CN108987769B - 使用电压分布控制的燃料电池系统起动 - Google Patents

使用电压分布控制的燃料电池系统起动 Download PDF

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CN108987769B
CN108987769B CN201810465440.2A CN201810465440A CN108987769B CN 108987769 B CN108987769 B CN 108987769B CN 201810465440 A CN201810465440 A CN 201810465440A CN 108987769 B CN108987769 B CN 108987769B
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fuel cell
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CN108987769A (zh
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J·卡斯泰卢乔
才俊
S·E·加西亚
A·J·马斯林
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Abstract

一种燃料电池系统，该燃料电池系统用于车辆或其它系统且包括燃料电池堆叠、DC‑DC升压转换器以及控制器。该堆叠具有多个燃料电池和堆叠电压。该控制器经由升压转换器在燃料电池堆叠的起动期间调节堆叠电压，并且经编程有多个校准电压分布，每个校准电压分布具有对应的幅值和变化率。控制器构造成执行方法，该方法响应于燃料电池堆叠的经请求起动而检测燃料电池堆叠的空气起动。该控制器然后在燃料电池堆叠的实际起动期间将堆叠电压实施为预定电压分布，且经由升压转换器的调节并且使用多个校准电压分布来这样做。

Description

使用电压分布控制的燃料电池系统起动
背景技术
燃料电池堆叠是能够从在相同构造燃料电池的堆叠中发生的配对氧化/还原反应中产生电力的一种电化学装置。每个燃料电池均包括用于在相反电荷电极之间输送带电颗粒的电解质。铂基或其它合适的催化剂加速电极处的催化过程。氢和氧是氧化/还原反应的基本燃料，这允许水能作为惰性反应副产物而产生。于是，燃料电池可用作车辆推进系统、发电设备以及其它移动或静止系统中的替代清洁能量源。
在燃料电池系统中，将堆叠起动过程限定为配对氧化/还原反应的启动和堆叠最终达到稳定输出电压的之后时间点之间的经过阶段。因此，燃料电池系统在结束起动过程的情形下开始输出可用水平的功率。某些问题可能妨碍给定的燃料电池系统经历成功起动，例如“空气起动”事件或者电池电压的突发峰值。当在延长的关闭时间段之后可忽略不计水平的氢保留在堆叠阳极中时，例如当燃料电池车辆在关闭状态中停车经过一周时，发生空气起动事件。空气起动可能导致负阳极电势以及可能的堆叠退化。在高于900毫伏水平上的电压峰值可能导致催化剂氧化和腐蚀，这进而会减小催化剂的可用表面积并且不利地影响燃料电池效率。
发明内容
这里公开一种控制方法，该控制方法用于在堆叠起动过程期间控制燃料电池堆叠的输出电压(即，堆叠电压)，且根据预定电压分布来这样做，而每个分布均具有对应的幅值和变化率。该方法包括使用直流-直流(DC-DC)升压转换器，以将堆叠电压控制为预定电压分布，从而很大程度地防止堆叠阳极的负电势，以及降低催化剂氧化的发生。
