polarization curve 22 for the minimum cell voltage. Point 24 represents the maximum current (or current density) available from the stacks 12 and 14 for the average cell polarization curve and point 26 represents the maximum current available from the stacks 12 and 14 for the minimum cell polarization curve 22. [0019] Figure 3 is a flow chart diagram 40 showing a process of the invention for determining the maximum net fuel cell stack output power at any given time during fuel cell operation, and the applications for which this calculated power value can be used. At box 42, the algorithm obtains the parameters from a non-volatile memory that are used to estimate the polarization curves for the stacks 12 and 14 from, for example, the process disclosed in the '898 application. Further, the algorithm sets an average cell voltage limit at box 42 and a minimum cell voltage limit at box 44. In one non-limiting example, the average cell voltage limit can be about 0.525 V and the minimum cell voltage limit can be about 0.3 V for a 230 V, 440 cell fuel cell stack. The algorithm then calculates the maximum net power available from the fuel cell stacks 12 and 14 using the average cell voltage limit at box 42 and calculates the maximum power using the minimum cell voltage limit at box 46. [0020] Figure 4 is a flow chart diagram 50 showing a process for determining the maximum net power for both the average cell voltage and the minimum cell voltage, according to an embodiment of the present invention. The process starts at the far left of the polarization curves 20 and 22 and moves down along the curves 20 and 22 until the average cell voltage limit and the minimum cell voltage limit at points 24 and 26 are reached. At box 52, the algorithm divides the current density range of the stacks 12 and 14 into N sample regions, where k identifies the specific sample region being analyzed. In one non-limiting example, the current density range can be 0.1 - 2.0 A/cm2 and the sample regions can be every 0.1 A/cm2. The algorithm then obtains a current density j for the sample region being examined, and calculates the cell voltage at that current density j for both the average cell voltage and the minimum cell voltage using the polarization curves 20 and 22. In one non-limiting example, the cell voltage at the specific current density is calculated as: Where, is the cell voltage (V), j is the current density (A/cm2), RHFR is the cell HFR resistance (ohm cm2), is the thermodynamic reversible cell potential (V),  is the background current density from cell shorting/cell crossover (A/cm2), is the exchange current density (A/cm2), is the limiting current density (A/cm2), and is the mass transfer coefficient. [0021] Once the cell voltage is calculated, the algorithm determines whether the calculated cell voltage for that current density j is less than the predetermined cell voltage limit or at decision diamond 56 and, if not, the algorithm moves to the next sample region k at box 58 to calculate the average cell voltage and the minimum cell voltage at the box 54 for the new higher current density j. If the calculated cell voltage is less than or equal to the cell voltage limit or at the decision diamond 56, then the algorithm sets the current density j for the particular sample region as the maximum current density, and calculates the maximum power at box 60. The gross power is calculated as voltage times current where the maximum current density j is multiplied by the number of cells and the area of the cells to get the total current of the stacks 12 and 14. Further, a parasitic power estimation based current density (provided by a look-up table or suitable parasitic estimation algorithm) is subtracted from the power and a correction is added to get the maximum net power as: [0022] The gross power is how much the stack is producing and the net power is the gross power minus the parasitic power to operate the fuel cell system, such as operating the compressor, cooling fluid pumps, etc. Typically, tables are generated where the parasitic power is defined for a particular current density j based on experiments and the like. The correction is typically determined empirically and is generally around 5% of the maximum power. [0023] Once the algorithm has the maximum net power for the average cell voltage and the minimum cell voltage for both of the stacks 12 and 14, the algorithm determines the maximum fuel cell system net power as the minimum of the two maximum net powers for each stack 12 and 14 at box 62 in the flow chart diagram 40. [0024] Another non-limiting embodiment for calculation of maximum net power, which can be applied to N number of stacks, can be given by: min(max(AvgCellPowerEstimations), min(MinCellPowerEstimations)) [0025] Once the algorithm has the maximum net power that can be drawn from the stacks 12 and 14 at any particular time, this value is then used in various applications in the fuel cell system 10, such as predicting the number of hours before the end of life of the stacks 12 and 14 at box 64, sending the maximum power to the fuel cell power system at box 66, providing an energy estimate for acceptable drivability at box 68 and using the maximum power in adaptive control applications at box 70. [0025] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims. CLAIMS What is Claimed is: 1. A method for estimating the maximum stack power from a fuel cell stack during operation of the fuel cell stack, said method comprising: selecting an average cell voltage limit for an average fuel cell in the fuel cell stack; selecting a minimum cell voltage limit for a minimum performing fuel cell in the fuel cell stack; estimating a separate polarization curve of the fuel cell stack for both an average cell voltage and a minimum cell voltage; separating a current density range of the fuel cell stack into a predetermined number of sample regions in ascending order; selecting a first sample region; determining an average cell voltage and a minimum cell voltage at the current density for the selected sample region; determining whether the cell voltage is less than the predetermined average cell voltage limit and the minimum cell voltage limit; selecting a next sample region in the current density range if the cell voltage is not less than the average cell voltage limit or the minimum cell voltage limit; calculating a maximum net power for both the average cell voltage and the minimum cell voltage if the cell voltage is less than average cell voltage limit or the minimum cell voltage limit; and selecting the lesser of the average cell voltage maximum net power and the minimum cell voltage maximum net power as the maximum stack power. 2. The method according to claim 1 wherein calculating the net power includes calculating the net power as the maximum cell voltage times the overall current density times the number of fuel cells times the area of the fuel cells of the fuel cell stack minus predetermined parasitic power that are used while running the fuel cell stack. 3. The method according to claim 2 further comprising adding a correction to the calculated maximum power. 