In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, logical and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive or, unless otherwise indicated. Furthermore, all publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.
This document describes, among other things, a fuel cell module power delivery control system that can prevent a fuel cell module from reaching an overload condition. In an overload condition, fuel cell module operation is typically no longer stable, the fuel cell module can be locked out at an inefficient operating point, or the fuel cell module output voltage is at a substantial risk of collapse. A fuel cell module power delivery control system can be configured to allow a load connected to the fuel cell module to draw as much power as the fuel cell module is capable of providing, rather than limiting the fuel cell module to a preset output power.
The fuel cell module power delivery control system can also be realized with fairly minimal functional components, which occupy little space. In certain examples, the fuel cell module power delivery control system and one or more fuel cells (e.g., 11 serially-connected fuel cells) are small, such that they can be implemented in a portable handheld carrier. In certain examples, the fuel cell module power delivery control system is implemented using a DC-to-DC converter with a built-in low battery indicator function and three discrete resistors.
The control circuit 120 receives the fuel cell module status signal 115. Generally, the fuel cell module status signal 115 is a signal indicative of the status of the fuel cell module 105. In certain examples, the fuel cell module 105 is a single fuel cell. In other examples, the fuel cell module 105 includes more than one series-connected, parallel-connected, or series-parallel combination-connected fuel cell. The DC-to-DC converter 110 couples the fuel cell module 105 to the load unit 155. The DC-to-DC converter 110 receives a fuel cell module output 106 (e.g., voltage) from the fuel cell module 105 and delivers a resulting lower, higher, or similar output (e.g., voltage) at the DC-to-DC converter output 107 to the load unit 155. The load unit 155 can include a single individual load unit, or multiple individual load units that are connected in series, in parallel, or in a series-parallel combination.
In certain examples, the control circuit 120 can include all or a portion of the DC-to-DC converter 110, which typically includes a linear regulator, a switched-mode DC-to-DC converter, or the like. In certain examples, the DC-to-DC converter 110 includes a custom or off-the shelf monolithic or other DC-to-DC integrated circuit, such as a Texas Instruments TPS62050, or a Maxim MAX640, or a Linear Technology LT1705, or the like.
In certain examples, the voltage divider circuit 135 is automatically or user adjustable. The voltage divider circuit 135 can be static, or dependent upon the fuel cell module 105. For example, the voltage divider circuit 135 can be dependent upon the number of individual fuel cells included in the fuel cell module 105, or fuel cell module configuration (e.g., fuel cell connection in series, parallel, or a series-parallel combination). Additionally or alternatively, the voltage divider circuit 135 can be dependent upon fuel cell module operation, such as one or more operating conditions (e.g., temperature, humidity), or power delivery mode (e.g., efficiency, maximum power draw).
In certain examples, the comparator 125 receives, at a first comparator input, a voltage-divided or other signal indicative of the fuel cell module status signal 115, and compares it to a threshold value 130 received at a second comparator input. The threshold value 130 can be automatically or user adjustable or an automatically defined or user-defined static value. The threshold value 130 can be dependent upon one or more attributes of the fuel cell module 105, such as the number of individual fuel cells included in the fuel cell module 105, or fuel cell module configuration (e.g., fuel cell connection in series, parallel, or a series-parallel combination) or fuel cell module operation such as operating condition (e.g., temperature, humidity), or power delivery mode (e.g., efficiency, maximum power draw).
In certain examples, if the output of the voltage divider circuit 135 falls below the threshold value 130, the output of the comparator 125 closes a switch (Q1) 139, such as a field-effect or other transistor. Closing the switch (Q1) 139 allows the current provided by the fuel cell module status signal 115 to flow to ground through resistor R3, which pulls low the output of control circuit 120. When the output of the voltage divider circuit 135 exceeds the threshold value 130, the output of the comparator 125 opens the switch (Q1) 139. Opening the switch (Q1) 139 pulls the output voltage of the control circuit 120 to be equal to or approximately equal to the voltage of the fuel cell module status signal 115.
In certain examples, the DC-to-DC converter 110 includes an enable/disable feature, such as provided by an enable terminal 112. If the enable terminal 112 receives a logic high signal, the DC-to-DC converter 110 is enabled, or operable. If the enable terminal 112 receives a logic low signal, the DC-to-DC converter 110 is disabled, or non-operable.
