Abstract: This application relates to cast enclosures for battery replacement application, such as enclosures configured to house power units comprising a fuel cell and an energy storage device. The enclosures function as protective enclosures and counterweights, provide mounting points and conduits for gases, fluids, plumbing and wiring, and serve as thermal energy storage/transfer devices. The enclosures are formed in a mold or die and comprise wall portions defining a plurality of internal subcompartments for receiving the various system components. In one embodiment of the invention channels may be formed in the wall portions of the enclosures for circulating a heat transfer fluid therethrough.

Abstract: This application relates to a fuel dispensing system and method for safely regulating transfer of fuel between a fuel dispenser and a fuel recipient. The fuel dispensing system may be used, for example, to replenish electric vehicles that use refillable electrochemical power generation systems, such as fuel cell hybrid systems using hydrogen fuel. The system employs a combination of interlocks and other safety features specifically adapted for high-risk indoor environments. Fueling cannot commence until the dispenser and the recipient are electrically bonded to minimize the risk of spark generation. The system may include, for example, a fuel supply subsystem for preventing fuel flow except during a fueling session, an immobilization subsystem for preventing relative movement of the dispenser and the recipient during a fueling session, a communication subsystem for enabling data exchange between the dispenser and the recipient, and a leak detection subsystem for monitoring the fueling site for fuel leaks.

Abstract: A method and apparatus for digitally controlling the average input current of a switch mode power supply are disclosed. In preferred embodiments, the switch mode power supplies are DC-DC converters. One aspect of the invention relates to a method for controlling the switch of a switch mode power supply by digitally sampling the input current once during each power supply switching cycle at a time that is synchronized with the switching cycle. The predetermined time at which the input current is sampled may be midway through the time that the switch is in the “ON” state. This midway time may also be delayed slightly to compensate for delays associated with the switch.

Abstract: This application relates to a hybrid power supply apparatus comprising a fuel cell and an energy storage device for use in off-road electric vehicles, such as lift trucks. The apparatus is a substitute for conventional lead acid batteries and is sized to fit within a conventional lift truck battery receptacle tray. The fuel cell and fuel processor systems are designed to meet the average load requirements of the vehicle, while the batteries and power control hardware are capable of responding to very high instantaneous load demands. The invention has a similar electrical interface as conventional battery systems and does not require vehicle modification. The apparatus is air-cooled to ensure that the hybrid power components operate within a preferred temperature range and to maintain the external surfaces of the apparatus and exhaust gases within safe temperature limits.

Abstract: This application relates to a hybrid power supply apparatus including a fuel cell and an energy storage device for use in off-road electric vehicles, such as lift trucks. The apparatus is a substitute for conventional lead acid batteries and is sized to fit within a conventional lift truck battery receptacle tray. The fuel cell and fuel processor systems are designed to meet the average load requirements of the vehicle, while the batteries and power control hardware are capable of responding to very high instantaneous load demands. The invention has a similar electrical interface as conventional battery systems and does not require vehicle modification. The apparatus is air-cooled to ensure that the hybrid power components operate within a preferred temperature range and to maintain the external surfaces of the apparatus and exhaust gases within safe temperature limits.

Abstract: This application relates to a fuel dispensing system and method for safely regulating transfer of fuel between a fuel dispenser and a fuel recipient. The fuel dispensing system may be used, for example, to replenish electric vehicles that use refillable electro-chemical power generation systems, such as fuel cell hybrid systems using hydrogen fuel. The system employs a combination of interlocks and other safety features specifically adapted for high-risk indoor environments. Fueling cannot commence until the dispenser and the recipient are electrically bonded to minimize the risk of spark generation. The system may include, for example, a fuel supply subsystem for preventing fuel flow except during a fueling session, an immobilization subsystem for preventing relative movement of the dispenser and the recipient during a fueling session, a communication subsystem for enabling data exchange between the dispenser and the recipient, and a leak detection subsystem for monitoring the fueling site for fuel leaks.

Abstract: This application relates to a method and system for controlling the supply of fuel to a dead-ended hydrogen fuel cell. The invention may be utilized, for example, to more efficiently integrate the operation of a hydrogen fuel cell and a hydrogen generator, such as a reformer coupled with a hydrogen separation unit. The invention ensures that the production and consumption of hydrogen are effectively balanced to avoid negative feed line pressure fluctuations. The fuel supply control subsystem and hydrogen consumption control subsystems are, however, “decoupled” and hence independently operable. The invention may include an accumulator disposed in a flow path between the hydrogen generator and the fuel cell for storing hydrogen under pressure. The accumulator is sufficiently large in volume such that the pressure of hydrogen in the flow path does not deviate substantially from a target pressure, even during the waste purging sessions.

Abstract: This application relates to a hybrid power supply apparatus comprising a fuel cell and an energy storage device for use in off-road electric vehicles, such as lift trucks. The apparatus is a substitute for conventional lead acid batteries and is sized to fit within a conventional lift truck battery receptacle tray. The fuel cell and fuel processor systems are designed to meet the average load requirements of the vehicle, while the batteries and power control hardware are capable of responding to very high instantaneous load demands. The invention has a similar electrical interface as conventional battery systems and does not require vehicle modification. The apparatus is air-cooled to ensure that the hybrid power components operate within a preferred temperature range and to maintain the external surfaces of the apparatus and exhaust gases within safe temperature limits.

Abstract: A self-regulated system and method for cooling switching power supplies that take parasitic effects of switching which would normally be dissipated as heat in a typical RC snubber circuit, and use that waste energy to power a cooling element to automatically cool semiconductor switches of the power supplies and any DC or AC systems. The cooling element can be a variable speed fan, a liquid pump, a Peltier device, or the like, in which case the system and method provide power to the cooling element in proportion to the amount of current delivered to the power supply, and so the cooling system automatically adjusts itself to the level needed to protect the power supply.