4. The method according to claim 1 wherein determining an average cell voltage and a minimum cell voltage includes using the equation: where is the cell voltage,; is the current density, RHFR is the cell HFR resistance, is the thermodynamic reversible cell potential,  is the background current density from cell shorting/cell crossover, is the exchange current density, is the limiting current density and c is the mass transfer coefficient. 5. The method according to claim 1 wherein the average cell voltage limit is about 0.525 V and the minimum cell voltage limit is about 0.3 V. 6. The method according to claim 1 wherein separating a current density range of the fuel cell stack into a predetermined number of sample regions includes separating a current density range of 0.1 - 2.0 A/cm2 into sample regions of 0.1 A/cm2. 7. The method according to claim 1 wherein selecting a next sample region in the current density range includes selecting the next sample region in order from a low current density in the range to a high current density in the range. 8. The method according to claim 1 wherein the fuel cell stack is a split fuel cell stack where the maximum stack power is determined for both spilt stacks. 9. A method for estimating the maximum stack power from a fuel cell stack during operation of the fuel cell stack, said method comprising: selecting at least one cell voltage limit for a fuel cell in the fuel cell stack; estimating a polarization curve of the fuel cell stack for at least one cell; separating a current density range of the fuel cell stack into a predetermined number of sample regions; selecting a first sample region; determining a cell voltage at the current density for the selected sample region; determining whether the cell voltage is less than the predetermined cell voltage limit; selecting a next sample region in the current density range if the cell voltage is not less than the cell voltage limit; and calculating a maximum net power for the cell voltage if the cell voltage is less than the cell voltage limit. 10. The method according to claim 9 wherein selecting at least one cell voltage limit includes selecting an average cell voltage limit for an average fuel cell in the fuel cell stack and a minimum cell voltage limit for a minimum performing fuel cell in the fuel cell stack, and wherein estimating a polarization curve of the fuel cell stack includes estimating a polarization curve for both the average cell voltage and the minimum cell voltage, and wherein determining a cell voltage includes determining an average cell voltage and a minimum cell voltage at the current density for the selected sample region. 11. The method according to claim 9 wherein calculating the net power includes calculating the net power as the maximum cell voltage times the overall current density times the number of fuel cells times the area of the fuel cells of the fuel cell stack minus predetermined parasitic power that are used while running the fuel cell stack. 12. The method according to claim 11 further comprising adding a correction to the calculated maximum power. 13. The method according to claim 9 wherein determining the cell voltage includes using the equation: where is the cell voltage, j is the current density, RHFR is the cell HFR resistance, is the thermodynamic reversible cell potential,  is the background current density from cell shorting/cell crossover, is the exchange current density, is the limiting current density and c is the mass transfer coefficient. 14. The method according to claim 9 wherein separating a current density range of the fuel cell stack into a predetermined number of sample regions includes separating a current density range of 0.1 - 2.0 A/cm2 into sample regions of 0.1 A/cm2. 15. A system for estimating the maximum stack power from a fuel cell stack during operation of a fuel cell stack, said system comprising; means for selecting an average cell voltage for an average fuel cell in the fuel cell stack; means for selecting a minimum cell voltage for a minimum performing fuel cell in the fuel cell stack; means for estimating a polarization curve of the fuel cell stack for both an average fuel cell and a minimum fuel cell voltage; means for separating a current density range of the fuel cell stack into a predetermined number of sample regions; means for selecting a first sample region; means for determining an average cell voltage and a minimum cell voltage at the current density for the selected sample region; means for determining whether the cell voltage is less than the predetermined average cell voltage limit and the minimum cell voltage limit; means for selecting a next sample region in the current density range if the cell voltage is not less than the average cell voltage limit or the minimum cell voltage limit; means for calculating a maximum net power for both the average cell voltage and the minimum cell voltage if the cell voltage is less than the average cell voltage limit and the minimum cell voltage limit; and means for selecting the less of the average cell voltage maximum net power and the minimum cell voltage maximum net power as a maximum stack power. 16. The system according to claim 15 wherein the means for calculating the net power includes means for calculating the net power as the maximum cell voltage times the overall current density times the number of fuel cells times the area of the fuel cells of the fuel cell stack minus predetermined parasitic power that are used while running the fuel cell system. 17. The system according to claim 15 wherein the average cell voltage limit is about 0.525 V and the minimum cell voltage limit is about 0.3 V. 18. The system according to claim 15 wherein separating a current density range of the fuel cell stack into a predetermined number of sample regions includes separating a current density range of 0.1 - 2.0 A/cm2 into sample regions of 0.1 A/cm2. 19. The system according to claim 15 wherein the fuel cell stack is a split fuel cell stack where the maximum stack power is determined for both spilt stacks. 20. The system according to claim 15 wherein the means for selecting a next sample region in the current density range includes means for selecting the next sample region in order from a low current density in the range to a high current density in the range. An algorithm for determining the maximum net power available from a fuel cell stack as the stack degrades over time using an online adaptive estimation of a polarization curve of the stack. The algorithm separates the current density range of the stack into sample regions, and selects a first sample region from the far left of the estimated polarization curve. The algorithm then calculates the cell voltage for that current density sample region, and determines whether the calculated cell voltage is less than or equal to a predetermined cell voltage limit. If the calculated cell voltage is not less than the cell voltage limit, then the algorithm selects the next sample region along the polarization curve. When the calculated cell voltage does reach the cell voltage limit, then the algorithm uses that current density for the sample region being analyzed to calculate the maximum power of the fuel cell stack.