In certain examples, the DC-to-DC converter 110 includes a low battery feature. The low battery feature can include a logic high/low input (e.g., a low battery input terminal 117) and an open drain output (e.g., an open drain low battery output terminal 116). The low battery feature can operate as a comparator with a low battery value of “logic low”. When the signal to the low battery input terminal 117 drops to or below a “logic low” level, an open drain output is operable at the open drain low battery output terminal 116. The DC-to-DC converter 110 generally includes an enable/disable feature, such as the enable terminal 112. The open drain low battery output terminal 116 is typically connected to the enable terminal 112. When the signal provided to the low battery input terminal 117 drops to or below a “logic low” level, the DC-to-DC converter 110 is disabled. When DC-to-DC converter 110 is disabled, its current consumption is low, e.g., about 2 μA. Disabling the DC-to-DC converter 110 effectively detaches the fuel cell module 105 from the load unit 155, thereby allowing the fuel cell module 105 to recover to a more desirable operating point. The control circuit 120 can provide the fuel cell module status signal 115 to the low battery input terminal 117 to enable or disable the DC-to-DC converter 110 to couple or decouple the fuel cell module 105 to or from the load unit 155.
Generally, referring to the polarization curve 705 and the power curve 710, the fuel cell module output voltage 770 decreases and the fuel cell module output power 790 increases as the fuel cell module output current 780 increases. As the fuel cell module output current 780 increases, the power curve 710 reaches the power peak (P) 715, or maximum fuel cell module power output. The power peak 715 of the power curve 710 corresponds to a fuel cell module output voltage at the power peak 715 of VP 740, and a fuel cell module output current at the power peak 715 of IP 750. In one example, VP 740 is approximately 0.3 to 0.5 Volts per fuel cell, e.g., for 11 serially-connected fuel cells, VP 740 is approximately 3.3 to 5.5 Volts.
The load unit 155 may attempt to draw more power from the fuel cell module 105 than it can comfortably provide. When this happens, the fuel cell module output voltage 770 may drop below VP 740 and the fuel cell module output current may rise above IP 750. This situation may pose several problems. In the extreme, a short circuit in the load unit 155 may cause VP 740 to collapse to zero. First, the efficiency of the fuel cell module 105 is typically dependent on its operating voltage. Generally, the closer that the fuel cell module 105 operates to OCV 735, the higher its efficiency. At lower operating voltages, the fuel cell module 105 is typically less efficient, which, in general, means that more heat is generated for each unit of electricity produced. Secondly, once the fuel cell module 105 goes over the power peak 715, it may be difficult for it to recover to a higher operating voltage.
When the fuel cell module output voltage 770 is higher than VP 740 and the fuel cell module output current 780 is lower than IP 750, increasing the load on the fuel cell module 105 will typically increase the fuel cell module output current 780, decrease the fuel cell module output voltage 770, and increase the fuel cell module output power 790. When the fuel cell module output voltage 770 is lower than VP 740 and the fuel cell module output current is higher than IP 750, increasing the load on the fuel cell module 105 will typically increase the fuel cell module output current 780, decrease the fuel cell module output voltage 770, and decrease the fuel cell module output power 790. This reduction in the fuel cell module output power 790 may cause the load unit 155 to attempt to draw even more power by even greater increases in the fuel cell module output current 780 and reductions in the fuel cell module output voltage 770, which typically reduces the fuel cell module output power 790 even further. In the extreme, this power draw by the load unit 155 creates an overload condition on the fuel cell module 105.
Generally, once the fuel cell module 105 is operating over and beyond the top of the power peak 715, it can be difficult for the fuel cell module 105 to recover to a more efficient operating point above VP 740. When the fuel cell module 105 is operating over the top of the power peak 715, if the power draw on the fuel cell module 105 is reduced, the fuel cell module 105 can tend to want to move its operating point toward the right on the power curve 710 rather than toward the left, because moving right on the power curve 710 reduces the fuel cell module output power 790. However, moving right on the power curve 710 also corresponds to an increased current draw and a decreased fuel cell module operating voltage.
