Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/06—Combination of fuel cells with means for production of reactants or for treatment of residues
  • H01M8/0662—Treatment of gaseous reactants or gaseous residues, e.g. cleaning
  • H01M8/0687—Reactant purification by the use of membranes or filters
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/34—Chemical or biological purification of waste gases
  • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
  • B01D53/81—Solid phase processes
  • B01D53/82—Solid phase processes with stationary reactants
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
  • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
  • H01M8/04201—Reactant storage and supply, e.g. means for feeding, pipes
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
  • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
  • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
  • H01M8/0438—Pressure; Ambient pressure; Flow
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
  • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
  • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
  • H01M8/0444—Concentration; Density
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
  • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
  • H01M8/04992—Processes for controlling fuel cells or fuel cell systems characterised by the implementation of mathematical or computational algorithms, e.g. feedback control loops, fuzzy logic, neural networks or artificial intelligence
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2257/00—Components to be removed
  • B01D2257/30—Sulfur compounds
  • B01D2257/302—Sulfur oxides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2257/00—Components to be removed
  • B01D2257/30—Sulfur compounds
  • B01D2257/304—Hydrogen sulfide
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2257/00—Components to be removed
  • B01D2257/40—Nitrogen compounds
  • B01D2257/404—Nitrogen oxides other than dinitrogen oxide
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2257/00—Components to be removed
  • B01D2257/40—Nitrogen compounds
  • B01D2257/406—Ammonia
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2257/00—Components to be removed
  • B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
  • B01D2257/708—Volatile organic compounds V.O.C.'s
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2258/00—Sources of waste gases
  • B01D2258/06—Polluted air
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2259/00—Type of treatment
  • B01D2259/45—Gas separation or purification devices adapted for specific applications
  • B01D2259/4566—Gas separation or purification devices adapted for specific applications for use in transportation means
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2250/00—Fuel cells for particular applications; Specific features of fuel cell system
  • H01M2250/20—Fuel cells in motive systems, e.g. vehicle, ship, plane
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/30—Hydrogen technology
  • Y02E60/50—Fuel cells

Definitions

• Embodiments herein relate to monitoring systems for chemical filters used with fuel cell systems.
• Fuel cells are electricity producing devices that consume hydrogen in a chemical reaction with oxygen producing water as a waste byproduct. Fuel cells have two electrodes, the anode and cathode. Fuel cells can be of various designs including alkaline fuel cells, polymer electrolyte membrane fuel cells, phosphoric acid fuel cells, molten carbonate fuel cells, and solid oxide fuel cells. Generally, fuel cells use catalysts including those formed with platinum, nickel, cobalt, iron, manganese, as well as other materials.
• a fuel cell chemical filter monitoring system can be included having a processing unit and a sensor package.
• the sensor package can include one or more sensors.
• the sensor package can be configured to interface with an air flow channel of a fuel cell system upstream of a chemical filter and detect an amount of a chemical compound in the air flow channel.
• the sensor package can be operatively connected to the processing unit.
• the processing unit can be configured to track total exposure of the chemical filter to the chemical compound.
• the processing unit can be configured to estimate a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter.
• the chemical compound can include at least one selected from the group consisting of an acid species, a base species, and a volatile organic compound.
• the chemical compound can include at least one selected from the group consisting of SO2, H2S, NO2, NH3, and a volatile organic compound.
• the sensors can include at least one selected from the group consisting of an acid sensor, a base sensor, and a volatile organic compound (VOC) sensor.
• VOC volatile organic compound
• the sensors can include at least one selected from the group consisting of an SO2 sensor, an H2S sensor, an NO2 sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor.
• SO2 sensor an SO2 sensor
• H2S sensor an H2S sensor
• NO2 sensor an NO2 sensor
• NH3 sensor an NH3 sensor
• VOC volatile organic compound
• the fuel cell chemical filter monitoring system receives data regarding the total capacity from a remote system.
• the fuel cell chemical filter monitoring system receives data regarding the total capacity from the chemical filter itself.
• the fuel cell chemical filter monitoring system can be configured to send data regarding at least one of tracked total exposure and estimated remaining filter life.
• the data can be sent to a vehicle control system.
• the data can be sent to a vehicle CANbus system.
• the data can be sent to a remote monitoring system.
• the sensor package can further include at least one selected from the group consisting of a temperature sensor, a relative humidity sensor, and a pressure sensor.