Abstract: This application relates to a method and system for controlling the supply of fuel to a dead-ended hydrogen fuel cell. The invention may be utilized, for example, to more efficiently integrate the operation of a hydrogen fuel cell and a hydrogen generator, such as a reformer coupled with a hydrogen separation unit. The invention ensures that the production and consumption of hydrogen are effectively balanced to avoid negative feed line pressure fluctuations. The fuel supply control subsystem and hydrogen consumption control subsystems are, however, “decoupled” and hence independently operable. The invention may include an accumulator disposed in a flow path between the hydrogen generator and the fuel cell for storing hydrogen under pressure. The accumulator is sufficiently large in volume such that the pressure of hydrogen in the flow path does not deviate substantially from a target pressure, even during the waste purging sessions.

Abstract: This application relates to a system and method for regulating the temperature of a self-contained fuel cell apparatus preferably comprising a fuel reformer. The invention maintains the various components of the fuel cell apparatus within preferred operating temperature ranges while ensuring that exhaust gases and external surfaces of the apparatus do not exceed safe temperature levels. The invention is particularly suited for self-contained hybrid power supply applications, for example for non-road electric vehicles. The various components of the apparatus are strategically configured relative to air flow paths to fully utilize the cooling capacity of the process stream and minimize parasitic loads. In some embodiments the inlet air is pre-heated to enable operation of the apparatus in low temperature environments, such as industrial freezers.

Abstract: A self-regulated system and method for cooling switching power supplies that take parasitic effects of switching which would normally be dissipated as heat in a typical RC snubber circuit, and use that waste energy to power a cooling element to automatically cool semiconductor switches of the power supplies and any DC or AC systems. The cooling element can be a variable speed fan, a liquid pump, a Peltier device, or the like, in which case the system and method provide power to the cooling element in proportion to the amount of current delivered to the power supply, and so the cooling system automatically adjusts itself to the level needed to protect the power supply.

Abstract: A system and method for improving the performance of a hybrid power supply apparatus comprising a power generating device, such as a fuel cell, and a primary energy storage device, such as a battery. The purpose of the invention is to provide an equalization charge to the battery from a source other than the fuel cell when the battery achieves a predetermined state of charge condition, thereby avoiding the need to operate the fuel cell in a low power output mode. When the predetermined state of charge condition is detected by a controller, the fuel cell is shut-down. In one aspect of the invention the equalization charge is provided to the battery by a secondary energy storage device, such as a plurality of capacitors or secondary batteries. The predetermined state of charge condition may be satisfied, for example, when the state of charge of the battery exceeds a predetermined threshold, such as 80% of the battery's storage capacity, for a predetermined period of time.

Abstract: This application relates to a hybrid power supply apparatus comprising a fuel cell and an energy storage device for use in off-road electric vehicles, such as lift trucks. The apparatus is a substitute for conventional lead acid batteries and is sized to fit within a conventional lift truck battery receptacle tray. The fuel cell and fuel processor systems are designed to meet the average load requirements of the vehicle, while the batteries and power control hardware are capable of responding to very high instantaneous load demands. The invention has a similar electrical interface as conventional battery systems and does not require vehicle modification. The apparatus is air-cooled to ensure that the hybrid power components operate within a preferred temperature range and to maintain the external surfaces of the apparatus and exhaust gases within safe temperature limits.

Abstract: This application relates to a control system and method for use in a hybrid power supply apparatus comprising a current generating device, such as a fuel cell, and an energy storage device, such as a battery. The invention ensures that the fuel cell operates in a quasi steady state mode irrespective of fluctuations in load power demands. By restricting the operation of the fuel cell to discrete steady modes with minimal state changes, the useful service life of the fuel cell is prolonged. The control scheme ensures that the current generating device will run in a near steady mode even in the presence of a dynamic load.

Abstract: This application relates to a control system and method for use in a hybrid power supply apparatus comprising a current generating device, such as a fuel cell, and an energy storage device, such as a battery. The invention ensures that the fuel cell operates in a quasi steady state mode irrespective of fluctuations in load power demands. By restricting the operation of the fuel cell to discrete steady modes with minimal state changes, the useful service life of the fuel cell is prolonged. The control scheme ensures that the current generating device will run in a near steady mode even in the presence of a dynamic load.

Abstract: A system and method for improving the performance of a hybrid power supply apparatus comprising a power generating device, such as a fuel cell, and a primary energy storage device, such as a battery. The purpose of the invention is to provide an equalization charge to the battery from a source other than the fuel cell when the battery achieves a predetermined state of charge condition, thereby avoiding the need to operate the fuel cell in a low power output mode. When the predetermined state of charge condition is detected by a controller, the fuel cell is shut-down. In one aspect of the invention the equalization charge is provided to the battery by a secondary energy storage device, such as a plurality of capacitors or secondary batteries. The predetermined state of charge condition may be satisfied, for example, when the state of charge of the battery exceeds a predetermined threshold, such as 80% of the battery's storage capacity, for a predetermined period of time.

Abstract: This application relates to a system and method for regulating the temperature of a self-contained fuel cell apparatus preferably comprising a fuel reformer. The invention maintains the various components of the fuel cell apparatus within preferred operating temperature ranges while ensuring that exhaust gases and external surfaces of the apparatus do not exceed safe temperature levels. The invention is particularly suited for self-contained hybrid power supply applications, for example for non-road electric vehicles. The various components of the apparatus are strategically configured relative to air flow paths to fully utilize the cooling capacity of the process stream and minimize parasitic loads. In some embodiments the inlet air is pre-heated to enable operation of the apparatus in low temperature environments, such as industrial freezers.