Anode reactive bleed and injector shift control strategy

A system and method for correcting a large fuel cell voltage spread for a split sub-stack fuel cell system. The system includes a hydrogen source that provides hydrogen to each split sub-stack and bleed valves for bleeding the anode side of the sub-stacks. The system also includes a voltage measuring device for measuring the voltage of each cell in the split sub-stacks. The system provides two levels for correcting a large stack voltage spread problem. The first level includes sending fresh hydrogen to the weak sub-stack well before a normal reactive bleed would occur, and the second level includes sending fresh hydrogen to the weak sub-stack and opening the bleed valve of the other sub-stack when the cell voltage spread is close to stack failure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a fuel cell system that corrects cell voltage instability due to hydrogen starvation and, more particularly, to a fuel cell system including split sub-stacks that injects fresh hydrogen into a weak sub-stack before a reactive anode bleed is commanded in an effort to recover from a low cell voltage and improve system stability.

2. Discussion of the Related Art

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 protons and electrons. The protons pass through the electrolyte to the cathode. The 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.

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.

Several fuel cells are typically combined in a fuel cell stack to generate the desired power. For example, a typical fuel cell stack for a vehicle may have two hundred or more stacked fuel cells. The fuel cell stack receives a cathode input reactant 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 reactant gas that flows into the anode side of the stack. The stack also includes flow channels through which a cooling fluid flows.

The fuel cell stack includes a series of bipolar plates positioned between the several MEAs in the stack, where the bipolar plates and the MEAs are positioned between two end plates. The bipolar plates include an anode side and a cathode side for adjacent fuel cells in the stack. Anode gas flow channels are provided on the anode side of the bipolar plates that allow the anode reactant gas to flow to the respective MEA. Cathode gas flow channels are provided on the cathode side of the bipolar plates that allow the cathode reactant gas to flow to the respective MEA. One end plate includes anode gas flow channels, and the other end plate includes cathode gas flow channels. The bipolar plates and end plates are made of a conductive material, such as stainless steel or a conductive composite. The end plates conduct the electricity generated by the fuel cells out of the stack. The bipolar plates also include flow channels through which a cooling fluid flows.

The MEAs are permeable and thus allow nitrogen in the air from the cathode side of the stack to permeate therethrough and collect in the anode side of the stack, referred to in the industry as nitrogen cross-over. Even though the anode side pressure may be higher than the cathode side pressure, the cathode side partial pressures will cause air to permeate through the membrane. Nitrogen in the anode side of the fuel cell stack dilutes the hydrogen such that if the nitrogen concentration increases beyond a certain percentage, such as 50%, the fuel cell stack becomes unstable and may fail. It is known in the art to provide a bleed valve at the anode exhaust gas output of the fuel cell stack to remove nitrogen from the anode side of the stack.

Some fuel cell systems employ anode flow-shifting where the fuel cell stack is split into sub-stacks and the anode reactant gas is flowed through the split sub-stacks in alternating directions. In these types of designs, a bleed manifold unit (BMU) is sometimes provided between the split sub-stacks that includes the valves for providing the anode exhaust gas bleed.

An algorithm may be employed to provide an online estimation of the nitrogen concentration in the anode exhaust gas during stack operation to know when to trigger the anode exhaust gas bleed. The algorithm may track the nitrogen concentration over time in the anode side of the stack based on the permeation rate from the cathode side to the anode side, and the periodic bleeds of the anode exhaust gas. When the algorithm calculates an increase in the nitrogen concentration above a predetermined threshold, for example 10%, it may trigger the bleed. This bleed, sometimes referred to as a proactive bleed, is typically performed for a duration that allows multiple stack anode volumes to be bled, thus reducing the nitrogen concentration below the threshold.

Another type of known anode exhaust gas bleed is known as a reactive bleed. In a reactive bleed, an algorithm calculates the fuel cell voltages and triggers a bleed when a stack cell voltage spread threshold is exceeded. Cell voltage spread is the difference between the maximum and minimum cell voltages of split sub-stack. The purpose of the reactive bleed is to reduce the cell spread due to cell starvation. This is typically due to excessive nitrogen accumulation or liquid water flooding in the flow fields in the anode side of the stack.

