Abstract: A method for gathering information from battery sensors—for instance, information regarding the state-of-charge (SOC), temperature and/or other characteristics of battery cells in a vehicle battery pack—and using that information to estimate or predict battery degradation or state-of-health (SOH). According to an exemplary embodiment, the method uses both a time-based algorithm and an event-based algorithm to predict or estimate battery degradation. The event-based algorithm may select certain data from the battery conditions (e.g., a state-of-charge (SOC) swing (?SOC) or an SOC maximum (SOCMax)), instead of using the entire set of battery condition data, and may use this information in its prediction or estimate.

Abstract: A method for revising a reference polarization curve of a fuel cell stack that identifies the relationship between the voltage and the current of the stack over time. When the stack is operating at a low load where kinetic voltage losses of the stack dominate, a first adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve. When the stack is operating at higher loads where ohmic voltage losses of the stack dominate, a second adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve.

Abstract: A device and method to predict and regulate nitrogen concentration in a flow shifting system. In one aspect of the system, a bleed valve fluidly coupled to multiple fuel cell stacks is used to reduce the presence of nitrogen in an anode flowpath. One or more sensors can be used to measure voltage within one or both of the fuel cell stacks. By assessing fuel cell voltage changes within the anode flowpath and equating such changes with nitrogen fraction buildup, the system can manipulate the bleed valve at appropriate times to improve system operability. In one form of equating the sensed voltage changes with the nitrogen fraction buildup, a predictive algorithm can be used by a logic device in a controller to compare the sensed voltage so that the controller instructs the bleed valve when to open and close. In a variation, the controller can compare the sensed voltages against stored data rather than rely on a formula or related algorithm.

Abstract: A fuel cell system includes a fuel cell stack, an anode reactant source and a shut-off valve that selectively prohibits anode reactant flow from the anode reactant source to the fuel cell stack through a conduit. A control module initiates closure of the shut-off valve to prohibit anode reactant flow through the conduit and determines a shutdown schedule based on a residual mass of the anode reactant within the conduit. The control module operates the fuel cell system using the residual mass and based on the shutdown schedule.

Abstract: A fuel cell stack that includes cascaded stack stages and tube bundle flow restrictions for providing a cathode input gas to each stage in the stack. The stack includes a first flow pipe for providing cathode gas flow to a first stage of the plurality of stages of the fuel cell stack. The fuel cell stack also includes a second flow pipe that receives a cathode exhaust gas flow from the first stage and fresh cathode gas flow, where the cathode exhaust gas flow and the fresh cathode gas flow are combined and sent to a second stage of the plurality of stages of the fuel cell stack. The tube bundle flow restriction is positioned within the second flow pipe and controls the flow of the cathode gas flow to the second stage, where the flow restriction provides a laminar flow through the control valve to the second stage.

Abstract: A method for revising a reference polarization curve of a fuel cell stack that identifies the relationship between the voltage and the current of the stack over time. When the stack is operating at a low load where kinetic voltage losses of the stack dominate, a first adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve. When the stack is operating at higher loads where ohmic voltage losses of the stack dominate, a second adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve.

Abstract: A method for revising a reference polarization curve of a fuel cell stack that identifies the relationship between the voltage and the current of the stack over time. When the stack is operating at a low load where kinetic voltage losses of the stack dominate, a first adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve. When the stack is operating at higher loads where ohmic voltage losses of the stack dominate, a second adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve.

Abstract: A heating system for optimizing execution of heating tasks in a fuel cell vehicle is disclosed, the system including a stack coolant loop with a fuel cell stack, a primary pump, and a radiator module. A bypass coolant loop is disposed parallel with and is connected to the stack coolant loop between the fuel cell stack and the radiator module. The bypass loop including a cabin heat exchanger and a coolant heater, along with a secondary pump for pumping coolant through the heaters when desired.

Abstract: A system for cooling a fuel cell stack and a drive unit in a fuel cell vehicle is disclosed, wherein the system includes a drive unit and a fuel cell stack. An oil cooling loop for the drive unit includes a three way valve, a liquid to liquid heat exchanger, and a pump. The liquid to liquid heat exchanger may be used to transfer drive unit off heat into the stack coolant loop. By not using an oil to air heat exchanger overall heat exchanger arrangement air side pressure drop can be minimized and airflow increased. The three way valve allows decoupling of the cooling loops if needed to inhibit negative impact on the fuel cell stack.

Abstract: A system and method for controlling a bleed valve and a compressor in a fuel cell system during an anode exhaust gas bleed so as to maintain the concentration of hydrogen within a mixed cathode exhaust gas and anode gas below a predetermined percentage. The system uses a valve orifice model to calculate the flow rate of the anode exhaust gas through the bleed valve to identify how much airflow from the compressor is required to dilute the hydrogen in the anode gas to be below the predetermined percentage. The system also uses sensor inaccuracies and production tolerances in the valve orifice model to ensure that the concentration of hydrogen in the mixed anode and cathode exhaust gas is below the determined percentage.