Referring to the power curve 710, the same fuel cell module output power can be realized at two different values of the fuel cell module output current and two different values of the fuel cell module output voltage, one on the left side of the power peak 715 and one on the right side of the power peak 715. Typically, fuel cell module 105 operation is preferred to be on the left side of the power peak 715, or only slightly over the power peak 715 (e.g., within 25% past the power peak 715). This range is shown in
Generally, it can be difficult for the fuel cell module 105 to “tunnel” through to the equivalent fuel cell module output power on the left side of the power peak 715 once it has exceeded the power peak 715 to a certain extent (e.g., more than 25% past the power peak 715). Once the fuel cell module output power 790 exceeds the power peak 715 to such an extent, its operating point effectively becomes “locked out” on the right side of the power peak 715, shown in
At 810, the fuel cell module power delivery control system 150 receives the fuel cell module status signal 115, such as upon activation of the method 800, or in response to a user input or a triggering event.
At 815, the fuel cell module power delivery control system 150 determines if overload 730 is imminent, such as by using a comparator 125, which can be included in the control circuit 120, such as within the DC-to-DC converter 110. In such an example, the comparator 125 compares the fuel cell module status signal 115 to a static or adjustable threshold value 130, such as a preset or adjustable low battery value provided by the DC-to-DC converter 110. If, at 815, the fuel cell module power delivery control system 150 determines that overload 730 is not imminent, then process flow returns to 810. If, at 815, the fuel cell module power delivery control system 150 determines that overload 730 is imminent, then process flow continues to 820.
At 820, the fuel cell module power delivery control system 150 automatically reduces an electrical loading upon the output of the fuel cell module 105. This can include reducing the current through the DC-to-DC converter 110, such as by using its enabling/disabling function to cycle the DC-to-DC converter 110 on and off. Additionally or alternatively, this can include reducing the current draw of the load unit 155, such as by increasing a current-limiting resistance to the load unit 155.
At 825, the fuel cell module power delivery control system 150 receives the fuel cell module status signal 115. At 830, the fuel cell module power delivery control system 150 determines if overload 730 is imminent. If, at 830, the fuel cell module power delivery control system 150 determines that overload 730 is imminent, then process flow returns to 820. If, at 830, the fuel cell module power delivery control system 150 determines that overload 730 is no longer imminent, then process flow continues to 835.
At 835, the fuel cell module power delivery control system 150 automatically permits increased electrical loading upon the fuel cell module output, such as by allowing increased current draw of the load unit 155 or through the DC-to-DC converter 110.
At 840, the fuel cell module power delivery control system 150 receives the fuel cell module status signal 115. At 845, the fuel cell module power delivery control system 150 uses the fuel cell module status signal 115 to determine if overload 730 is imminent. If, at 845, the fuel cell module power delivery control system 150 determines that overload 730 is not imminent, then process flow returns to 835. If, at 845, the fuel cell module power delivery control system 150 determines that overload 730 is imminent, then process flow returns to 820.
At 910, the fuel cell module power delivery control system 150 receives the fuel cell module status signal 115, such as upon system activation, in response to a user input, or in response to a triggering event.
At 915, the fuel cell module power delivery control system 150 determines if overload 730 is imminent, such as by using the comparator 125 included in the control circuit 120 or the DC-to-DC converter 110. In certain examples, the comparator 125 compares the fuel cell module status signal 115 to a static or adjustable threshold value 130, which can be provided by a built-in low battery voltage circuit on the DC-to-DC converter 110. If, at 915, the fuel cell module power delivery control system 150 determines that overload 730 is not imminent, then process flow returns to 910. If, at 915, the fuel cell module power delivery control system 150 determines that overload 730 is imminent, then process flow continues to 920.
At 920, the fuel cell module power delivery control system 150 automatically disables the DC-to-DC converter 110, such as by using an enable/disable input on the DC-to-DC converter 110 or by using a low battery input on the DC-to-DC converter 110.
At 925, the fuel cell module power delivery control system 150 receives the fuel cell module status signal 115. At 930, the fuel cell module power delivery control system 150 determines if overload 730 is imminent. If, at 930, fuel cell module power delivery control system 150 determines that overload 730 is imminent, then process flow returns to 925. If, at 930, the fuel cell module power delivery control system 150 determines that overload 730 is no longer imminent, then process flow continues to 935.
At 935, the fuel cell module power delivery control system 150 automatically enables the DC-to-DC converter 110, such as by using an enable/disable input on the DC-to-DC converter 110, or by using a low battery input on DC-to-DC converter 110. Process flow then returns to 910.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
The Abstract is provided to comply with 37 C.F.R. §1.72(b), which requires that it allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.