• the sensor package can further include a flow sensor.
• the fuel cell chemical filter monitoring system can be configured to receive data regarding environmental levels of the chemical compound from a remote system using geolocation data from the geolocation circuit.
• the fuel cell chemical filter monitoring system can be configured to receive data regarding environmental levels of the chemical compound from a remote system.
• the fuel cell chemical filter monitoring system can be configured to use the received data to calibrate the one or more sensors. In an eighteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the fuel cell chemical filter monitoring system can be configured to use the received data to modulate estimate calculations regarding remaining life of the chemical filter.
• the processing unit can be configured to receive an input regarding a filter change event.
• the input can be a user input.
• the input can be received from another sensor or system.
• the processing unit can be configured to receive data from a vehicular data system.
• the processing unit can be configured to receive data regarding power output from the fuel cell.
• the processing unit can be configured to use the data regarding power output to modulate estimate calculations regarding remaining life of the chemical filter.
• the vehicular data system can include a CANbus system.
• the sensor package further can include parallel flow paths, wherein individual sensors can be disposed within individual parallel flow paths.
• the fuel cell chemical filter monitoring system can be configured to issue an alert when the remaining life the chemical filter crosses a threshold value.
• the fuel cell chemical filter monitoring system can be configured to issue alerts according to a tiered severity scheme when the remaining life the chemical filter crosses one or more threshold values.
• the processing unit can be configured to estimate a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and the data regarding the total capacity of the chemical filter using a linear equation, a non-linear equation, a machine-learning derived algorithm, a neural network, a simulation, or a digital twin.
• a method of monitoring a fuel cell chemical filter can be included.
• the method can include interfacing with an air flow channel of a fuel cell system upstream of a chemical filter, detecting an amount of a chemical compound in the air flow channel, tracking total exposure of the chemical filter to the chemical compound, and estimating a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter.
• the method can further include sending data regarding at least one of tracked total exposure and estimated remaining filter life.
• the method can further include receiving data regarding environmental levels of the chemical compound from a remote system.
• the method can further include sending geolocation data to the remote system.
• receiving data regarding environmental levels of the chemical compound from a remote system can include using the received data to modulate estimate calculations regarding remaining life of the chemical filter.
• receiving data regarding environmental levels of the chemical compound from a remote system can include using the received data to calibrate one or more sensors.
• the method can further include receiving an input regarding a filter change event.
• the method can further include receiving data from a vehicular data system.
• the method can further include receiving data regarding power output from the fuel cell.
• receiving the data regarding power output from the fuel cell includes using the data regarding power output to modulate estimate calculations regarding remaining life of the chemical filter.
• the method can further include issuing an alert when the remaining life the chemical filter crosses a threshold value.
• the method can further include issuing alerts according to a tiered severity scheme when the remaining life the chemical filter crosses one or more threshold values.
• FIG. l is a schematic view of fuel cell chemical filter monitoring system in accordance with various embodiments herein.
• FIG. 2 is a schematic view of components of a fuel cell chemical filter monitoring system in accordance with various embodiments herein.
• FIG. 3 is a schematic view of components of a fuel cell chemical filter monitoring system in accordance with various embodiments herein.
• FIG. 4 is a schematic view of components of a fuel cell chemical filter monitoring system in accordance with various embodiments herein.
• FIG. 5 is a schematic view of a portion of a sensor package in accordance with various embodiments herein.
• FIG. 6 is a schematic view of a portion of a sensor package in accordance with various embodiments herein.
• FIG. 7 is a schematic view of a portion of a sensor package in accordance with various embodiments herein.
• FIG. 8 is a flowchart of operations in accordance with various embodiments herein.
• FIG. 9 is a flowchart of operations in accordance with various embodiments herein.
• FIG. 10 is a flowchart of operations in accordance with various embodiments herein.
• FIG. 11 is a block diagram view of components of a processing unit in accordance with various embodiments herein.
• VOCs volatile organic compounds
• the fuel cell chemical filter monitoring systems can include a processing unit and a sensor package.
• the sensor package can include one or more sensors.
• the sensor package can be configured to interface with an air flow channel of a fuel cell system upstream of a chemical filter and detect an amount of a chemical compound in the air flow channel.
• the sensor package can be operatively connected to the processing unit.
• the processing unit can be configured to track total exposure of the chemical filter to the chemical compound.
