Abstract: A humidity control system for a fuel cell stack includes a gas supply and a humidifier including an outlet and an inlet connected to the gas supply. A fuel cell stack includes an inlet that is connected to the outlet of the humidifier. A bypass line and a valve bypass gas around the humidifier to control the humidity of gas entering the fuel cell stack. The valve is located in the bypass line, between the gas supply and the humidifier, or between the humidifier and the fuel cell stack. The valve is a gas restriction valve, a throttle valve, or a directional valve. A humidity sensor generates a humidity signal based on humidity of gas entering the fuel cell stack. A controller connected to the humidity sensor and the valve controls the valve based on the humidity signal. The inlet of the fuel cell stack is one of a cathode flow line and an anode flow line of the fuel cell stack.

Abstract: A gas flow control system for a fuel cell includes a gas supply and a humidifier. A fuel cell stack includes a cathode flow line with an inlet and an outlet. The inlet of the cathode flow line is connected to the outlet of the humidifier. A combustor includes an inlet that receives gas from the outlet of the cathode flow line. A valve and a bypass line bypass gas around the humidifier and the fuel cell stack to the combustor. The valve is preferably one of a gas restriction valve, a throttle valve, and a directional valve. A gas flow sensor generates a gas flow signal based on gas flowing through at least one of the humidifier, the cathode flow line of the fuel cell stack, and the bypass line. A flow controller that is connected to the gas flow sensor and the valve controls the valve based on the gas flow signal.

Abstract: A method of operating a combustor to heat a fuel processor in a fuel cell system, in which the fuel processor generates a hydrogen-rich stream a portion of which is consumed in a fuel cell stack and a portion of which is discharged from the fuel cell stack and supplied to the combustor, and wherein first and second streams are supplied to the combustor, the first stream being a hydrocarbon fuel stream and the second stream consisting of said hydrogen-rich stream, the method comprising the steps of monitoring the temperature of the fuel processor; regulating the quantity of the first stream to the combustor according to the temperature of the fuel processor; and comparing said quantity of said first stream to a predetermined value or range of predetermined values.

Abstract: A venting methodology and system for rapid shutdown of a fuel cell apparatus of the type used in a vehicle propulsion system. H2 and air flows to the fuel cell stack are slowly bypassed to the combustor upon receipt of a rapid shutdown command. The bypass occurs over a period of time (for example one to five seconds) using conveniently-sized bypass valves. Upon receipt of the rapid shutdown command, the anode inlet of the fuel cell stack is instantaneously vented to a remote vent to remove all H2 from the stack. Airflow to the cathode inlet of the fuel cell stack gradually diminishes over the bypass period, and when the airflow bypass is complete the cathode inlet is also instantaneously vented to a remote vent to eliminate pressure differentials across the stack.

Abstract: A method and apparatus for controlling the temperature of a combustor in a fuel cell apparatus includes a fast acting air bypass valve connected in parallel with an air inlet to the combustor. A predetermined excess quantity of air is supplied from an air source to a series connected fuel cell and combustor. The predetermined excess quantity of air is provided in a sufficient amount to control the temperature of the combustor during start-up of the fuel processor when the load on the fuel cell is zero and to accommodate any temperature transients during operation of the fuel cell.

Abstract: In one aspect, the invention provides a method of operating a combustor to heat a fuel processor to a desired temperature in a fuel cell system, wherein the fuel processor generates hydrogen (H2) from a hydrocarbon for reaction within a fuel cell to generate electricity. More particularly, the invention provides a method and select system design features which cooperate to provide a start up mode of operation and a smooth transition from start-up of the combustor and fuel processor to a running mode.

Abstract: A venting methodology and pressure sensing and vent valving arrangement for monitoring anode bypass valve operating during the normal shutdown of a fuel cell apparatus of the type used in vehicle propulsion systems. During a normal shutdown routine, the pressure differential between the anode inlet and anode outlet is monitored in real time in a period corresponding to the normal closing speed of the anode bypass valve and the pressure differential at the end of the closing cycle of the anode bypass valve is compared to the pressure differential at the beginning of the closing cycle. If the difference in pressure differential at the beginning and end of the anode bypass closing cycle indicates that the anode bypass valve has not properly closed, a system controller switches from a normal shutdown mode to a rapid shutdown mode in which the anode inlet is instantaneously vented by rapid vents.