Abstract: A system and method for controlling a bleed valve and a compressor in a fuel cell system during an anode exhaust gas bleed so as to maintain the concentration of hydrogen within a mixed cathode exhaust gas and anode gas below a predetermined percentage. The system uses a valve orifice model to calculate the flow rate of the anode exhaust gas through the bleed valve to identify how much airflow from the compressor is required to dilute the hydrogen in the anode gas to be below the predetermined percentage. The system also uses sensor inaccuracies and production tolerances in the valve orifice model to ensure that the concentration of hydrogen in the mixed anode and cathode exhaust gas is below the determined percentage.

Abstract: A correlation between a variance in a voltage output of fuel cell(s) of a fuel cell stack and a level of nitrogen in the anode side of the fuel cell stack provides an indirect indication of the nitrogen level in the anode side. Base on this correlation, the variance in voltage output can be used to determine an anode effluent venting requirement to avoid nitrogen fouling of the fuel cell stack.

Abstract: A transient load can be applied to a fuel cell stack to generate an AC voltage across and an AC current through the fuel cell stack. The AC voltage and AC current can be used to ascertain an impedance of the fuel cell stack. The ascertained impedance can be correlated to a state of hydration of the fuel cell stack thereby providing an independent determination of the state of hydration. The independently determined state of hydration can be used as a diagnostic tool to verify a different independent determination of the state of hydration and/or as an input for controlling operation of the fuel cell stack.

Abstract: A method of controlling the ventilation system for an energy source in a fuel cell vehicle is disclosed, which includes an HVAC system, a fluid reserve, and a rechargeable energy storage system (RESS), capable of controlling a temperature of the RESS to militate against damage to or a shortened life of the battery, while maximizing vehicle durability, efficiency, performance, and passenger comfort.

Abstract: A fuel cell system and method for controlling relative humidity in a fuel cell system. A controller can be signally coupled to one or more sensors and configured to operate at least one flow manipulation device in response to changes in a relative humidity of a reactant passing through the cathode flowpath of the fuel cell in order to maintain the relative humidity within a prescribed range. The controller correlates one or more of a temperature setpoint, pressure setpoint, stoichiometry setpoint or actual operating condition of any of them to an operating condition of the system. In this way, a desired level of relative humidity can be achieved, maintained or both while minimizing the use of power-robbing flow manipulation devices, such as a pump, compressor, fan or related component.

Abstract: A device and method to predict and regulate nitrogen concentration in a flow shifting system. In one aspect of the system, a bleed valve fluidly coupled to multiple fuel cell stacks is used to reduce the presence of nitrogen in an anode flowpath. One or more sensors can be used to measure voltage within one or both of the fuel cell stacks. By assessing fuel cell voltage changes within the anode flowpath and equating such changes with nitrogen fraction buildup, the system can manipulate the bleed valve at appropriate times to improve system operability. In one form of equating the sensed voltage changes with the nitrogen fraction buildup, a predictive algorithm can be used by a logic device in a controller to compare the sensed voltage so that the controller instructs the bleed valve when to open and close. In a variation, the controller can compare the sensed voltages against stored data rather than rely on a formula or related algorithm.

Abstract: A method for revising a reference polarization curve of a fuel cell stack that identifies the relationship between the voltage and the current of the stack over time. When the stack is operating at a low load where kinetic voltage losses of the stack dominate, a first adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve. When the stack is operating at higher loads where ohmic voltage losses of the stack dominate, a second adaptation value is revised as the difference between the actual stack voltage and the stack voltage of the reference polarization curve.

Abstract: A fuel cell stack that includes cascaded stack stages and tube bundle flow restrictions for providing a cathode input gas to each stage in the stack. The stack includes a first flow pipe for providing cathode gas flow to a first stage of the plurality of stages of the fuel cell stack. The fuel cell stack also includes a second flow pipe that receives a cathode exhaust gas flow from the first stage and fresh cathode gas flow, where the cathode exhaust gas flow and the fresh cathode gas flow are combined and sent to a second stage of the plurality of stages of the fuel cell stack. The tube bundle flow restriction is positioned within the second flow pipe and controls the flow of the cathode gas flow to the second stage, where the flow restriction provides a laminar flow through the control valve to the second stage.

Abstract: A fuel cell system includes a fuel cell stack, an anode reactant source and a shut-off valve that selectively prohibits anode reactant flow from the anode reactant source to the fuel cell stack through a conduit. A control module initiates closure of the shut-off valve to prohibit anode reactant flow through the conduit and determines a shutdown schedule based on a residual mass of the anode reactant within the conduit. The control module operates the fuel cell system using the residual mass and based on the shutdown schedule.

Abstract: The present invention utilizes a correlation between a variance in a voltage output of fuel cell(s) of a fuel cell stack and a level of nitrogen in the anode side of the fuel cell stack. The correlation provides an indirect indication of the nitrogen level in the anode side. Based on this correlation, the variance in voltage output can be used to determine an anode effluent venting requirement to avoid nitrogen fouling of the fuel cell stack.