• the processing unit can be configured to estimate a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter.
• FIG. 1 shows the fuel cell chemical filter monitoring system 108 within a vehicle 102.
• the vehicle 102 can include a fuel cell system 104 and a chemical filter 106 that is monitored.
• monitoring systems herein are not limited to fuel cells used with vehicles. Rather, monitoring systems herein can be used with fuel cells used in any application.
• the monitoring system 108 can be in electronic communication (wired and/or wireless) with various other systems and components to send and/or receive data.
• wireless communications to a data network can be executed with communications passing through a cell tower 120.
• communications can be passed using other wireless data communication network infrastructure including, for example, satellite based architecture or other data networks.
• at least some data communications can be via wired infrastructure.
• the system 108 can be in data communication with remote computing resources (servers - real or virtual, databases, and the like) such as those in or available through the cloud 122.
• the system 108 can be in data communication with a remote system 124, such as one including a remote database 126, for purposes of sending and/or receiving data.
• the sensor package of the system 108 can be configured to interface with an air flow channel of the fuel cell system 104.
• the sensor package of the system 108 can be configured to interface with an air flow channel of the fuel cell system 104 upstream of the chemical filter 106.
• the sensor package of the system 108 and can detect and record amounts of various chemical compounds in the air flow channel. In this manner, the system 108 can track the total amounts of chemicals that the filter 106 is exposed to. By subtracting such amounts from the known total capacity of the chemical filter 106 to absorb or otherwise sequester such chemical compounds or the known remaining capacity of the filter, the remaining useful life of the chemical filter 106 can be estimated.
• the total starting capacity of the chemical filter 106 can be a starting point in making calculations to estimate the remaining useful life of the chemical filter 106. Then, as amounts of chemicals are detected with the sensor package, the remaining capacity can be calculated as the starting capacity minus all detected amounts of chemicals observed in the aggregate since the chemical filter 106 was new or serviced. In some embodiments, the rate at which the chemical filter 106 is exposed to chemical compounds can be calculated (units per time period) and this rate can then be used along with the total remaining capacity to calculate an expected time at which the chemical filter will reach its full capacity (e.g., no remaining useful life).
• the processing unit can be configured to estimate a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and the data regarding the total capacity of the chemical filter using a linear equation, a non-linear equation, a machine-learning derived algorithm, a neural network, a deep learning model, a simulation, or a digital twin.
• a training set of data can be obtained relating detected amounts of chemical compounds of interest and the consumption of capacity of the chemical filter.
• the training set of data can be used to train a machine learning model and the output of the same can then be used by the system in order to calculate consumption of the capacity of the chemical filter and then calculate a remaining useful life of the chemical filter.
• a supervised machine learning approach can be used with the training set of data to develop a machine learning model or algorithm that can be used by the system herein.
• Other machine learning approaches used can include unsupervised machine learning, semi-supervised machine learning, reinforcement learning, and the like.
• Algorithms applied can include nearest neighbor, naive Bayes, decision trees, linear regression, support vector machines, neural networks, and the like.
• Other algorithms applied can include k-mean clustering, association rules, Q-learning, temporal difference, deep adversarial networks, and the like.
• data regarding total capacity can be specific for individual chemical species of interest (e.g., capacity for compound “A” is 5 “units”, capacity for compound “B” is 7 “units”, etc.). In some embodiments, data regarding total capacity can relate to certain classes of compounds. In some embodiments, data regarding total capacity can represent an aggregate of all chemical species that the filter element can absorb or otherwise sequester.
• the total capacity of total capacity of the chemical filter can be input into the fuel cell chemical filter monitoring system 108 manually by a system user (located at the site of the vehicle or remotely located).
• the fuel cell chemical filter monitoring system 108 receives data regarding the total capacity of the chemical filter from a remote system 124.
• the fuel cell chemical filter monitoring system 108 receives data regarding the total capacity of the chemical filter from the chemical filter 106 itself.
• the chemical filter can include a data tag (such as a RFID tag or NFC tab) bearing data thereon including, for example, the model of the chemical filter and/or the capacity of the chemical filter.
• the total capacity of a chemical filter along with data reflecting the quantity of chemicals it has already been exposed to can be stored within memory of the fuel cell chemical filter monitoring system 108.
• the total capacity of the chemical filter can be estimated based on filter parameters such as filter geometry, absorbent materials used and their properties, sizing, and the like.
