SYSTEM FOR SUPPLYING COMPRESSED AIR TO A FUEL CELL SYSTEM
20220393206 · 2022-12-08
Inventors
Cpc classification
H01M8/04201
ELECTRICITY
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L50/72
PERFORMING OPERATIONS; TRANSPORTING
B60T17/02
PERFORMING OPERATIONS; TRANSPORTING
H01M2250/20
ELECTRICITY
Y02T90/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60L50/72
PERFORMING OPERATIONS; TRANSPORTING
B60T17/02
PERFORMING OPERATIONS; TRANSPORTING
H01M8/04082
ELECTRICITY
Abstract
System for supplying compressed air to a fuel cell of a vehicle, comprising a first compressor having an inlet for receiving air and an outlet for delivering compressed air to the fuel cell; an air storage tank arranged upstream and in series with the first compressor and configured to store compressed air of high pressure; an air selection control assembly comprising a selection valve and a switch actuator configured to operate the selection valve, wherein said selection valve is arranged in between air storage tank and inlet of the first compressor, and further in fluid communication with an inlet conduit for receiving fresh air, said switch actuator being configured to operate the selection valve to selectively control flow of air to the first compressor such that air can be supplied from the air storage tank to the first compressor or from the fresh air inlet conduit to the first compressor.
Claims
1. A system for supplying compressed air to a fuel cell of a vehicle comprising: a first compressor having an inlet for receiving air and an outlet for delivering compressed air to the fuel cell; an air storage tank arranged upstream and in series with the first compressor, and configured to store compressed air of high pressure; and an air selection control assembly comprising a selection valve and a switch actuator configured to operate the selection valve; wherein the selection valve is arranged in between the air storage tank and the inlet of the first compressor, and further in fluid communication with an inlet conduit for receiving fresh air; wherein the switch actuator is configured to operate the selection valve to selectively control a flow of air to the first compressor such that air can be supplied from the air storage tank to the first compressor or from the fresh air inlet conduit to the first compressor.
2. The system of claim 1, wherein the air selection control assembly is controllable to control the flow of air in response to a determined air characteristic level such that a supply of air to the first compressor is provided from the air storage tank if the determined air characteristic level is below a threshold value.
3. The system of claim 1, wherein the air selection control assembly is controllable to control the flow of air from the fresh air inlet conduit to the first compressor during normal operation of the vehicle at normal ambient pressure.
4. The system of claim 1, further comprising a control unit in communication with the switch actuator of the air selection control assembly, wherein the switch actuator is configured to operate the selective valve on the basis of instructions from the control unit.
5. The system of claim 1, further comprising a pressure reduction system arranged in between the first compressor and the air storage tank, the pressure reduction system being configured to reduce the pressure of the high pressure compressed air.
6. The system of claim 1, wherein the air storage tank is further arranged in fluid communication with a second compressor for receiving and compressing ambient air and for delivering the compressed air to the air storage tank.
7. The system of claim 6, wherein the second compressor is arranged to operate from recuperation of brake energy from a braking event.
8. The system of claim 7, wherein the second compressor is drivingly connected to a motor operable from produced power from regenerative braking, whereby the air storage tank is filled, or re-filled, with compressed air from the second compressor during the braking event.
9. The system of claim 1, further comprising a charge air cooler (CAC) arranged in between the first air compressor and the fuel cell, and configured to reduce the temperature of the compressed air prior to being supplied to the fuel cell.
10. The system of claim 1, further comprising a humidifier arranged in between the first air compressor and the fuel cell, and configured to control the humidity of the compressed air prior to being supplied to the fuel cell.
11. A fuel cell system comprising a fuel cell stack and the system of claim 1, wherein the system is in fluid communication with the fuel cell stack.
12. An electric powertrain system for a vehicle, comprising the fuel cell system of claim 1, a battery system, and an electrical machine, wherein the fuel cell system and the battery system are selectively connectable to the electrical machine.
13. A vehicle comprising the electric powertrain system according to claim 12 for providing propulsion to the vehicle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The above, as well as additional objects, features and advantages of the present disclosure, will be better understood through the following illustrative and non-limiting detailed description of exemplary embodiments of the present disclosure, wherein:
[0037]
[0038]
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE DISCLOSURE
[0039] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which an exemplary embodiment of the disclosure is shown. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein; rather, the embodiment is provided for thoroughness and completeness. Like reference character refer to like elements throughout the description.