燃料电池系统包括燃料电池堆叠并且还包括DC-DC升压转换器和控制器，该燃料电池堆叠具有多个燃料电池和堆叠电压。控制器经编程有校准电压分布，每个校准电压分布具有对应的幅值和变化率，且该控制器构造成经由DC-DC升压转换器调节在燃料电池堆叠的起动期间的堆叠电压。控制器还构造成响应于燃料电池堆叠的经请求起动而检测燃料电池堆叠的空气起动。响应于所检测的空气起动，该控制器经由升压转换器的调节而在燃料电池堆叠的实际起动期间实施堆叠电压的预定电压分布，且使用校准电压分布而这样做。
校准电压分布包括对应于阳极加压阶段的第一电压分布和对应于阴极填充阶段的第二电压分布，且第二电压分布所具有的变化率小于第一电压分布的变化率。
该控制器经编程为使用气体浓度评估(GCE)模型的输出来检测燃料电池堆叠的空气起动。在该实施例中，GCE模型的输出可以是燃料电池堆叠的阳极板中的经评估氧水平。该控制器可接收燃料电池堆叠的关闭时间、温度以及压力数值的每个作为一组输入，且GCE模型的输出根据该组输入所确定。
DC-DC升压转换器可包括半导体开关和门驱动电路，且该控制器在电压恢复操作模式期间经由门驱动电路通过控制半导体开关的占空比来施加或实施电压分布。
该控制器可包括微处理器，该微处理器是DC-DC升压转换器的一部分，且在电压恢复操作模式期间控制半导体开关的占空比。该控制器构造成通过以电流控制模式来控制DC-DC升压转换器而在完成起动之后实施电压分布。
该燃料电池系统可包括高电压DC电池、电气地连接于电池的功率逆变器模块、轴以及可操作用以将转矩输出至轴的电动机器。在非限制的机动车辆实施例中，道路车轮能可旋转地连接于轴。
车辆包括燃料电池堆叠和DC-DC升压转换器、电池组、功率逆变器模块(PIM)、电动机器、驱动车轮以及控制器，该电池组连接于燃料电池系统并且具有DC输出电压，该功率逆变器模块电气地连接于电池组并且构造成将DC输出电压转换成交流(AC)电压，该电动机器电气地连接于PIM并且经由AC电压通电以产生输出电压，该驱动车轮连接于电动机器并且经由输出转矩驱动而推进车辆。
该控制器构造成执行方法，包括响应于燃料电池堆叠的经请求起动来检测燃料电池堆叠的空气起动，且该控制器经编程有校准电压分布，每个校准电压分布均具有对应的幅值和变化率。该方法还包括在燃料电池堆叠的实际空气起动期间响应于所检测空气起动实施堆叠电压的预定电压分布，包括使用多个校准电压分布来调节DC-DC升压转换器的操作。校准电压分布在一实施例中包括对应于阳极加压阶段的第一电压分布和对应于阴极填充阶段的第二电压分布，且第二电压分布所具有的变化率小于第一电压分布的变化率。
上文概述并不旨在表示本发明的每个实施例或每个方面。而是，前文概述仅仅提供对这里阐述的新颖方面和特征的一些的示例。当结合附图和所附权利要求时，从用于执行本发明的代表性实施例和代表性模式的以下详细描述中，本发明的上述特征和优点以及其它特征和优点会显而易见。此外，该公开内容在表述上包括上文和下文呈现的元件和特征的组合和子组合。
附图说明
图1是具有燃料电池堆叠和控制器的示例车辆的示意图，该控制器构造成在堆叠起动过程期间将堆叠的输出电压，即堆叠电压控制为预定电压分布。
图2A和2B分别是针对氢起动和空气起动的代表性电压分布。
图3是描述用于使用预定电压分布来控制图1所示燃料电池系统在起动期间的堆叠电压的示例方法的流程图。
本发明易于做出各种修改和替代形式，且一些代表性实施例已借助示例在附图中示出并且将在这里进行详细地描述。然而，应理解地是，本发明的新颖方面并不限于附图中说明的特定形式。而是，本发明覆盖落在由所附权利要求所限定的本发明范围和精神内的所有修改、等同物、组合、子组合、序列、组群以及替代物。
具体实施方式
现参照附图，其中，类似的附图标记旨在若干附图中的类似特征，图1示意地示出示例燃料电池系统12。燃料电池系统12包括适合于用作车辆10中的直流(DC)电源的燃料电池堆叠14，该车辆例如是如图所示的机动车辆，或者船只或其它海运交通工具、航空交通工具、机器人或其它移动平台。替代地，燃料电池堆叠14可用作作为静止发电设备(未示出)的一部分的电源或者用在需要车载DC电源发电的其它系统中。为了说明一致性，图1所示燃料电池堆叠14之后会在支持车辆10上推进功能的范围内进行描述，而不会将燃料电池堆叠14限制为此种应用。