• the fuel cell chemical filter monitoring system 108 can be configured to issue an alert when the remaining useful life of the chemical filter 106 crosses a threshold value.
• the fuel cell chemical filter monitoring system 108 can be configured to issue an alert when the remaining useful life of the chemical filter 106 falls below a threshold value.
• the threshold value can be denominated in various ways. In some embodiments, the threshold value is a percentage of capacity of the chemical filter, such as 30%, 20%, 10%, 5%, 1%, or the like, or an amount falling within a range between any of the foregoing.
• the threshold value is an estimated amount of time (based on current rates of chemical filter use) until the chemical filter has reached its capacity, such as 30 minutes, 1 hour, 6 hours, 12 hours, 24 hours, or the like, or an amount of time falling within a range between any of the foregoing.
• the threshold value is an estimated amount of miles the vehicle can travel until the chemical filter has reached its capacity (based on calculated usage rates per time period and average speeds per time period), such as 10 miles, 50 miles, 100 miles, 200 miles, or the like, or a distance falling within a range between any of the foregoing.
• the fuel cell chemical filter monitoring system 108 can be configured to issue alerts according to a tiered severity scheme when the remaining life the chemical filter 106 crosses one or more threshold values. For example, a first alert can be issued when the remaining capacity of the chemical filter falls below 10% of its total capacity and a second alert, at a higher severity level than the first alert, can be issued when the remaining capacity of the chemical filter falls below 2% of its total capacity. Many different tiered alerting schemes are contemplated herein.
• the fuel cell chemical filter monitoring system 108 can be configured to send data on to other systems (co-located with the vehicle and/or located remotely), such as data regarding at least one of tracked total exposure, estimated remaining filter life, alerts, etc.
• the fuel cell chemical filter monitoring system 108 can send data to a vehicle control or data system.
• the fuel cell chemical filter monitoring system 108 can send data to a vehicle CANbus system.
• the fuel cell chemical filter monitoring system can send data to a remote monitoring system.
• the fuel cell chemical filter monitoring system 108 can receive data from such sources.
• Geolocation data can include latitude/longitude coordinates and/or other location identifying information such as a nearest address, nearest landmark, etc.
• Geolocation data shall include reference to all location identifying data, unless the context dictates otherwise.
• geolocation data can be derived from a satellite-based geolocation system. Such systems can include, but are not limited to, GPS L1/L2, GLONASS G1/G2, BeiDou B1/B2, Galileo El/E5b, SBAS, or the like.
• the system can include a geolocation circuit that can include appropriate signal receivers or transceivers to interface with a satellite and/or the geolocation circuit can interface with and/or receive data from a separate device or system that provides geolocation data or derives geolocation data from a satellite or other device.
• geolocation data herein is not limited to just that which can be received from or derived from interface with a satellite. Rather, geolocation data can also be derived from addresses, beacons, landmarks, various referential techniques, IP address evaluation, and the like.
• Geolocation data can be used by the system in various ways.
• the vehicle geolocation 110 can be used to retrieve data regarding environmental levels of a chemical compound at the geolocation 110 of the vehicle 102 from a remote system 124.
• the system 108 can be in data communication (such as through the cloud 122 or another data network) with an API serving as a source of data, such as an environmental conditions API 130.
• the environmental conditions API 130 can provide data on ambient levels of various chemical compounds at specific geolocation such as concentrations of one or more of SO2, H2S, NO2, NH3, and various volatile organic compounds.
• the fuel cell chemical filter monitoring system can be configured to receive data regarding environmental levels of the chemical compound from a remote system using geolocation data from the geolocation circuit.
• the fuel cell chemical filter monitoring system 108 can be configured to use the received data to calibrate one or more sensors. Aspects of this are described with respect to FIG. 10 below. In various embodiments, the fuel cell chemical filter monitoring system 108 can be configured to use the received data to modulate estimate calculations regarding remaining life of the chemical filter 106. Aspects of this are described with respect to FIG. 10 below. Referring now to FIG. 2, a schematic view of components of a fuel cell chemical filter monitoring system 108 is shown in accordance with various embodiments herein.
• the fuel cell system 104 includes a hydrogen supply tank 202 in fluid communication with a hydrogen supply line 204 that conveys the hydrogen to the fuel cell.