When a reactive bleed is commanded in a split sub-stack system, the system controller typically determines which bleed valve to open based on the current shift direction of the anode flow. In one known system, a saw tooth command signal is employed to determine which of the split sub-stacks is receiving hydrogen at any particular point in time. The saw tooth command signal is based on a range of values from 0 to 1, where if the saw tooth command signal is between 0 and 0.5, then hydrogen is sent to a first sub-stack and when the saw tooth command signal is between 0.5 and 1, the flow shift is reversed, and the hydrogen is sent to the second split sub-stack. During a bleed command, the bleed valve for the sub-stack that is down-stream to the sub-stack that is receiving the fresh hydrogen is opened, where the flow shift remains in this configuration until the bleed request is terminated. When the bleed request is terminated, the command signal is reset to 0 so that the first sub-stack is always the sub-stack that receives fresh hydrogen first after a bleed request has been terminated.

Two problems can be observed by this type of command for anode flow shifting and bleed requests. First, if a cell voltage spread of either of the split sub-stacks exceeds a spread threshold and a reactive bleed is commanded, the orientation of the flow shift may be such that the weak sub-stack having the greatest cell voltage spread may not be the one that is currently receiving hydrogen, and thus, will be the one from which the bleed occurs. In other words, if one of the sub-stacks has a low performing cell and that sub-stack is the down-stream sub-stack for the current flow shift direction, then the reactive bleed that would be commanded would inject fresh hydrogen into the other sub-stack and the bleed would be provided through the bleed valve at the output of the low performing sub-stack. Thus, the more stable of the two sub-stacks is the sub-stack that is receiving the fresh hydrogen during the bleed event, which would cause the voltage spread of the weak sub-stack to increase.

Further, after the bleed request is terminated, the saw tooth command signal is reset to 0 so that the same sub-stack is always the one that is receiving the hydrogen first. This causes the sub-stack that receives hydrogen by the saw tooth command signal during 0-0.5 to receive 50% more hydrogen that the other sub-stack. This situation can be illustrated as follows. Suppose the bleed request duration is τ and the saw tooth command signal period is T. In a worst case situation, as a result of the reset of the saw tooth command signal to 0 after a bleed request is terminated, the duration for the second sub-stack to receive hydrogen is τ+T/2 and the duration for the first sub-stack to receive hydrogen is τ+T. Therefore, the ratio of the duration for the each sub-stack receiving fresh hydrogen is given by:

For low current density, the bleed request duration τ is usually small compared to the saw tooth command signal period T, and therefore, RAtoBis large. For example, for a stack current density j=0.1, the saw tooth command signal shift period T=6.09 seconds and the bleed period τ=3 s. Therefore:

This means that the first sub-stack tends to receive hydrogen 50% more often than the second sub-stack for the same bleed request condition. This calculation also explains that stack voltage drop occurs more often in low current density conditions and the second sub-stack tends to be the weak stack more often.

SUMMARY OF THE INVENTION

In accordance with the teachings of the present invention, a system and method are disclosed for correcting a large fuel cell voltage spread for a split sub-stack fuel cell system. The system includes a hydrogen source that provides hydrogen to each split sub-stack and bleed valves for bleeding the anode side of the sub-stacks. The system also includes a voltage measuring device for measuring the voltage of each cell in the split sub-stacks. The system provides two levels for correcting a large stack voltage spread problem. The first level includes sending fresh hydrogen to the weak sub-stack well before a normal reactive bleed would occur, and the second level includes sending fresh hydrogen to the weak sub-stack and opening the bleed valve of the other sub-stack when the cell voltage spread is close to stack failure.

According to another embodiment, after a bleed request is terminated, a saw tooth command signal that determines the flow shift direction for the system is reset so that the sub-stack that was not receiving the fresh hydrogen when the bleed request was initiated is the first one to receive the fresh hydrogen after the bleed request is terminated.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following discussion of the embodiments of the invention directed to a system and method for correcting a large stack cell voltage spread for a split sub-stack and a fuel cell system is merely exemplary in nature, and is in no way intended to limit the invention or its applications or uses.

