Abstract: A heatable cryo-valve for a cryogenic tank storing liquid hydrogen. In one embodiment, the cryo-valve includes a valve plate mounted to a valve body by a spring. The spring forces the valve plate against a valve seat to prevent hydrogen from flowing through the cryo-valve when the valve is in a closed position. A resistive heating device is position proximate the valve plate. An electrical current applied to the heating device causes the device to expand, which pushes the device against the valve plate and against the bias of the spring to move the valve plate off of the valve seat and allow hydrogen to flow therethrough. The cryo-valve can be designed so that the heating device does not come in direct contact with the liquid hydrogen.

Abstract: An isolation fault detection system for detecting isolation faults in a fuel cell system associated with a fuel cell hybrid vehicle. The isolation fault detection system measures a stack voltage potential, a positive fuel cell voltage potential, a negative fuel cell voltage potential, a positive battery voltage potential, and an overall battery voltage potential. The isolation fault detection system then uses these voltage potentials in mesh equations to compare the measured voltage potentials to voltage potentials that would occur during a loss of isolation. In one embodiment, the isolation fault detection system uses these five measured voltage potentials to determine whether an isolation fault has occurred at four separate locations in the fuel cell hybrid vehicle. The system also can detect the location of the isolation fault.

Abstract: A system and method for determining vehicle CG height and mass in real-time. The method includes selecting a set of vehicle parameters to be considered that includes the vehicle mass and the center of gravity height of the vehicle. Frequency responses are generated using the dynamic model and a plurality of different values for the selected vehicle parameters. During vehicle operation, frequency responses are calculated from a measured vehicle lateral acceleration to a roll angle and/or a roll rate of the vehicle. The generated frequency responses and the calculated frequency responses are compared to determine which of the generated frequency responses more closely matches the calculated frequency responses. The generated frequency responses that most closely match the calculated frequency responses are used to determine the center of gravity height and the vehicle mass from the values for the vehicle parameters.

Abstract: A primary reactor for a fuel processor system that employs steam and air to convert a liquid hydrocarbon fuel into a hydrogen-rich gas stream. The liquid fuel and an air-steam mixture are mixed in a mixing region within the reactor. The fuel mixture is then directed through an electrically heated catalyst region that heats the mixture to the operation temperature of a light-off catalyst at system start-up. The heated fuel mixture is then directed through a light-off catalyst monolith where the hydrocarbon fuel is dissociated. Once the fuel mixture is heated to the operating temperature of the light-off catalyst, the electrically heated catalyst region is turned off because the exothermic reaction in the light-off catalyst monolith generates the heat necessary to sustain the catalytic reaction.

Abstract: A system and method for reducing cathode carbon corrosion during start-up of a fuel cell stack. If a long enough period of time has gone by since the last system shutdown, then both the anode side and the cathode side of the stack will be filled with air. If the system includes split sub-stacks, then a start-up sequence uses a fast hydrogen purge through each sub-stack separately so as to minimize the time of the hydrogen/air front flowing through the anode side of the stacks. The start-up sequence then employs a slow hydrogen purge through the sub-stacks at the same time. If the time from the last shutdown is short enough where a significant amount of hydrogen still exists in the cathode side and the anode side of the sub-stacks, then the fast hydrogen purge can be eliminated, and the start-up sequence proceeds directly to the slow hydrogen purge.

Abstract: A fuel cell system that controls an anode exhaust gas bleed during power up-transients. The fuel cell system includes a by-pass valve that allows compressor air to by-pass the fuel cell stack and be directly emitted into the cathode exhaust gas stream. The system detects a power up-transient by monitoring the rate of closing of the by-pass valve and the rate of change of an increase in the compressor airflow set-point. If these parameters pass a certain threshold, then the system determines that a power up-transient is occurring, and prevents an anode exhaust gas bleed for a predetermined period of time. If cathode pulsing is occurring where power up-transients come one after another, then the system will continuously reset the time period for preventing the anode exhaust gas bleed until a second time limit is reached, where the bleed is then forced.