• the fuel cell system 104 can include an anode 206 and a cathode 208.
• the fuel cell system 104 also includes an air supply line 210. Typically, ambient gases 218 are pulled into the air supply line 210.
• the air provided by the air supply line 210 can be the source of the oxygen needed for the fuel cell to operate.
• the fuel cell chemical filter monitoring system 108 can interface with (and be in fluid communication with) the air supply line 210 upstream from the chemical filter 106.
• the fuel cell chemical filter monitoring system 108 includes a sensor package 212.
• the sensor package 212 includes various chemical sensors as described herein.
• the fuel cell chemical filter monitoring system 108 can also includes a processing unit 214. In some embodiments, the sensor package 212 and the processing unit 214 can be physically integrated. In other embodiments, they can be physical separate but in wired or wireless communication with one another.
• FIG. 2 also shows a chemical filter 106. Exemplary chemical filters 106 are described in U.S. Pat. No. 7,138,008, the content of which is herein incorporated by reference.
• the fuel cell system 104 also includes a waste stream output 216, such as to convey water and other byproducts out of the fuel cell.
• the sensor package 212 can be configured to interface with the air flow channel or air supply line 210 of a fuel cell system 104 upstream of the chemical filter 106. In various embodiments, the sensor package 212 can be configured to detect an amount of a chemical compound in the air supply line 210.
• the chemical compound can include at least one including at least one of an acid species, a base species, and a volatile organic compound. In various embodiments, the chemical compound can include at least one including at least one of SO2, EES, NO2, NEE, and a volatile organic compound.
• the sensor package 212 can include at least one sensor selected from the group consisting of a sensor for an acid species, a sensor for a base species, and a sensor for a volatile organic compound.
• the sensor package 212 can include at least one sensor selected from the group consisting of a SO2 sensor, a EES sensor, aNCh a sensor, a NEE sensor, and a volatile organic compound sensor.
• the sensor package 212 can be operatively connected to the processing unit 214. Other sensors can also be included herein.
• the sensor package 212 can also include at least one selected from the group consisting of a temperature sensor, a relative humidity sensor, and a pressure sensor.
• the sensor package 212 can also include a flow sensor.
• the processing unit 214 can be configured to receive an input regarding a filter change event.
• the input can be a user input.
• the input can be received from another sensor or system, such as a sensor attached to the chemical filter configured to detect removal of the same.
• the system can determine the capacity of the new filter (through user input, reference to a database, as preprogrammed, or as received from the new filter itself) and then reset the stored remaining capacity data to reflect the total capacity of the new filter element.
• FIG. 3 a schematic view of components of a fuel cell chemical filter monitoring system 108 is shown in accordance with various embodiments herein.
• FIG. 3 is generally similar to FIG. 2. However, FIG. 3 also shows an ambient conditions sensor 306 (such as may be mounted on or in the vehicle), a vehicle CANBus system 304 or other vehicle control system or data network, an environmental conditions API 130, and a remote database 126.
• an ambient conditions sensor 306 such as may be mounted on or in the vehicle
• vehicle CANBus system 304 or other vehicle control system or data network such as may be mounted on or in the vehicle
• an environmental conditions API 130 such as may be mounted on or in the vehicle
• a remote database 126 such as may be mounted on or in the vehicle
• the ambient conditions sensor 306 can be mounted on or in the vehicle and can detect ambient conditions including, but not limited to, concentrations of at least one of SO2, H2S, NO2, NH3, and various volatile organic compounds, and/or temperature, pressure, relative humidity, and the like.
• the vehicle CANBus system 304 can provide information on the fuel cell, such as the power output of the fuel cell.
• the system 108 and/or the processing unit 214 thereof can be configured to receive data regarding power output (such as voltage) from the fuel cell.
• the processing unit 214 can be configured to use the data regarding power output to modulate estimate calculations regarding remaining life of the chemical filter 106. For example, if the power output is observed to drop, this may indicate problems with the fuel cell (or a subunit cell thereof). For example, this could mean that some chemical compounds have passed into the fuel cell causing damage thereto. In such a case, the system can make further calculations regarding remaining useful capacity on a more conservative basis. This is further described with respect to FIG. 9 below.
• FIG. 4 a schematic view of components of a fuel cell chemical filter monitoring system 108 is shown in accordance with various embodiments herein.
• FIG. 4 is generally similar to FIG. 2.