燃料电池堆叠14包括多个燃料电池15，这些燃料电池设置在阳极板14A和阴极板14C之间。虽然燃料电池堆叠14及其组成燃料电池15的具体类型可能随着燃料电池系统12的预期应用而改变，但根据一个示例实施例，每个燃料电池15可以是在低重量和体积下输送相对较高的功率密度的聚合物电解质膜/质子交换膜(PEM)类型的燃料电池。PEM类型的燃料电池使用呈铂或铂合金形式的催化剂以及固体电解质聚合物材料(未示出)。燃料电池15当构造成PEM类型的燃料电池时使用来自氢存储罐18的气态氢(箭头H2)和氧(箭头O2)的供源操作，且通常经由压缩机16从环境空气(箭头A)供给氧(箭头O2)。
在图1所示的示例燃料电池系统12内，堆叠旁通管线19可围绕燃料电池堆叠14行进。设置在旁通管线19内的旁通阀17具有可变打开/闭合位置，该位置可例如经由控制器50B自动地设定。旁通阀17的控制允许控制器50B能例如经由空气控制信号(箭头CCA)通过设定流过或绕过燃料电池堆叠14的氧(箭头O2)的量来调节燃料电池堆叠14的操作。从旁通阀17排放的含氧空气在从燃料电池堆叠14排出之前最终重新结合从阴极板14C排出的阴极废气(箭头CEX)。阳极废气(箭头AEX)类似地从阳极板14A排出。如下文所指示的是，控制器50B可替代地经由电气控制信号(箭头CCE)、即经由DC-DC升压转换器30的电压或电流控制来调节燃料电池堆叠14的操作。
图1所示燃料电池系统12进一步包括电压监控电路(VMC)20。VMC20可构造成监控燃料电池堆叠14的电压水平(之后称为堆叠电压)，以测量各个燃料电池15的最小和最大电池电压(箭头VC)并且计算平均电池电压。一些集体电压控制数值可由控制器50B使用，以响应于改变功率需求(例如，在所说明的车辆推进实施例中增大的驾驶员节气门请求)来调节燃料电池堆叠14的操作。
示例车辆10包括DC-DC升压转换器30，该DC-DC升压转换器设置在燃料电池系统12和高电压(HV)系统40之间，该高电压系统包括电池31。图1所示实施例中的升压转换器30包括半导体开关Q1和二极管(D2)，前者在这里示作示例绝缘栅双极晶体管(IGBT)。半导体开关Q1具有开/闭状态，该开/闭状态经由门驱动(GD)电路26使用来自另一控制器50A的门驱动信号(箭头CCG)或者在单个控制器实施例中通过控制器50B驱动。来自燃料电池堆叠14的堆叠电流(电流IS)的幅值和方向/符号可由电流传感器(SC)测量并且通信至控制器50A，其中，堆叠电流(箭头IS)的所测得幅值和方向用于控制半导体开关Q1的开/闭状态。
图1所示升压转换器30的预期功能是用于将输入电压(这里，堆叠电压(VS)增大为更高或者“经升压”的输出电压水平(VBO)。如本领域众所周知的是，电压升压操作可经由半导体开关Q1的脉冲宽度调制或者其它切换控制来实现。在半导体开关Q1接通且由此导电的时间段期间，堆叠电流(箭头IS)通过半导体开关Q1流向具有初级(1)和次级(2)绕组的感应器L1，且返回流入燃料电池堆叠14。随着感应器L1上电压升高，能量存储在感应器L1中。二极管(D1)和电容器(C1)可如图所示设置在感应器L1下游，且电容器C1与HV系统40平行。
当半导体开关Q1经指令而由控制器50A关闭时，存储在感应器L1中的能量导致堆叠电流(箭头IS)流向输出负载，该输出负载在图1所示的特定实施例中是HV系统40。升压转换器30(VBO)的输出处的电压(其是电容器C1上的电势)是堆叠电压(VS)和感应器L1上的电压之和。半导体开关Q1的关/开循环周期性地发生，且总体循环时间限定为关和开时间之和。因此，半导体开关Q1的占空比可限定为TON/TSWITCH，其中，TON是开关Q1的打开时间，且TSWITCH是总体循环时间。