[0040] With particular reference to
[0041]
[0042] While FCEVs may be configured in several different manners, the FCEV 10 in
[0043] The FCEV 10 illustrated in
[0044] In order to power the vehicle 10 in an efficient and reliable manner, the fuel cell stack 22 may generally need to be integrated with the above components and other components to form a complete fuel cell system. Such components may relate to the flow systems to the fuel cell stack 22, including the hydrogen supply system to an anode side of the fuel cell stack, an air supply system to an cathode side of the fuel cell stack, a coolant supply system to the cooling channel(s) of the fuel cell stack and possibly also water supply to a humidifier to humidify the hydrogen and the air flows.
[0045] These flow systems and other parts of the fuel cell system 20 are generally controlled by a control unit 90, as illustrated in
[0046] In regard to the fuel cell stack 22 of the fuel cell system 20, each one of the fuel cells making up the fuel cell stack 22 generally comprises the anode side receiving hydrogen as a fuel component and the cathode side receiving compressed air as another fuel component. While there are several different types of fuel cells, distinguished mainly by the type of electrolyte used, a so-called Proton Exchange Membrane (PEM) fuel cell is particularly suitable for use in heavy-duty vehicles, such as the vehicle in
[0047] PEM fuel cells have high power density, a solid electrolyte and also a long operational lifetime. PEM fuel cells generally operate in a temperature range of 50 to 100 degrees C. The PEM fuel cell is configured to create electricity from two reactants, hydrogen and oxygen, such as compressed air. Similar to the operation of a battery, the fuel cell contains two electrodes, i.e. an anode and a cathode. The anode and cathode electrodes are typically composed of carbon paper or cloth. These electrodes are separated by a catalyst-coated membrane. The membrane is thus sandwiched between the two electrodes (anode and cathode). The membrane is typically made from a highly conductive material such as Nafion or the like. Hydrogen, stored in the hydrogen storage system 26 (
[0048] The anode, membrane and cathode are generally sealed together to form a single membrane electrolyte assembly, commonly denoted as the MEA of the fuel cell. Generally, the fuel cell stack further comprises a plurality of bipolar plates arranged in-between the MEAs to form the fuel cell stack configuration of the fuel cell stack 22. The bipolar plate is configured to distribute the hydrogen and compressed air over the active surface area of the fuel cell. Generally, the bipolar plates are further configured to conduct electrical current from the anode of one fuel cell to the cathode of a consecutive fuel cell. Thus, the bipolar plates provide electrical conduction between the cells and removes heat from the active areas. While bipolar plates may differ for different applications, the bipolar plates are generally made of graphite or stamped metal. Moreover, it should be appreciated that the fuel cell stack 22 may comprise conventional end plates that further support the fuel stack 22 as well as a surrounding gasket to prevent the gases from escaping from between the bipolar plates of the fuel cell stack 22.
[0049] In addition, the fuel cell system 22 typically comprises a coolant system (not shown) for cooling the fuel cells of the fuel cell stack 22. The coolant system is connected to a coolant circuit, which has an electrically operated feed pump that circulates a coolant therein. The process heat created in the operation of the fuel cell(s) may be emitted to the environment via a radiator, which may likewise be located within the coolant circuit.
[0050] Due to the various flow systems of the fuel cell system 20, the fuel cell stack 22 comprises a number of inlets and outlets, as is generally known in the art, such as a cathode inlet and a cathode outlet, an anode inlet and an anode outlet, and a coolant inlet and a coolant outlet. The FCEV may also include other components as is commonly known in the field of fuel cell systems, and thus not further described herein. The above components and systems may collectively be denoted as the balance of plant of the FCEV 10, which is a common term used within FCEVs. The balance of plant refers to and encompasses typically all components of the fuel cell system except the fuel cell stack itself.
[0051] Referring now to
[0052] The system 30 is arranged to supply compressed air to the fuel cell(s) of the fuel cell stack 22, as illustrated in
[0053] The first compressor 33 is configured to pressurize air. The first compressor may be of a conventional compressor type, such as an electrical first compressor or a mechanical first compressor 33. The first compressor 33 comprises an inlet 91 for receiving air from the fresh air inlet conduit 51. In this example, the first compressor 33 is arranged in direct fluid communication with the atmosphere, indicated by reference numeral 93, for receiving the fresh air, as illustrated in
[0054] The first compressor 33 also comprises an outlet 92 for delivering compressed air to the fuel cell stack 22. The compressed air is supplied to the cathode side of the fuel cell stack 22 via a conduit of the fluid circuit 60 to an air inlet of the cathode side of the fuel cell stack 22, which is arranged to receive the compressed air for delivery to the cathode side of the fuel cells of the fuel cell stack 22. The air inlet of the cathode side of the fuel cell stack is indicated by reference numeral 94 in
[0055] While the outlet 92 of the first compressor 33 may in some examples be directly connected to the fuel cell stack 22, the system 30 typically comprises a charge air cooler, CAC, 32 and a humidifier 31 disposed in the fluid circuit 60 between the first compressor 33 and the fuel cell stack 22, as also illustrated in
[0056] More specifically, the system 30 optionally comprises the CAC 32 arranged in-between the first air compressor 33 and the humidifier 31. The CAC 32 is configured to reduce the temperature of the compressed air downstream, and prior to being supplied to, the fuel cell(s) of the fuel cell stack 22. The CAC 32 is integrated into the system 30 due to the high temperature of the air leaving the first compressor 33. Therefore, the CAC 32 may be used to reduce the compressed air temperature before the compressed air enters the fuel cell stack 22.