• FIG. 4 also shows a downstream sensor 402.
• the downstream sensor 402 can be used for sensing various chemical compounds referred to herein.
• the downstream sensor 402 can specifically be used to detect one or more VOCs.
• Sensor packages used herein can take on many different configurations and form factors.
• the flow of air can be separated into multiple parallel channels.
• FIG. 5 a schematic view of a portion of a sensor package 212 is shown in accordance with various embodiments herein.
• the sensor package 212 includes an inflow channel 502 and an outflow channel 504.
• the air flow can be divided up into multiple parallel flow paths.
• the air flow can be divided into a first path 506, a second path 510, a third path 514, a fourth path 518, and a fifth path 522.
• Sensors can be disposed within the flow paths.
• a first sensor 508 can be disposed within first path 506.
• a second sensor 512 can be disposed within second path 510.
• a third sensor 516 can be disposed within third path 514.
• a fourth sensor 520 can be disposed within fourth path 518.
• a fifth sensor 524 can be disposed within fifth path 522.
• FIG. 6 a schematic view of a portion of a sensor package 212 is shown in accordance with various embodiments herein.
• FIG. 6 is generally similar to FIG. 5.
• a flow sensor 602 is also included.
• flow sensor 602 is located in outflow channel 504.
• flow sensor 602 could also be located in housing 502, or one or more of the parallel flow paths.
• the sensors can include at least one including at least one of an SO2 sensor, an H2S sensor, an NO2 sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor.
• sensors can include an acid sensor, a base sensor, and a VOC sensor.
• FIG. 7 is generally similar to FIG. 5.
• the parallel flow paths includes a first path 506, a second path 510, and a third path 514.
• sensors can detect classes of compounds instead of individual chemical compounds.
• sensors can detect acids, bases, and the like.
• the sensors can include an acid sensor 708 disposed within the first path 506, a base sensor 712 disposed within the second path 510, and a VOC sensor 716 disposed within the third path 514.
• FIG. 8 shows a method of monitoring a fuel cell chemical filter 800.
• the method of monitoring a fuel cell chemical filter 800 can include an operation of detecting an amount of a chemical compound in an air flow channel 802.
• the method of monitoring a fuel cell chemical filter 800 can also include an operation of a tracking total exposure of a chemical filter to a chemical compound 804.
• the method of monitoring a fuel cell chemical filter 800 can also include an operation of estimating a remaining life of a chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter 806.
• the method 900 can include an operation of calculating a baseline value for remaining useful filter file (RUL) 902. In some embodiments, the method can further include an operation of getting fuel cell voltage output values 904. In some embodiments, the method can further include an operation of calculating an adjusted value for remaining useful filter life 906 in view of the fuel cell voltage output values. As an example, if the power output from the fuel cell is observed to drop, this may indicate problems with the fuel cell (or a subunit cell thereof). This could mean that some chemical compounds have passed into the fuel cell causing damage thereto and/or reduced power out therefrom.
• the system can make further calculations regarding remaining useful capacity on a more conservative basis. For example, the calculated remaining useful life that was present at the time that fuel cell power output dropped can be used as the new point where zero remaining useful life is estimated. So, for example, if the baseline calculation for remaining useful life indicates that the remaining useful life is 20% of the total starting capacity, but fuel cell power output drops at that point, then further calculations of remaining useful life can be scaled accordingly such as by multiplying values for remaining useful life by a correction factor.
• the method 1000 can include an operation of getting on-board sensor data 1002, such as from a sensor package.
• the method 1000 can further include an operation of getting vehicle geolocation 1004.
• the method 1000 can further include an operation of getting environmental condition data for the given geolocation 1006.
• the method 1000 can further include an operation of calibrating sensors and/or adjusting remaining useful life calculations 1008.
• the environmental condition data can be taken as being accurate and data from the sensors in the sensor package can be adjusted using a correction factor such that they accurately reflect concentrations of chemical species as indicated by the environmental condition data.
• remaining useful life calculations can be adjusted using the environmental condition data. For example, if the environmental condition data indicated high levels of various chemical species of interest, then the system can adjust the remaining useful life calculations to be more conservative (e.g., to reflect that the remaining useful life has been used up more quickly).
• FIG. 11 a block diagram view of components of a processing unit 214 is shown in accordance with various embodiments herein. It will be appreciated, however, that a greater or lesser number of components can be included with various embodiments and that this schematic diagram is merely illustrative.