作为图1中示出的示例燃料电池系统12的一部分，控制器50A和控制器50B可经编程有实施本方法100的指令，且这些控制器可以是如图所示的单独的基于任务专用微处理器的装置或者单个装置。方法100用于使用不同的校准电压分布(例如，基于气体浓度评估模型55的输出)来将空气起动与氢起动加以区分，以及在燃料电池堆叠14的起动期间使用升压转换器30来将燃料电池系统12控制为这些电压分布。在正常操作期间，控制器50A、50B根据堆叠电流(箭头IS)来控制半导体开关Q1的占空比。在执行图3所示方法100期间，尤其是在电压恢复模式期间，控制器50A、50B过渡为根据堆叠电压(VS)来控制半导体开关Q1的占空比，以严格地调节升压输出电压(VBO)。
仍参照图1，当图1所示燃料电池系统12对诸如多相电动机器(ME)34的交流(AC)装置供电时，电动机器34的AC电压(VAC)需求的幅值可能超出燃料电池堆叠14的可用DC电压(VDC)的幅值。因此，升压转换器30用于增大供给至电动机器34的电压水平。附加地，功率逆变器模块(PIM)32可电气地连接于HV系统40并且用于将DC高电压总线33上的DC电压转换为适合于激励电动机器34的各个相绕组35的AC电压水平，该电动机器例如是适合于推进车辆10的牵引电动机。来自电动机器34的输出转矩(箭头TO)可输送至输出构件36以执行车辆10上的工作，例如使得一组道路车轮39(出于简化起见仅仅示出其中的一个)旋转，以在车辆10可选地体现为机动车辆时推进车辆10。
虽然出于简化起见而省略，但作为图1所示燃料电池系统12的一部分，打开的/闭合的一组开关或接触器21可经由控制器50A或50B控制，以例如在车辆10并不运行时或者在潜在的高电压电气故障期间，使得燃料电池堆叠14从燃料电池系统12的剩余部分脱开。附加地且类似地为了简化说明而省略，低电压辅助功率可经由辅助功率模块(例如，DC-DC降压转换器)提供给给辅助电池，该辅助功率模块可用于将高电压总线33上的电压水平降低至适合于存储在辅助电池中的低电压水平，例如12-15VDC。
参照图2A，燃料电池堆叠14的氢起动在这里限定为这样的起动事件，其中，图1所示堆叠阳极14A中的初始氧浓度为零或接近零，且初始氢浓度超过零。在氢起动期间，在堆叠起动的阳极加压阶段期间，不应在堆叠电压(VS)中发生显著改变。空气(箭头A)引入到图1所示阴极板14C中会导致堆叠电压(VS)升高。燃料电池堆叠14允许获得的最大电压水平(V1)封顶，以使得电压退化最小。最大容许电压水平(V1)类似于堆叠14的最大/运行时间电压抑制水平(VMAX)，但可设定为略微较低的水平。
针对给定氢起动的氢起动分布在0VDC下或接近VDC开始。预期的是，在空气(箭头A)从图1所示阴极板14C进入时，控制器50B能在0VDC附近操作堆叠14相对较短持续时间至高达最大容许电压(V1)。因此，一旦堆叠电压(VS)达到V1水平，允许该堆叠电压以更渐进的速率达到VMAX的水平。
图2B示出针对空气起动的通用分布。空气起动利用图1所示阳极板14A中的不可忽略氧浓度开始。在该情况中，堆叠电压(VS)在起动的阳极加压阶段期间快速地上升，并且需要较低的堆叠电压限值(V1)和较高的堆叠电流，以适当地缓解潜在电压退化(这主要由于阴极碳腐蚀而引起)。腐蚀事件的持续时间等于氢气完全地填充并置换燃料电池堆叠14的初始气体容积所花费的时间量，该事件量通常在100-500ms之间。在完成阳极加压阶段之后，堆叠电压(VS)会上升至氢起动电压限值(V2)。图2B所示的示例起动事件会以类似于氢起动事件的方式完成。