Full Text

METHOD FOR MAXIMUM NET POWER CALCULATION FOR FUEL CELL
SYSTEM BASED ON ONLINE POLARIZATION CURVE ESTIMATION
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] This invention relates generally to an algorithm for
determining the maximum power available from a fuel cell stack as the stack
degrades over time and, more particularly, to an algorithm for determining the
maximum power available from a fuel cell stack using an online polarization
curve estimation process as the stack degrades over time.
2. Discussion of the Related Art
[0002] Hydrogen is a very attractive fuel because it is clean and
can be used to efficiently produce electricity in a fuel cell. A hydrogen fuel cell
is an electro-chemical device that includes an anode and a cathode with an
electrolyte therebetween. The anode receives hydrogen gas and the cathode
receives oxygen or air. The hydrogen gas is dissociated in the anode to
generate free hydrogen protons and electrons. The hydrogen protons pass
through the electrolyte to the cathode. The hydrogen protons react with the
oxygen and the electrons in the cathode to generate water. The electrons
from the anode cannot pass through the electrolyte, and thus are directed
through a load to perform work before being sent to the cathode.
[0003] Proton exchange membrane fuel cells (PEMFC) are a
popular fuel cell for vehicles. The PEMFC generally includes a solid polymer
electrolyte proton conducting membrane, such as a perfluorosulfonic acid
membrane. The anode and cathode typically include finely divided catalytic
particles, usually platinum (Pt), supported on carbon particles and mixed with
an ionomer. The catalytic mixture is deposited on opposing sides of the
membrane. The combination of the anode catalytic mixture, the cathode
catalytic mixture and the membrane define a membrane electrode assembly
(MEA). MEAs are relatively expensive to manufacture and require certain
conditions for effective operation.