• the processing unit 214 can include a housing 1102 and a control circuit 1104.
• the control circuit 1104 can include various electronic components including, but not limited to, a microprocessor, a microcontroller, a FPGA (field programmable gate array) chip, an application specific integrated circuit (ASIC), or the like.
• a microprocessor e.g., a central processing unit (CPU)
• a microcontroller e.g., a central processing unit (CPU)
• a FPGA field programmable gate array
• ASIC application specific integrated circuit
• the processing unit 214 can include a first sensor channel 1120, a second sensor channel 1122, a third sensor channel 1124, a fourth sensor channel 1126, and a fifth sensor channel 1128.
• the sensor channels can provide an interface with the sensors used and, in various embodiments, execute various operations on the data/signals from the sensors including amplification, noised reduction, sampling frequency adjustments, and the like. However, it will be appreciated that greater or lesser numbers of sensor channels can be used herein.
• the processing power of the control circuit 1104 and components thereof can be sufficient to perform various operations including various operations on data from sensors including, but not limited to averaging, time-averaging, statistical analysis, normalizing, aggregating, sorting, deleting, traversing, transforming, condensing (such as eliminating selected data and/or converting the data to a less granular form), compressing (such as using a compression algorithm), merging, inserting, timestamping, filtering, discarding outliers, calculating trends and trendlines (linear, logarithmic, polynomial, power, exponential, moving average, etc.), predicting filter RUL (remaining useful life), identifying an RUL condition, predicting performance, predicting costs associated with replacing filter elements vs. not-replacing filter elements, and the like.
• Normalizing operations performed by the control circuit 1104 can include, but are not limited to, adjusting one or more values based on another value or set of values.
• on-board sensor data e.g., data from sensors of the sensor package
• environmental condition data can be normalized based on environmental condition data.
• control circuit can calculate a time for replacement of a filter / filter element and generate a signal regarding the time for replacement. In various embodiments, the control circuit can calculate a time for replacement of a filter element and issue a notification regarding the time for replacement through a user output device. In various embodiments, the control circuit can calculate a time for replacement of a filter element based on signals from the sensors herein as well as data regarding the capacity of the filter / filter element.
• the control circuit initiates an alert or alarm if a predetermined alarm condition has been met.
• the alarm condition can include one or more a maximum value for a signal received from a chemical sensor herein, crossing a threshold value for remaining useful life of a chemical filter herein, or the like.
• the processing unit 214 can include a power supply circuit 1132.
• the power supply circuit 1132 can include various components including, but not limited to, a battery 1134, a capacitor, a powerreceiver such as a wireless power receiver, a transformer, a rectifier, and the like.
• the power supply circuit 1132 can receive power from a power supply on the vehicle itself such as a DC power source associated with the vehicle (or even an AC power source in some scenarios).
• the processing unit 214 can include an output device 1136.
• the output device 1136 can include various components for visual and/or audio output including, but not limited to, lights (such as LED lights), a display screen, a speaker, and the like.
• the output device can be used to provide notifications or alerts to a system user such as current system status, an indication of a problem, a required user intervention, a proper time to perform a maintenance action, or the like.
• the processing unit 214 can include memory 1138 and/or a memory controller.
• the memory can include various types of memory components including dynamic RAM (D-RAM), read only memory (ROM), static RAM (S-RAM), disk storage, flash memory, EEPROM, battery-backed RAM such as S-RAM or D-RAM and any other type of digital data storage component.
• the electronic circuit or electronic component includes volatile memory.
• the electronic circuit or electronic component includes non-volatile memory.
• the electronic circuit or electronic component can include transistors interconnected to provide positive feedback operating as latches or flip flops, providing for circuits that have two or more metastable states, and remain in one of these states until changed by an external input. Data storage can be based on such flip-flop containing circuits. Data storage can also be based on the storage of charge in a capacitor or on other principles.
• the non-volatile memory 1138 can be integrated with the control circuit 1104.
• the processing unit 214 can include a clock circuit 1140.
• the clock circuit 1140 can be integrated with the control circuit 1104. While not shown in FIG. 11, it will be appreciated that various embodiments herein can include a data/communi cation bus to provide for the transportation of data between components.
• an analog signal interface can be included.
• a digital signal interface can be included.
• the processing unit 214 can include a communications circuit 1142.