FIG. 1is a schematic block diagram of a fuel cell system10including split fuel cell sub-stacks12and14that operate under anode flow-shifting. When the flow is in one direction, an injector bank16injects fresh hydrogen into the anode side of the sub-stack12on anode input line24. Anode gas that is output from the sub-stack12is sent to the sub-stack14on connecting line20. When the flow is in the opposite direction, an injector bank18injects fresh hydrogen into the anode side of the sub-stack14on anode input line26that is output from the sub-stack14and sent to the sub-stack12on the line20.

A BMU30is provided at an anode input to the split sub-stacks12and14and provides an anode exhaust gas bleed during certain times to remove nitrogen from the anode side of sub-stacks12and14based on any suitable bleed schedule. The BMU30includes a line32that connects the anode input lines24and26and an exhaust line34that connects the line32to the exhaust of the system10, typically the cathode side exhaust of the sub-stacks12and14. A first bleed valve36is provided in the line32proximate to the sub-stack12and a second bleed valve38is provided in the line32proximate the sub-stack14. An exhaust valve40is provided in the line34that is opened during the anode bleed and other times as may be required.

The system10also includes a cell voltage monitor (CVM)46that measures the voltage of each cell in the sub-stacks12and14of the split stack fuel cell system. A controller48controls the injector banks16and18and the valves36,38and40. The controller48receives the voltage measurement signals from the CVM46and determines the minimum cell voltage, the maximum cell voltage and the voltage spread for each of the sub-stacks12and14.

When the system10is operating under anode flow-shifting and no bleed is commanded, the bleed valves36and38are both closed, so that depending on the direction of the anode gas flow, the output of the second sub-stack is dead-ended. If a bleed is commanded, and the flow is in the direction from the sub-stack12to the sub-stack14through the line20, then the bleed valve38is opened and the bleed valve36is closed. Likewise, if a bleed is commanded and the flow is in the direction from the sub-stack14to the sub-stack12through the line20, then the first bleed valve36is opened and the second bleed valve38is closed. Thus, the anode exhaust gas is bled out of the exhaust line34through the exhaust valve40.

FIG. 2is a graph with time on the horizontal axis and magnitude on the vertical axis showing a saw tooth command signal for determining the anode flow-shifting timing sequence as discussed above. The slope of the line represents the frequency of the flow shifting and whether the value of the command line is between 0 and 0.5 and 0.5 and 1 determines which of the sub-stacks12or14is currently receiving fresh hydrogen. Particularly, if the command line is between 0 and 0.5 one of the sub-stacks will be receiving fresh hydrogen and when the command is between 0.5 and 1 the flow shift reverses were the other sub-stack receives the fresh hydrogen. The plateaus in the command line represent times when a bleed is occurring, where the flow shifting is suspended and the sub-stack12or14that is currently receiving hydrogen determines that the other of the sub-stack12or14will be bled. When the bleed request is terminated where the plateau ends, it is apparent that the flow-shifting command signal is reset to 0 so that the same sub-stack12or14is the first one to receive fresh hydrogen after a bleed request is terminated.

According to one embodiment of the invention, instead of resetting the saw tooth command signal to 0 each time a bleed request has terminated, the saw tooth command signal is set to the opposite of which stack received hydrogen last. Therefore, if a bleed request is commanded when the sub-stack12is receiving hydrogen, where the bleed is from the sub-stack14, then the saw tooth command signal will be reset to 0 or 0.5 (corresponding to sub-stack14) so that the sub-stack14receives hydrogen first when the bleed request is terminated. Likewise, if the sub-stack14is receiving hydrogen when a bleed is requested, the saw tooth command signal will be reset to 0 or 0.5 (corresponding to sub-stack12) after the bleed request is terminated so that the sub-stack12is the first to receive hydrogen when the bleed request is terminated.

When a split sub-stack system experiences a low cell voltage it is advantageous to determine which sub-stack is underperforming to adequately react to the problem. The present invention recognizes that an injection of fresh hydrogen into the sub-stack with the low performing cell prior to an anode bleed improves cell voltage recovery outcomes. Therefore, an algorithm is provided to determine whether the cell voltage of each sub-stack is within desirable minimum cell voltage levels and the stack voltage spread is within an acceptable range, and if not, taking suitable remedial action.

