Abstract: A multi-function fuel delivery system and method of providing fuel delivery is provided that addresses space-related and cost related challenges as well as other challenges by combining a noise attenuating function, a hydrogen heating function, and a fuel supply rail capable of supplying hydrogen to multiple injectors within a single volume where a heat-transfer core utilizes an existing available internal volume of an attenuating volume or a fuel rail of a hydrogen supply manifold. A hydrogen fuel manifold, a hydrogen heat exchanger, and a fuel rail are housed in a single chamber such that a hydrogen fuel heating/cooling function, a hydrogen fuel noise/vibration attenuating function, providing the heat to the heat-transfer core, and providing the noise-attenuated H2 are performed in the single chamber.

Abstract: A process for detecting a low-level leak in a fuel cell system is provided. The process includes, within a computerized fuel cell controller, operating programming to monitor operation of the fuel cell system, determine an expected reduction in pressure within an anode gas loop of the fuel cell system based upon the monitored operation, determine a calibrated threshold pressure change based upon the expected reduction in pressure and a margin selected to indicate excess hydrogen gas within the anode gas loop indicating a fuel injector leak, when a fuel injector of the fuel cell system is commanded to a closed state, monitor a pressure within the anode gas loop through a time period, compare the monitored pressure within the anode gas loop through the time period to the calibrated threshold pressure change, and when the comparing indicates the excess hydrogen gas is present, taking remedial action.

Abstract: A process for detecting a low-level leak in a fuel cell system is provided. The process includes, within a computerized fuel cell controller, operating programming to monitor operation of the fuel cell system, determine an expected reduction in pressure within an anode gas loop of the fuel cell system based upon the monitored operation, determine a calibrated threshold pressure change based upon the expected reduction in pressure and a margin selected to indicate excess hydrogen gas within the anode gas loop indicating a fuel injector leak, when a fuel injector of the fuel cell system is commanded to a closed state, monitor a pressure within the anode gas loop through a time period, compare the monitored pressure within the anode gas loop through the time period to the calibrated threshold pressure change, and when the comparing indicates the excess hydrogen gas is present, taking remedial action.

Abstract: A process for anode overpressure remedial action in a fuel cell system is provided. The process includes monitoring a pressure of hydrogen gas at an anode of a fuel cell stack of the fuel cell system, diagnosing a mechanically stuck open injector based upon the monitored pressure, and based upon diagnosing the mechanically stuck open injector, closing a valve within a hydrogen storage system to prevent flow of the hydrogen gas from a hydrogen storage tank into a gas line connecting the hydrogen storage tank to the mechanically stuck open injector and maintaining operation of the fuel cell stack to deplete the hydrogen gas at the anode.

Abstract: An anode system is arranged to supply pressurized hydrogen to the anode of a fuel cell, and includes a multi-injector system. A controller is executable to monitor, via a pressure sensor, pressure in the anode system and command actuations of the plurality of hydrogen injectors. The controller may detect a fault in the multi-injector system when the commanded actuations of the plurality of hydrogen injectors are greater than a first threshold and the pressure in the anode system cell is less than a second threshold. The controller may execute alternating actuation of the hydrogen injectors of the multi-injector system and monitor the pressure in the anode system to detect a fault in one of the hydrogen injectors based upon the pressure in the anode system.