图3示出上文所述的方法100的示例实施例。方法100的各方面可通过计算机可执行指令(即，由控制器50A和/或50B执行的软件应用或应用程序)来实施。软件可存储在控制器50A、50B的各种存储器(M)的任何上，包括计算机可读取的诸如CD-ROM、磁盘、磁泡存储器和半导体存储器，例如各种类型的RAM或ROM。此外，方法100的各方面可在分布式计算环境中实践，其中，任务通过经由诸如控制器局域网(CAN)总线(未示出)的通信网络链接的远程处理装置执行。虽然参照图3描述了特定算法，但在本发明的范围内可使用实施示例机器可读指令的其它方法。
通常，控制器50A和50B通过使用方法100以常规电流控制模式操作图1所示DC-DC升压转换器30通过第一若干起动阶段，即，堆叠放电、低电压功率限制以及辅助功率管理。基于来自气体浓度评估(GCE)模型55的描述，判定当前的起动时间是空气起动还是氢起动。如果是氢起动，则来自GCE模型55的电压分布信息会包括电压设定值和电压升高速率。如果起动事件是空气起动，则来自GCE模型55的电压分布会包括三个区段，每个区段均具有不同的电压设定值和升高速率。可指令DC-DC升压转换器30在阳极加压、阴极填充以及电压稳定的阶段期间以电压控制模式操作，且然后在完成最后阶段的电压稳定时会返回至常规/电流控制模式。
通常，方法100包括响应于燃料电池堆叠14的经请求起动来经由控制器50B检测燃料电池堆叠14的空气起动，且该控制器50B经编程有校准电压分布，每个校准电压分布均具有对应的幅值和变化率。然后，响应于所检测的空气起动，方法100包括在燃料电池堆叠14的实际起动期间实施堆叠电压的预定电压分布，包括使用校准电压分布来调节DC-DC升压转换器30的操作。
在以步骤S102开始的示例实施例中，在请求图1所示燃料电池系统12起动(例如图1中示出车辆10的基于点火请求的起动)的情形下，控制器50B唤醒并且开始与燃料电池系统12通信。方法100然后行进至步骤S104。
步骤S104使得能经由控制器50A的操作来以常规/电流控制模式操作图1所示升压转换器30。如本领域已知的是，诸如图1所示示例堆叠14的燃料电池堆叠的操作根据多个阶段行进；堆叠放电、低电压功率限制、辅助功率管理、阳极加压、阴极填充以及电压稳定。步骤S104包括通过指令升压转换器30在默认模式中操作来控制堆叠放电、低电压功率限制以及辅助功率管理阶段，该默认模式即这样的电流控制模式，其中，图1所示半导体开关S1的占空比根据由传感器(SC)测得的堆叠电流(箭头IS)确定。方法100然后行进至步骤S106。
步骤S106可包括确定是否存在空气起动事件。例如，上文参照图1所述的GCE模型55可用于评估是否有氧(箭头O2)留存在阳极板14A中。在一个示例实施例中，GCE模型55可考虑关闭时间、环境温度和/或燃料电池堆叠14、燃料电池堆叠14内氧和氢的存在以及燃料电池堆叠14的诸如尺寸、材料之类的已知特性，且控制器50B输出经评估氧水平。一旦控制器50B确定氧存在于阳极板14A中，控制器50可指示空气起动起作用。如果检测到空气起动，方法100行进至步骤S107。否则，控制器50B确定氢起动起作用，而是行进至步骤S108。在任一情形中，控制器50B将升压转换器30的操作模式从电流控制自动地切换至电压控制，以使得根据堆叠电流(VS)来控制升压转换器30的占空比。
步骤S107、S109和S111包括以适合于最小化所检测空气起动的冲击的方式经由控制器50A和升压转换器30来控制阳极加压、阴极填充以及电压稳定阶段，且然后行进至步骤S114。类似地，步骤S108、S110和S112在行进至步骤S114之前执行，并且包括以适合于氢起动的方式控制阳极加压、阴极填充以及电压稳定状态。通过比较图2A和2B的轨迹可观察到操作中的不同。