[0057] As also illustrated in
[0058] The system 30 also comprises an air storage tank 35, as illustrated in
[0059] As illustrated in
[0060] In order to deliver compressed air to the air storage tank 35 in an efficient and simple manner, the air storage tank 35 is here arranged in fluid communication with a second compressor 36, as illustrated in
[0061] The air supply to the second compressor 36 can be provided in several different manners. As illustrated in
[0062] Optionally, the second compressor 36 is arranged to operate from recuperation of brake energy from a braking event. As such, the second compressor 36 is operable to absorb energy generated from the braking event. To this end, the second compressor 36 is arranged to receive power from the electrical machine 78. In other words, in the FCEV 10, the electrical machine(s) may often be used for braking while driving downhill. In such driving situations, a huge amount of generated power and energy needs to be stored somewhere or dissipated. If the battery system, or any other energy storage system, is small, the generated energy and power needs to be dissipated using retarder devices which results in wastage of energy. In this context, the second compressor 36 is configured to be used to absorb some part of this brake power and subsequently use it to compress air to a higher pressure, which can be stored in the air storage tank 35 to be used at later stage, for example at high altitudes. Such configuration allows for providing an electrical powertrain system where energy is recuperated more effectively without oversizing the battery system or any other energy storage system.
[0063] In addition, or alternatively, the second compressor may be an electrically operated compressor powered directly by the battery system 76.
[0064] As mentioned above, the system 30 also comprises the air selection control assembly 38, as shown in
[0065] In the present case, the selection valve 38a is a conventional selection valve comprising a first inlet 96 for the air storage tank 35 and a second inlet 97 for the fresh air inlet conduit 51. Accordingly, the selection valve 38a is arranged in fluid communication with the air storage tank 35 and the first compressor 33. The selection valve 38a is also in fluid communication with the atmosphere at 93 for receiving fresh air. In addition, the selection valve 38a comprises an outlet 98 to the first compressor 33. By this arrangement, the air selection control assembly 38 is configured to control the supply of air to the first compressor 33 via the selection valve 38a and the switch actuator 38b, such that air is either supplied from the fresh air inlet conduit 51 or from the air storage tank 35. The selection valve 38a may be actuated pneumatically or electrically by means of the switch actuator 38b, as is commonly known in the art. During normal operation of the fuel cell system and the vehicle, the selection valve 38a is generally set in a first user configuration where fresh air is received from the fresh air inlet conduit 51 and subsequently transferred to the first compressor 33. However, in more demanding driving situations where the vehicle is requiring a high-power demand and/or at high altitudes, the air characteristics of the air from the surroundings of the vehicle may not be sufficient for operating the fuel cell stack 22. In such situations, there is thus more favorable to supply stored compressed air from the air storage tank 35. Hence, when there is a demand for using compressed air from the air storage tank 33, the selection valve 38a is controlled to switch to a second user configuration, in which compressed air is received from the air storage tank 35. While there are several different configurations of designing the air selection control assembly 38, the air selection control assembly 38 illustrated in
[0066] In regard to the further operation of the air selection control assembly 38, the air selection control assembly 38 is here controllable in response to a control signal from the control unit 90. The air selection control assembly 38 is thus configured to control the supply of air to the first compressor 33 in response to a signal from the control unit 90 indicating an inadequate level of pressure at the inlet 91 of the first compressor 33 as compared to the pressure level at the sea level.
[0067] The control signal generally contains data with respect to a determined air characteristic level of the air surrounding the vehicle, i.e. the atmospheric air. By way of example, the air characteristic level is any one of an ambient pressure level and an air quality level. The ambient pressure level may typically be determined by a sensor, such as a pressure sensor arranged to monitor the ambient pressure outside the vehicle. Analogously, the air quality level may be determined by a suitable sensor configured to measure the quality of the air outside the vehicle. Based on data from at least one of these sensors, the air selection control assembly 38 can be controlled to switch between receiving air from the fresh air inlet conduit 51 and receiving compressed air from the air storage tank 35. Generally, the air selection control assembly 38 is controllable to direct air from the fresh air inlet conduit 51 to the first compressor 33 during substantially normal operation of the vehicle at normal ambient pressure and direct air from the air storage tank 35 to the first compressor 33 during a high-load operation of the vehicle at high-pressure atmospheric level.