[0004] Several fuel cells are typically combined in a fuel cell
stack to generate the desired power. The fuel cell stack receives a cathode
input gas, typically a flow of air forced through the stack by a compressor.
Not all of the oxygen is consumed by the stack and some of the air is output
as a cathode exhaust gas that may include water as a stack by-product. The
fuel cell stack also receives an anode hydrogen input gas that flows into the
anode side of the stack.
[0005] The stack controller needs to know the current/voltage
relationship, referred to as a polarization curve, of the fuel cell stack to
schedule reactants in accordance with power demands. The relationship
between the voltage and the current of the stack is typically difficult to define
because it is non-linear, and changes depending on many variables, including
stack temperature, stack partial pressures and cathode and anode
stoichiometries. Additionally, the relationship between the stack current and
voltage changes as the stack degrades over time. Particularly, an older stack
will have lower cell voltages, and will need to provide more current to meet the
power demands than a new, non-degraded stack.
[0006] Fortunately, many fuel cell systems, once they are above
a certain temperature, tend to have repeatable operating conditions at a given
current density. In those instances, the voltage can be approximately
described as a function of stack current density and age.
SUMMARY OF THE INVENTION
[0007] In accordance with the teachings of the present invention,
an algorithm is disclosed for determining the maximum net power available
from a fuel cell as the fuel cell stack degrades over time using an online
adaptive estimation of a polarization curve of the stack. The algorithm first
obtains estimation parameters from the fuel cell system, such as average cell
voltage and minimum cell voltage, and estimates a polarization curve for the
stack for both an average cell voltage and a minimum cell voltage,
respectively. The algorithm then calculates the maximum power available
from the stack for both the average cell voltage and the minimum cell voltage

from the polarization curve estimation. To do this, the algorithm separates the
current density range of the stack into sample regions, and selects a first
sample region from the far left of the estimated polarization curve. The
algorithm then calculates the cell voltage for that current density sample
region, and determines whether the calculated cell voltage is less than or
equal to a predetermined cell voltage limit. If the calculated cell voltage is not
less than the cell voltage limit, then the algorithm selects the next sample
region along the polarization curve. When the calculated cell voltage does
reach the cell voltage limit, then the algorithm uses that current density for the
sample region being analyzed to calculate the maximum power of the fuel cell
stack. The algorithm then selects the lesser of the maximum power for both
the average cell voltage and the minimum cell voltage as the maximum fuel
cell system output voltage.
[0008] Additional features of the present invention will become
apparent from the following description and appended claims, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is a block diagram of a fuel cell system
including split stacks and a controller;
[0010] Figure 2 is a graph with fuel cell stack current density on
the horizontal axis and fuel cell stack voltage on the vertical axis showing a
polarization curve for a minimum cell in the fuel cell stack and an average cell
in the fuel cell stack;
[0011] Figure 3 is a flow chart diagram showing a process for
determining the maximum fuel cell stack power at any particular point in time
for a fuel cell stack, according to an embodiment of the present invention; and
[0012] Figure 4 is a flow chart diagram showing a process for
calculating the maximum fuel cell stack power, according to an embodiment of
the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] The following discussion of the embodiments of the
invention directed to an algorithm for determining the maximum net power
available from a fuel cell system as the fuel cell stack degrades over time
using an online polarization curve estimation process is merely exemplary in
nature, and is in no way intended to limit the invention or it's applications or
uses.
[0014] Many control parameters of a fuel cell system require
knowledge of the polarization curve of the fuel cell stack, such as knowing the
maximum voltage potential and current draw available from the fuel cell stack.
As mentioned above, as the stack ages, the stack polarization curve also
changes as a result of stack degradation. U.S. Patent Application serial No.
11/669,898, filed January 31, 2007, titled Algorithm for Online Adaptive
Polarization Curve Estimation of a Fuel Cell Stack, assigned to the Assignee
of this Application and herein incorporated by reference, discloses an
algorithm for calculating the polarization curve of a fuel cell stack online as the
fuel cell system is being operated. The algorithm of the '898 application
estimates two or more stack parameters from collected data as the stack is
being operated, and uses the parameters to calculate the polarization curve.
When the fuel cell stack is running and certain data validity criteria have been
met, the algorithm goes into a good collection mode where it collects stack
data, such as stack current density, average cell voltage and minimum cell
voltage. When the stack is shut-down, the algorithm uses a cell voltage
model to solve a non-linear least squares problem to estimate predetermined
parameters that define the polarization curve. If the estimated parameters
satisfy certain termination criteria, then the estimated parameters are stored
to be used by a system controller to calculate the polarization curve of the
stack for future stack runs.
[0015] The present invention proposes an algorithm for
determining the maximum net power available from a fuel cell stack using an
online polarization curve estimation process, such as that disclosed in the