当如图2A中所示控制氢起动时，氢起动以t0在0VDC下或者接近0VDC开始。在空气从阴极板14C进入图1所示燃料电池堆叠14时，允许堆叠电压(VS)以t1和t2之间的更块速率上升至(V1)的水平。然后，会允许堆叠电压(VS)一旦其达到(V1)的水平就以t2和t3之间的减小速率逐渐地达到VMAX。
当如图2B中所示控制空气起动时，控制器50B控制升压转换器30，以实现多个不同的电压上升速率，即K1、K2和K3。随着电压以在t0和t1之间的第一速率(K1)上升至电压水平V1，步骤S107控制阳极加压，然后，步骤S109以第二和第三速率(K2和K3)将阴极填充阶段控制为更高的电压水平V2，且如图2B中示出的第二速率(K2)小于第一速率(K1)。在达到较高电压水平(V2)的情形下，控制器50B可缓慢地减小堆叠电压(VS)，直到达到最大电压(VMAX)为止。之后，在步骤S114处，升压转换器30的控制可恢复至电流控制，用于燃料电池堆叠14的稳态操作。
虽然已参照所说明的实施例详细地描述了本发明的各方面，但本领域技术人员会认识到的是，可对其做出许多修改，而不会偏离本发明的范围。本发明并不局限于这里公开的精确构造和组成；从前文描述中显而易见的任何和所有修改、改变和变型落在所附权利要求中限定的本发明范围内。此外，本概念在表述上包括之前元件和特征的任何和所有组合以及子组合。

Claims (9)

1.一种燃料电池系统，包括：
燃料电池堆叠，所述燃料电池堆叠具有多个燃料电池和堆叠电压；
DC-DC升压转换器；以及
控制器，所述控制器构造成在所述燃料电池堆叠的起动期间经由所述DC-DC升压转换器调节所述堆叠电压，并且经编程有多个校准电压分布，每个校准电压分布具有对应的幅值和变化率；
其中，所述控制器构造成响应于所述燃料电池堆叠的经请求起动来检测所述燃料电池堆叠的空气起动，并且响应于所检测的空气起动，使用所述多个校准电压分布经由所述DC-DC升压转换器的调节而在所述燃料电池堆叠的实际起动期间实施所述堆叠电压的预定电压分布。
2.根据权利要求1所述的燃料电池系统，其中，所述多个校准电压分布包括对应于阳极加压阶段的第一电压分布和对应于阴极填充阶段的第二电压分布，且所述第二电压分布所具有的变化率小于所述第一电压分布的变化率。
3.根据权利要求1所述的燃料电池系统，其中，所述控制器经编程为使用气体浓度评估模型的输出来检测所述燃料电池堆叠的空气起动，其中，所述气体浓度评估模型的输出是所述燃料电池堆叠的阳极板中的经评估氧水平。
4.根据权利要求3所述的燃料电池系统，其中，所述控制器构造成接收所述燃料电池堆叠的关闭时间、温度以及压力数值的每个作为一组输入，且其中所述气体浓度评估模型的所述输出根据所述一组输入所确定。
5.根据权利要求1所述的燃料电池系统，其中，所述DC-DC升压转换器包括半导体开关和门驱动电路，且所述控制器构造成在起动期间的电压恢复操作模式期间经由所述门驱动电路通过控制所述半导体开关的占空比来实施所述预定电压分布。
6.根据权利要求5所述的燃料电池系统，其中，所述控制器包括微处理器，所述微处理器是所述DC-DC升压转换器的一部分，且在所述起动期间的电压恢复操作模式期间控制所述半导体开关的所述占空比。
7.根据权利要求1所述的燃料电池系统，其中，所述控制器构造成通过以电流控制模式来控制所述DC-DC升压转换器而在完成所述起动之后实施所述预定电压分布。
8.根据权利要求1所述的燃料电池系统，进一步包括：
电池；
功率逆变器模块，所述功率逆变器模块电气地连接于所述电池；
轴；以及
电动机器，所述电动机器用于将转矩输出至所述轴。
9.根据权利要求8所述的燃料电池系统，进一步包括道路车轮，所述道路车轮旋转地连接于所述轴。
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