Abstract: In an improved method, the voltage of one or more cells in a fuel cell stack is monitored. The monitored voltage is compared to first and second preselected voltage values as a function of load, where the second preselected value is less than the first preselected value. Next, either a first signal is generated if the monitored voltage is less than the first preselected voltage value and greater than or equal to the second preselected voltage value; or a second signal is generated if the monitored voltage is less than the second preselected voltage value.

Abstract: A venting methodology and system for rapid shutdown of a fuel cell apparatus of the type used in a vehicle propulsion system. H2 and air flows to the fuel cell stack are slowly bypassed to the combustor upon receipt of a rapid shutdown command. The bypass occurs over a period of time (for example one to five seconds) using conveniently-sized bypass valves. Upon receipt of the rapid shutdown command, the anode inlet of the fuel cell stack is instantaneously vented to a remote vent to remove all H2 from the stack. Airflow to the cathode inlet of the fuel cell stack gradually diminishes over the bypass period, and when the airflow bypass is complete the cathode inlet is also instantaneously vented to a remote vent to eliminate pressure differentials across the stack.

Abstract: In one embodiment, the method of the invention monitors one or more of the following conditions: a relatively low temperature value of the gas stream; a relatively high temperature value of the gas stream; and a rate-of-change of monitored temperature. In a preferred embodiment, the rate of temperature change is monitored to prevent the occurrence of an unacceptably high or low temperature condition. Here, at least two temperatures of the recirculating gas stream are monitored over a period of time. The rate-of-change of temperature versus time is determined. Then the monitored rate-of-change of temperature is compared to a preselected rate-of-change of value. The monitoring of rate-of-change of temperature provides proactive means for preventing occurrence of an unacceptably high temperature in the catalytic reactor.

Abstract: A control method for monitoring a fuel cell stack in a fuel cell system in which the actual voltage and actual current from the fuel cell stack are monitored. A preestablished relationship between voltage and current over the operating range of the fuel cell is established. A variance value between the actual measured voltage and the expected voltage magnitude for a given actual measured current is calculated and compared with a predetermined allowable variance. An output is generated if the calculated variance value exceeds the predetermined variance. The predetermined voltage-current for the fuel cell is symbolized as a polarization curve at given operating conditions of the fuel cell. Other polarization curves may be generated and used for fuel cell stack monitoring based on different operating pressures, temperatures, hydrogen quantities.

Abstract: A method is provided for the shutdown of a fuel cell system to relieve system overpressure while maintaining air compressor operation, and corresponding vent valving and control arrangement. The method and venting arrangement are employed in a fuel cell system, for instance a vehicle propulsion system, comprising, in fluid communication, an air compressor having an outlet for providing air to the system, a combustor operative to provide combustor exhaust to the fuel processor.

Abstract: A method for controlling the heat output of a combustor in a fuel cell apparatus to a fuel processor where the combustor has dual air inlet streams including atmospheric air and fuel cell cathode effluent containing oxygen depleted air. In all operating modes, an enthalpy balance is provided by regulating the quantity of the air flow stream to the combustor to support fuel cell processor heat requirements. A control provides a quick fast forward change in an air valve orifice cross section in response to a calculated predetermined air flow, the molar constituents of the air stream to the combustor, the pressure drop across the air valve, and a look up table of the orifice cross sectional area and valve steps. A feedback loop fine tunes any error between the measured air flow to the combustor and the predetermined air flow.

Abstract: A method of controlling the operation of a fuel cell system wherein each shutdown command for the system is subjected to decision logic which determines whether the command should be a normal shutdown command or rapid shutdown command. If the logic determines that the shutdown command should be a normal shutdown command, then the system is shutdown in a normal step-by-step process in which the hydrogen stream is consumed within the system. If the logic determines that the shutdown command should be a rapid shutdown command, the hydrogen stream is removed from the system either by dumping to atmosphere or routing to storage.