'898 application. The algorithm uses previously saved estimation parameters
to generate the polarization curve online, and calculates a maximum net
power from the system based on stack health. As the parameters vary with
the life of the stack, so does the maximum net power. The algorithm provides
the vehicle controller with an estimate of the maximum power available from
the stack. It can use this information to change the way it distributes power
requests to the battery and the fuel cell stack.
[0016] From this, the reliability of the fuel cell system is
improved if the vehicle does not request more power from the stack than it
can produce. For example, assume a fuel cell module can typically provide
90 kW, but stack voltage has degraded so that it can only provide 80 kW. If
85 kW is requested, the balance of plant set-points will go to 85 kW even
though the stack cannot produce that much power. Further, information of
predicted maximum power level will be available for service personnel if the
stack needs servicing. If the maximum power level is significantly degraded,
the fuel cell system can modify set-points to enhance vehicle reliability.
During system start-up, the rate at which the stack is initially loaded CAN be
reduced as a result of a reduced power output. Although it will take longer for
the vehicle to drive away, the risk of failed start-ups is reduced. Further, extra
thermal loads can be turned on when the fuel cell system is warming up. A
degraded stack often has a reduced ability to manage liquid water. Additional
stack warming will quickly reduce the risk of unstable operation. If the stack is
heavily degraded, relative humidity set-points can be modified to better
manage liquid water.
[0017] Figure 1 is a block diagram of a fuel cell system 10
including a first split stack 12, a second split stack 14 and a controller 16. The
controller 16 receives information from the split stacks 12 and 14, and controls
the split stacks 12 and 14. The controller 16 uses the information to calculate
the polarization curve of the stacks 12 and 14 in real time, and provide the
maximum net power available from the stacks 12 and 14.
[0018] In order to determine the maximum net power from the
fuel cell stacks 12 and 14, the present invention uses the average cell voltage

of the stacks 12 and 14 and the minimum cell voltage of the stacks 12 and 14.
Figure 2 is a graph with current density on the horizontal axis and voltage on
the vertical axis. The graph includes two polarization curves, namely
polarization curve 20 for the average cell voltage and polarization curve 22 for
the minimum cell voltage. Point 24 represents the maximum current (or
current density) available from the stacks 12 and 14 for the average cell
polarization curve and point 26 represents the maximum current available
from the stacks 12 and 14 for the minimum cell polarization curve 22.
[0019] Figure 3 is a flow chart diagram 40 showing a process of
the invention for determining the maximum net fuel cell stack output power at
any given time during fuel cell operation, and the applications for which this
calculated power value can be used. At box 42, the algorithm obtains the
parameters from a non-volatile memory that are used to estimate the
polarization curves for the stacks 12 and 14 from, for example, the process
disclosed in the '898 application. Further, the algorithm sets an average cell
voltage limit at box 42 and a minimum cell voltage limit at
box 44. In one non-limiting example, the average cell voltage limit can be
about 0.525 V and the minimum cell voltage limit can be about 0.3 V for a 230
V, 440 cell fuel cell stack. The algorithm then calculates the maximum net
power available from the fuel cell stacks 12 and 14 using the average cell
voltage limit at box 42 and calculates the maximum power using the
minimum cell voltage limit at box 46.
[0020] Figure 4 is a flow chart diagram 50 showing a process
for determining the maximum net power for both the average cell voltage and
the minimum cell voltage, according to an embodiment of the present
invention. The process starts at the far left of the polarization curves 20 and
22 and moves down along the curves 20 and 22 until the average cell voltage
limit and the minimum cell voltage limit at points 24 and 26
are reached. At box 52, the algorithm divides the current density range of the
stacks 12 and 14 into N sample regions, where k identifies the specific sample
region being analyzed. In one non-limiting example, the current density range