Abstract: A system and method for determining whether a fuel cell stack is overheating. The system measures the temperature of end cells in the stack using end cell temperature sensors, and calculates an average end cell temperature based on the end cell temperature measurements. The system also measures the temperature of a cooling fluid being output from the fuel cell stack. The system determines if any of the measured end cell temperatures are outlying by comparing each end cell temperature measurement to the average. The system determines that the cooling fluid outlet temperature sensor has possibly failed if the cooling fluid outlet temperature is greater than the average end cell temperature and the cooling fluid outlet temperature minus the average end cell temperature is greater than a predetermined temperature value.

Abstract: A low cost radar system that employs monopulse beamforming to detect objects in the road-way both in elevation and azimuth. In one non-limiting embodiment, a beamforming receiver architecture includes a first beamforming device and a plurality of antennas coupled to the first beamforming device, and a second beamforming device and a plurality of antennas coupled to the second beamforming device. The first and second beamforming devices are oriented 90° relative to each other so that the receive beams provided by the first beamforming device detect objects in azimuth and the receive beams provided by the second beamforming device detect objects in elevation. A first switch is provided to selectively couple the sum pattern signal from the first and second beamforming devices to one output line, and a second switch is provided to selectively couple the difference pattern signals from the first and second beamforming devices to another output line.

Abstract: A system and method for identifying a person as an authorized driver of a vehicle based on settings of the vehicle. The system includes a sensor for detecting a presence of a driver in the vehicle. The system also includes one or more control modules corresponding to the parameters of the vehicle. The parameters can be controlled by the control modules. The system also includes a driver ID controller coupled to the control modules and the sensor. The driver ID controller is configured to recognize the driver as an authorized driver based on inputs from the sensor and the control modules. The driver ID controller can also command the control units to adjust the parameters to predefined one or more attributes corresponding to the authorized driver.

Abstract: A hybrid fuel cell system that employs a fuel cell stack and an ultracapacitor. A diode is provided on a high voltage electrical bus between the fuel cell stack and the ultracapacitor so that high voltage from the ultracapacitor does not affect the operation of the fuel cell stack. During system start-up, a by-pass switch is closed to by-pass the ultracapacitor so that power from the ultracapacitor can be used to start various system loads, such as a cathode side air compressor that provides air to the fuel cell stack. A 12 volt-to-high voltage converter is employed to provide a low power, high voltage supply from a low voltage battery to the system loads at start-up when the by-pass switch is opened, but before a fuel cell stack switch is closed.

Abstract: A fuel cell system that employs a technique for safely removing hydrogen gas that accumulates within a cooling fluid reservoir. The fuel cell system includes a fuel cell stack and a compressor for providing airflow to the cathode side of the fuel cell stack. The system also includes an air filter box having an air filter that is in fluid communication with an air pocket in the reservoir. The air intake to the compressor flows through the air filter box, and sucks the gas from the reservoir, which is then sent to the cathode side of the fuel cell stack to be converted to water by the electro-chemical reaction therein.

Abstract: A system and method for estimating vehicle states, such as vehicle roll-rate, vehicle roll angle, vehicle lateral velocity and vehicle yaw-rate, for use in rollover reduction. The system includes an extended Kalman filter observer responsive to a steering angle signal, a yaw-rate signal, a roll-rate signal, a speed signal and a lateral acceleration signal that calculates an estimated yaw-rate signal, an estimated roll-rate, an estimated roll angle and an estimated lateral velocity. The system also includes a lateral velocity estimation processor responsive to the roll-rate signal, the estimated roll angle signal, the estimated lateral velocity signal and the lateral acceleration signal that calculates a modified lateral velocity estimation signal when the vehicle is operating in a non-linear region.

Abstract: A fuel cell system that provides a flow of anode exhaust gas into the cathode side of the fuel cells without allowing the anode exhaust gas flow and the cathode input flow to mix in a large volume. In one embodiment, strategically positioned perforations in the MEAs allow the anode exhaust gas to cross over to the cathode channels near the cathode input. These perforations could be provided as an array of small holes in an MEA sub-gasket or an MEA carrier frame. In an alternate embodiment, openings are provided through the bipolar plates that allow the anode exhaust to flow into the cathode channels. This configuration would require a special anode half-plate at one end of the stack to provide the opening.