• the communications circuit can include components such as an antenna 1144, amplifiers, filters, digital to analog and/or analog to digital converters, and the like.
• the communications circuit 1142 can facilitate wired and/or wireless communications to and from the system.
• operations described herein and method steps can be performed as part of a computer-implemented method executed by one or more processors of one or more computing devices.
• operations described herein and method steps can be implemented instructions stored on a non- transitory, computer-readable medium that, when executed by one or more processors, cause a system to execute the operations and/or steps.
• a method of monitoring a fuel cell chemical filter can include interfacing with an air flow channel of a fuel cell system upstream of a chemical filter.
• the method can also include detecting an amount of a chemical compound in the air flow channel.
• the method can also include tracking total exposure of the chemical filter to the chemical compound.
• the method can also include estimating a remaining life of the chemical filter based on the tracked total exposure of the chemical filter and data regarding the total capacity of the chemical filter.
• the method can further include sending data regarding at least one of tracked total exposure and estimated remaining filter life.
• the method can further include receiving data regarding environmental levels of the chemical compound from a remote system.
• the method can further include sending geolocation data to the remote system in order to get data regarding environmental levels of the chemical compound that is specific for the geolocation of the vehicle or other system.
• receiving data regarding environmental levels of the chemical compound from a remote system can include using the received data to modulate estimate calculations regarding remaining life of the chemical filter.
• receiving data regarding environmental levels of the chemical compound from a remote system can include using the received data to calibrate one or more sensors.
• the method can further include receiving an input regarding a filter change event.
• the method can further include issuing an alert when the remaining life the chemical filter crosses a threshold value. In an embodiment, the method can further include issuing alerts according to a tiered severity scheme when the remaining life the chemical filter crosses one or more threshold values.
• Various embodiments herein include one or more sensors. Further details about the sensors are provided as follows. However, it will be appreciated that this is merely provided by way of example and that further variations are contemplated herein.
• Sensors herein can include, but are not limited to, an SO2 sensor, an H2S sensor, an NO2 sensor, an NH3 sensor, and a volatile organic compound (VOC) sensor.
• sensors herein can be specific for a particular compound.
• sensors herein can be specific for a class or group of compounds.
• estimates of the concentration of the specific compound can be generated by multiplying by a correction factor which takes into account the amount of the signal that is related to the specific compound in question. For example, if the sensor signal reflects contributions from all bases, then a contribution factor can be used to estimate the amount of NH3 reflected in the overall signal.
• the correction factor can be derived through a calibration procedure. Concentration values can be converted to total exposure amounts by adjusting for the flow rate and the sampling time. Total exposure amounts can be tracked and subtracted from filter total capacity values to get remaining capacity.
• Sensors herein can operate according to many different principles of operation.
• Sensors herein can include, but are not limited to, electrochemical sensors.
• electrochemical sensors can operate by contacting and/or reacting with a gas sample and producing an electrical signal proportional to the gas concentration of a specific chemical species or the concentration of a specific class of gases within the gas sample.
• chemical sensors herein can be optical chemical sensors.
• Other sensor types herein can include, but are not limited to, liquid film ion sensors, ion selective FETs, solid film ion sensors, semiconductor gas sensors, contact combustion gas sensors, polymer gas sensors, capacitance-based sensors, resistance-based sensors, and the like.
• Exemplary sensors herein can include, but are not limited to, the ALPHASENSE H2S-B4, ALPHASENSE SO2-B4, ALPHASENSE NO2-B43F, SGX SENSORTECH MiCS-5914, BOSCH BME688, and the like.
• sensitivities can be 1000 ppm, 500 ppm, 100 ppm, 10 ppm, 5 ppm, 1 ppm, 100 ppb, 50 ppb, 25 ppb, 10 ppb, or even 5 ppb, or a sensitivity falling within a range between any of the foregoing.
• configurations herein where the sensor package is configured to interface with and airflow channel upstream from the chemical filter are advantageous because sensors with lesser sensitivity values can be used.
• upstream of the chemical filter the concentrations of chemical species of interest herein are relatively high compared with what they may be downstream of the chemical filter. Thus, sensors can be used herein with relatively lesser sensitivity.
• the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration.
• the phrase “configured” can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.

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• 2023
  • 2023-09-27 EP EP23793557.2A patent/EP4595134A2/de active Pending
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