can be 0.1 - 2.0 A/cm2 and the sample regions can be every 0.1 A/cm2. The
algorithm then obtains a current density j for the sample region being
examined, and calculates the cell voltage at that current density j for both the
average cell voltage and the minimum cell voltage using the polarization
curves 20 and 22. In one non-limiting example, the cell voltage at the specific
current density is calculated as:

Where, is the cell voltage (V),
j is the current density (A/cm2),
RHFR is the cell HFR resistance (ohm cm2),
is the thermodynamic reversible cell potential (V),
 is the background current density from cell shorting/cell crossover (A/cm2),
is the exchange current density (A/cm2),
is the limiting current density (A/cm2), and
is the mass transfer coefficient.
[0021] Once the cell voltage is calculated, the algorithm
determines whether the calculated cell voltage for that current density j is
less than the predetermined cell voltage limit or at
decision diamond 56 and, if not, the algorithm moves to the next sample
region k at box 58 to calculate the average cell voltage and the minimum cell
voltage at the box 54 for the new higher current density j. If the calculated cell
voltage is less than or equal to the cell voltage limit or at
the decision diamond 56, then the algorithm sets the current density j for the
particular sample region as the maximum current density, and calculates the
maximum power at box 60. The gross power is calculated as voltage times
current where the maximum current density j is multiplied by the number of
cells and the area of the cells to get the total current of the stacks
12 and 14. Further, a parasitic power estimation based current density

(provided by a look-up table or suitable parasitic estimation algorithm) is
subtracted from the power and a correction is added to get the maximum net
power as:

[0022] The gross power is how much the stack is producing and
the net power is the gross power minus the parasitic power to operate the fuel
cell system, such as operating the compressor, cooling fluid pumps, etc.
Typically, tables are generated where the parasitic power is defined for a
particular current density j based on experiments and the like. The correction
is typically determined empirically and is generally around 5% of the
maximum power.
[0023] Once the algorithm has the maximum net power for
the average cell voltage and the minimum cell voltage for both of the stacks
12 and 14, the algorithm determines the maximum fuel cell system net power
as the minimum of the two maximum net powers for each stack 12
and 14 at box 62 in the flow chart diagram 40.
[0024] Another non-limiting embodiment for calculation of
maximum net power, which can be applied to N number of stacks, can be
given by:
min(max(AvgCellPowerEstimations), min(MinCellPowerEstimations))
[0025] Once the algorithm has the maximum net power
that can be drawn from the stacks 12 and 14 at any particular time, this value
is then used in various applications in the fuel cell system 10, such as
predicting the number of hours before the end of life of the stacks 12 and 14
at box 64, sending the maximum power to the fuel cell power system at box
66, providing an energy estimate for acceptable drivability at box 68 and using
the maximum power in adaptive control applications at box 70.

[0025] The foregoing discussion discloses and describes
merely exemplary embodiments of the present invention. One skilled in the
art will readily recognize from such discussion and from the accompanying
drawings and claims that various changes, modifications and variations can
be made therein without departing from the spirit and scope of the invention
as defined in the following claims.