Abstract: A system for controlling the power output of a fuel cell stack and a battery in a hybrid fuel cell system. The system includes a power damping filter that receives a power request signal, and damps the request to reduce large changes in the power request. A battery state of charge controller receives the difference between a battery state of charge set-point and the actual battery state of charge, and provides a battery power signal that attempts to maintain the battery state of charge at the set-point. The damped power signal and the battery power signal are added to generate a system power demand signal that satisfies the driver power request using the battery power and fuel cell stack power, and uses the fuel cell stack power to charge the battery during low power transients or if the battery state of charge is below the set-point.

Abstract: A command interpreter for a vehicle stability enhancement system that uses a three degree-of-freedom vehicle model employing non-linear suspension and tire characteristics to calculate stability commands. The command interpreter includes a calculator that calculates a front tire lateral force, a calculator that calculates a rear tire lateral force and a command calculator that calculates a yaw-rate command signal, a lateral velocity command signal and a roll angle command signal. The front tire lateral force calculator and the rear tire lateral force calculator calculate the front and rear side-slip angles. The side-slip angles are then converted to a lateral force, where the conversion is selected based on the tire vertical load. The rear tire lateral force is modified for high side-slip angles so that the rear tire lateral force does not become saturated.

Abstract: An inductor that includes end core pieces and a plurality of center block core pieces between the end core pieces that define a plurality of gaps. The end core pieces are made of an amorphous alloy to provide good magnetic field properties and the center core pieces are stamped magnetic sheets forming a laminate structure to provide ease of manufacturability. In one non-limiting embodiment, the end core pieces are an amorphous iron alloy and the center core pieces are stamped silicon-iron.

Abstract: A propulsion system for a fuel cell hybrid vehicle that includes a fuel cell system and an EESS, where the propulsion system employs an algorithm for increasing system efficiency. A power limit value is defined as the maximum system efficiency times the charge/discharge efficiency of the EESS. If the vehicle operator requests a power greater than the power limit value, then the fuel cell system will preferably provide the power, and if the power request from the vehicle operator is less than the power limit value, then the EESS will preferably provide the power. The algorithm also considers changing operation conditions and parameters that impact the fuel cell system efficiency and the electric energy storage system efficiency, such as the state of charge of the EESS and regenerative braking.

Abstract: A technique for controlling the relative humidity of a cathode airflow to a fuel cell stack that includes compensating for valve non-linearities. The cathode input air flows through a water vapor transfer unit where it is humidified. The humidified cathode exhaust from the fuel cell stack is output to the water vapor transfer unit to provide the water vapor for humidifying the cathode input airflow. A first control valve controls the flow of the cathode exhaust through the water vapor transfer unit and a second control valve controls the flow of the cathode exhaust that by-passes the water vapor transfer unit to control both the relative humidity of the cathode input airflow and the pressure within the stack. By compensating for the non-linearity, the first and second valves control the relative humidity of the cathode airflow without changing the cathode output resistance.

Abstract: A hybrid fuel cell system that includes a fuel cell stack and a high voltage battery. The fuel cell system also includes a cell voltage controller that controls the average cell voltage of the cells in the fuel cell stack, a damped driver request module that damps a driver power request signal, and a power balancing module. The power balancing module maintains the cell voltage of the cells in the stack within a predetermined range, and uses excess power from the stack beyond what is requested to charge the battery. The power balancing module includes a base load limiter that prevents the cell voltage from going above a predetermined value, unless the battery is at is maximum state of charge.

Abstract: An adaptive vehicle control system that classifies a driver's driving style based on vehicle U-turn maneuvers. A process determines if the vehicle has started a turn if the yaw rate is greater than a first yaw rate threshold, and determines a vehicle heading angle based on the yaw rate and a sampling time if the vehicle has started a turn. The process then determines whether the vehicle maneuver has been completed by determining if the yaw rate is less than a second yaw rate threshold. The process then determines that the completed maneuver was a U-turn maneuver if the yaw rate is less than a third yaw rate threshold during the maneuver, the final vehicle heading angle is within a heading angle range and the duration of the maneuver is less than a predetermined time threshold. In one non-limiting embodiment, the heading angle range is between 165° and 195°.