[0068] Accordingly, by the arrangement of the air storage tank 35 in combination with the air selection control assembly 38 and the first compressor 33, it becomes possible to control air supply to the first compressor 33, either by directing air from the air storage tank 35 to the first compressor 33, e.g. at high altitudes, or directing fresh air from the fresh air inlet conduit 51 to the first compressor 33, e.g. at sea level. By arranging the air storage tank 35 in series with the first compressor 33, it becomes possible to store compressed air at high pressure in various operating situations of the fuel cell. By way of example, when the fuel cell of the vehicle is operated at high altitudes, the stored compressed air can be expanded and transferred to the air supply system of the fuel cell at a 1 bar pressure (at 4000 m ambient pressure is likely to be about 0.6 bar). In this manner, the system 30 allows for providing the same pressure at the inlet 91 of the first compressor 33 as at the sea level. As such, the system 30 is configured to improve the reliability of the fuel cell system during driving situations at high altitudes where the atmospheric pressure level is inadequate for operating the first compressor 33.
[0069] More specifically, during the normal operation of the FCEV 10, e.g. at sea level and low altitudes, the air selection control assembly 38 is arranged in the first user configuration where the first compressor 33 is connected directly to the atmospheric condition. However, when the control unit 90 detects that there is a significant pressure loss upstream of the first compressor 33, e.g. due to high altitude, the air supply is switched using the air selection control assembly 38 from atmospheric to the one stored in the air storage tank 35. By using a pressure reduction system 34, as further described herein, the air from the air storage tank 35 can be provided to the first compressor 33 at 1 bar pressure, thus enabling the fuel cell to deliver the same power as at sea level.
[0070] Then, during the braking operation (normal driving situation or while driving downhill), the electric machine(s) 78 produces electrical power which can be used to operate the second compressor 36 using a high voltage motor 73, as illustrated in
[0071] It should be noted that the operation of delivering compressed air from the air storage tank 35 to the first compressor 33 may generally also be controlled in view of the prevailing capacity of the air storage tank. By way of example, the system 30 is further controlled based on the prevailing pressure in the air storage tank 35 and the volume of the air storage tank 35. Thus, it should also be readily appreciated that the actual amount of air flow may be controlled in cooperation with other operational data of the fuel cell system and the vehicle. Such data may generally be gathered by conventional sensors, such as pressure and temperature sensors, and subsequently stored in the control unit 90, or in the ECU.
[0072] It should also be readily appreciated that the control unit 90 can be a part of an electronic control unit (ECU) for controlling the vehicle and various parts of the vehicle. In particular, the control unit 90 is arranged in communication with the fuel cell system 20 and the system 30. It may also be conceivable that the system 30 itself comprises the control unit 90 configured to allow control of the air selection control assembly 38 and the other components making up the system 30 so as to control the flow of air to the first compressor 33. It should be noted that the precise control of the system 30 and the air selection control assembly 38 depends on the particular application and the particular operation conditions.
[0073] In the example embodiment illustrated in
[0074] In
[0075] It should be noted that the configuration of the FCEV 10 and the fuel cell system 20 illustrated in
[0076] Moreover, the electrical powertrain system may include or be connected to a bi-directional charging port capable of both receiving energy from and providing energy to an external power supply. Such an external power supply may for example be a charging station connected to the power grid, a battery or another vehicle. The electrical powertrain system 24 can be considered to comprise one or more electrical machines connected to one or more wheels 80 of the vehicle, either directly or via a transmission arrangement (not shown). The vehicle may further comprise a combustion engine (not shown) for vehicle propulsion, and the combustion engine, battery, and fuel cells can together be controlled to provide power to the vehicle in an efficient manner.
[0077] As mentioned above, the present disclosure provides a system 30 and a fuel cell system 20 capable of providing compressed air to the fuel cell(s) of the fuel cell stack with a substantially equal pressure in a more reliable manner for different altitudes of the fuel cell stack and vehicle above sea level. That is, the system 30 allows for providing essentially the same pressure at the inlet of the first compressor 33 as the pressure level at the sea level. Hereby, there is provided an improved operation of the FCEV at high altitudes. To this end, the system 30 contributes to a more reliable operation of the fuel cell system in that a substantially same level of power as at sea level can be delivered also for a sufficient duration at high altitudes.
[0078] The system 30 can be incorporated into a fuel cell system 20 for a vehicle 10, such as an electric vehicle. In this type of application, the system 30 is in fluid communication with the fuel cell(s) of the fuel cell stack 22. As schematically illustrated in
[0079] It is to be understood that the present disclosure is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.