CLAIMS
What is Claimed is:
1. A method for estimating the maximum stack power from a fuel
cell stack during operation of the fuel cell stack, said method comprising:
selecting an average cell voltage limit for an average fuel cell in
the fuel cell stack;
selecting a minimum cell voltage limit for a minimum performing
fuel cell in the fuel cell stack;
estimating a separate polarization curve of the fuel cell stack for
both an average cell voltage and a minimum cell voltage;
separating a current density range of the fuel cell stack into a
predetermined number of sample regions in ascending order;
selecting a first sample region;
determining an average cell voltage and a minimum cell voltage
at the current density for the selected sample region;
determining whether the cell voltage is less than the
predetermined average cell voltage limit and the minimum cell voltage limit;
selecting a next sample region in the current density range if the
cell voltage is not less than the average cell voltage limit or the minimum cell
voltage limit;
calculating a maximum net power for both the average cell
voltage and the minimum cell voltage if the cell voltage is less than average
cell voltage limit or the minimum cell voltage limit; and
selecting the lesser of the average cell voltage maximum net
power and the minimum cell voltage maximum net power as the maximum
stack power.
2. The method according to claim 1 wherein calculating the net
power includes calculating the net power as the maximum cell voltage times
the overall current density times the number of fuel cells times the area of the
fuel cells of the fuel cell stack minus predetermined parasitic power that are
used while running the fuel cell stack.

3. The method according to claim 2 further comprising adding a
correction to the calculated maximum power.
4. The method according to claim 1 wherein determining an
average cell voltage and a minimum cell voltage includes using the equation:

where is the cell voltage,; is the current density, RHFR is the cell HFR
resistance, is the thermodynamic reversible cell potential,  is the
background current density from cell shorting/cell crossover, is the
exchange current density, is the limiting current density and c is the mass
transfer coefficient.
5. The method according to claim 1 wherein the average cell
voltage limit is about 0.525 V and the minimum cell voltage limit is about 0.3
V.
6. The method according to claim 1 wherein separating a current
density range of the fuel cell stack into a predetermined number of sample
regions includes separating a current density range of 0.1 - 2.0 A/cm2 into
sample regions of 0.1 A/cm2.
7. The method according to claim 1 wherein selecting a next
sample region in the current density range includes selecting the next sample
region in order from a low current density in the range to a high current
density in the range.

8. The method according to claim 1 wherein the fuel cell stack is a
split fuel cell stack where the maximum stack power is determined for both
spilt stacks.
9. A method for estimating the maximum stack power from a fuel
cell stack during operation of the fuel cell stack, said method comprising:
selecting at least one cell voltage limit for a fuel cell in the fuel
cell stack;
estimating a polarization curve of the fuel cell stack for at least
one cell;
separating a current density range of the fuel cell stack into a
predetermined number of sample regions;
selecting a first sample region;
determining a cell voltage at the current density for the selected
sample region;
determining whether the cell voltage is less than the
predetermined cell voltage limit;
selecting a next sample region in the current density range if the
cell voltage is not less than the cell voltage limit; and
calculating a maximum net power for the cell voltage if the cell
voltage is less than the cell voltage limit.
10. The method according to claim 9 wherein selecting at least one
cell voltage limit includes selecting an average cell voltage limit for an average
fuel cell in the fuel cell stack and a minimum cell voltage limit for a minimum
performing fuel cell in the fuel cell stack, and wherein estimating a polarization
curve of the fuel cell stack includes estimating a polarization curve for both the
average cell voltage and the minimum cell voltage, and wherein determining a
cell voltage includes determining an average cell voltage and a minimum cell
voltage at the current density for the selected sample region.

11. The method according to claim 9 wherein calculating the net
power includes calculating the net power as the maximum cell voltage times
the overall current density times the number of fuel cells times the area of the
fuel cells of the fuel cell stack minus predetermined parasitic power that are
used while running the fuel cell stack.
12. The method according to claim 11 further comprising adding a
correction to the calculated maximum power.
13. The method according to claim 9 wherein determining the cell
voltage includes using the equation:

where is the cell voltage, j is the current density, RHFR is the cell HFR
resistance, is the thermodynamic reversible cell potential,  is the
background current density from cell shorting/cell crossover, is the
exchange current density, is the limiting current density and c is the mass
transfer coefficient.
14. The method according to claim 9 wherein separating a current
density range of the fuel cell stack into a predetermined number of sample
regions includes separating a current density range of 0.1 - 2.0 A/cm2 into
sample regions of 0.1 A/cm2.
15. A system for estimating the maximum stack power from a fuel
cell stack during operation of a fuel cell stack, said system comprising;
means for selecting an average cell voltage for an average fuel
cell in the fuel cell stack;
means for selecting a minimum cell voltage for a minimum
performing fuel cell in the fuel cell stack;