FIG. 3is a flow diagram60showing a process for correcting a large cell voltage spread. The flow chart diagram60is for one of the split sub-stacks12and14with the understanding that the same operation is performed for the other sub-stack12or14, either simultaneously or in an alternating manner. Periodically, the system10initiates the procedure for monitoring the split sub-stack voltage spread at box62. At box64, the controller48determines if the voltage spread of the sub-stack12or14is greater than a first spread threshold. In one non-limiting embodiment, the first threshold is 150 mV as being a suitable voltage significantly below the value where a stack quick stop needs to occur, but provides an indication that one of the cells in the sub-stack12or14may be failing. If the cell voltage spread is not greater than the first threshold, then the algorithm returns to the start box62.

If the cell voltage spread of the sub-stack12or14is greater than the first threshold at the decision diamond64, meaning that the voltage of at least one of the cells in the sub-stack12or14is beginning to fall, the algorithm injects hydrogen into that sub-stack12or14at box66. After some predetermined period of time, for example 5 seconds, the algorithm will then determine whether injecting fresh hydrogen into the sub-stack12or14is correcting the high voltage spread problem at decision diamond68, and if so, the algorithm proceeds to box70to wait for the next anode exhaust gas bleed.

If injecting hydrogen into the sub-stack12or14does not cause the cell voltage spread to fall below the first threshold at the decision diamond68, then the algorithm determines whether the cell voltage spread of the sub-stack12or14is greater than a second spread threshold at decision diamond72. The second threshold is a voltage spread where the sub-stack has a more serious problem where it may be near to stack failure, which may require a quick stop. In one non-limiting embodiment, the second voltage spread threshold is about 250 mV. If the cell voltage spread of the sub-stack12or14has not reached the second threshold at the decision diamond72, then the algorithm returns to the box66to continue injecting fresh hydrogen into the sub-stack12or14with the hope that this process will eventually correct the problem and the cell voltage spread will fall below the first threshold. In addition, due care must be taken to ensure that the stronger of the two sub-stacks does not become unstable while attending to the weak sub-stack by continuously flowing fresh hydrogen into the weak sub-stack for an un-restricted time period. Thus, it is imperative to force a switch at a predetermined periodic rate to briefly feed fresh hydrogen into the strong sub-stack to proactively prevent the stronger sub-stack from becoming hydrogen starved.

If the cell voltage spread of the sub-stack12or14is greater than the second threshold at the decision diamond72, meaning that injecting the fresh hydrogen into the sub-stack is not correcting the problem causing the low cell voltage, then the algorithm continues injecting fresh hydrogen into the sub-stack12or14and opens the bleed valve of the other sub-stack12or14at box74in a continued effort to correct the cell voltage spread problem. The algorithm then determines whether the bleed request has been terminated at decision diamond76, which may occur because the cell voltage spread has fallen below the first threshold, meaning that injecting the fresh hydrogen and opening the bleed valve has solved the cell voltage spread problem. If the bleed request has terminated at the decision diamond76, the algorithm returns to the box70to wait for the next regular anode bleed. If, however, the fresh hydrogen and the bleed do not correct the cell voltage spread problem, the algorithm will return to the box74in an attempt to continue to remediate the weak sub-stack at box82. If after a predetermined period of time the condition of the sub-stack has not improved, a forced switch to feed the stronger sub-stack will occur for a brief time period before returning to the box74. This system will remain in a repeating control loop until either the weak sub-stack recovers or until the minimum cell voltage continues to drop below an absolute minimum voltage threshold around 0 mV at box80, resulting in a decision to provide a quick stop at box78.

Thus, the process discussed above provides two levels for correcting a large cell voltage spread problem. The first level to correct the problem includes injecting fresh hydrogen into a failing sub-stack well before a normal reactive bleed would occur, and the second level includes injecting fresh hydrogen into the failing sub-stack and opening the bleed valve of the other sub-stack when the cell voltage spread is close to stack failure.