means for estimating a polarization curve of the fuel cell stack
for both an average fuel cell and a minimum fuel cell voltage;
means for separating a current density range of the fuel cell
stack into a predetermined number of sample regions;
means for selecting a first sample region;
means for determining an average cell voltage and a minimum
cell voltage at the current density for the selected sample region;
means for determining whether the cell voltage is less than the
predetermined average cell voltage limit and the minimum cell voltage limit;
means for selecting a next sample region in the current density
range if the cell voltage is not less than the average cell voltage limit or the
minimum cell voltage limit;
means for calculating a maximum net power for both the
average cell voltage and the minimum cell voltage if the cell voltage is less
than the average cell voltage limit and the minimum cell voltage limit; and
means for selecting the less of the average cell voltage
maximum net power and the minimum cell voltage maximum net power as a
maximum stack power.
16. The system according to claim 15 wherein the means for
calculating the net power includes means for calculating the net power as the
maximum cell voltage times the overall current density times the number of
fuel cells times the area of the fuel cells of the fuel cell stack minus
predetermined parasitic power that are used while running the fuel cell
system.
17. The system according to claim 15 wherein the average cell
voltage limit is about 0.525 V and the minimum cell voltage limit is about 0.3
V.
18. The system according to claim 15 wherein separating a current
density range of the fuel cell stack into a predetermined number of sample

regions includes separating a current density range of 0.1 - 2.0 A/cm2 into
sample regions of 0.1 A/cm2.
19. The system according to claim 15 wherein the fuel cell stack is a
split fuel cell stack where the maximum stack power is determined for both
spilt stacks.
20. The system according to claim 15 wherein the means for
selecting a next sample region in the current density range includes means for
selecting the next sample region in order from a low current density in the
range to a high current density in the range.

An algorithm for determining the maximum net power available from a
fuel cell stack as the stack degrades over time using an online adaptive
estimation of a polarization curve of the stack. The algorithm separates the
current density range of the stack into sample regions, and selects a first
sample region from the far left of the estimated polarization curve. The
algorithm then calculates the cell voltage for that current density sample
region, and determines whether the calculated cell voltage is less than or
equal to a predetermined cell voltage limit. If the calculated cell voltage is not
less than the cell voltage limit, then the algorithm selects the next sample
region along the polarization curve. When the calculated cell voltage does
reach the cell voltage limit, then the algorithm uses that current density for the
sample region being analyzed to calculate the maximum power of the fuel cell
stack.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=IhgFrttE1dUlfkYXe6qoIw==&loc=wDBSZCsAt7zoiVrqcFJsRw==

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Patent Number

272304

Indian Patent Application Number

151/KOL/2009

PG Journal Number

14/2016

Publication Date

01-Apr-2016

Grant Date

29-Mar-2016

Date of Filing

28-Jan-2009

Name of Patentee

GM GLOBAL TECHNOLOGY OPERATIONS, INC.

Applicant Address

300 GM RENAISSANCE CENTER DETROIT, MICHIGAN

Inventors:

#	Inventor's Name	Inventor's Address
1	JOHN P. SALVADOR	42 HILLCREST DRIVE PENFIELD, NEW YORK 14526
2	KIRAN MALLAVARAPU	245 EAST STREET, APT. 502 HONEYOYE FALLS, NEW YORK 14472
3	FRANK X LEO	209 SCOFIELD ROAD HONEOYE FALLS, NEW YORK 14472
4	BALASUBRAMANIAN LAKSHMANAN	38 SADDLE BROOK PITRTSFORD, NEW YORK 14534
5	SRIRAM GANAPATHY	128 GREYSTONE LANE, APT, 13 ROCHESTER, NY 14618

PCT International Classification Number

H01M 8/04

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	12/027,042	2008-02-06	U.S.A.