Dr R Clague October 2015

Transcription

1 Dr R Clague October 2015 ralph.clague@intelligent-energy.com 2014 Intelligent Energy Limited The information in this document is the property of Intelligent Energy Limited and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Intelligent Energy Limited. This information is given in good faith based upon the latest information available to Intelligent Energy Limited, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Intelligent Energy Ltd or any of its subsidiary or associated companies. 1

2 Global Company International power technology company with over 400 staff worldwide Substantial and growing intellectual property portfolio of over 900 patents (granted and pending) Established in 2001, with a history of over 25 years fuel cell innovation Headquarters and main operation in Loughborough, UK, offices in London, California, Bangalore and Osaka 2

3 Commercial Application Across Sectors Intelligent Energy solutions are applied across sector and markets Motive Power; Two-wheeled vehicles, automotive, commercial vehicles Consumer Electronics (CE); Portable and extended operating power Distributed Power and Generation (DP&G); CHP, backup and emergency power 3

4 Full Range Personal Mobility up to 100kW We offer our partners rapid access to power technology markets, combining their well-established channels to mass markets with our fieldproven technologies and integration knowledge Cost effective, simple, powerful World leading power density 4

5 Gen4 Introduction Gen4 Fuel Cell System overview: NET power output: 4kW continuous Storage ambient temperature: -40C to +85C Operating ambient temperature : -10C to +45C System net electrical efficiency: >50% Vibration: 5g x, y, z (or any combination) Shock: half sine wave 50g/6ms System weight: <20kg Isolation resistance: 10MOhm HV Safety: IP XXD, HVIL, double pole isolation on HV output Environmental protection: IP65 or better, resistant to salt spray, ozone, mixed gas (IEC ) Restricted substances: compliant with GADSL Pressure release valve: not included Inlet hydrogen solenoid: included Inlet pressure monitoring: included 5

6 Intelligent Energy Systems Engineering Process SIMILAR What does Systems Engineering give IE? Working in the Automotive space, IE must align with a recognised safety standard such as IEC or ISO Complying with overarching quality and safety standards requires a structured approach to design. With a Systems approach, quality and safety are inherently managed from the beginning of the design process As a software controlled high power electronic device, the optimal design can only be achieved by thinking at a System level. Simulation and model based design give early visibility of performance and integration feasibility. 6

7 Air Cooled Fuel Cell Control Requirements State the Problem: What needs to be controlled and why. Externally Gen4 should: Deliver power when required Communicate with the vehicle or test bench Protect the external environment To achieve this, at stack level we need to monitor and control: Hydrogen fuel flow rates fuel starvation leads to cell voltage collapse Oxidant flow rates lack of oxygen leads to cell voltage collapse Cooling air inlet temperature too cold, flooding: too hot, drying Stack current current can be interrupted if required Stack voltage distribution all cells should be worked at the same level Stack temperature distribution temperature affects cell voltage and degradation Which means in the Membrane-Electrode Assembly (MEA) we need to control: Membrane hydration state too wet, liquid water floods the reaction sites: too dry, high resistance Nitrogen build up on the anode N2 crosses from anode to cathode, suffocating reaction sites Liquid water build up on anode and cathode droplet formation must be controlled Cell temperature - Cell voltage - 7

8 Intelligent Energy Systems Engineering Process Investigate Alternatives. High Level Requirements: Deliver power when required Communicate with the vehicle or test bench Protect the external environment 8

9 Air Cooled Fuel Cell System Abstraction Model the System: Functional block diagram. 9

10 Control Subsystem Sensor and Actuator Requirements H2 Control Inlet valve Pressure sensor Purge valve Air Control Ambient air temperature sensor Inlet air temperature sensor Inlet air shutoff mechanism Recirculated air conditioning mechanism Recirculated air mixing mechanism Air movement device (fans) Exhaust air flow control mechanism Power Control Derive stable low voltage power rails for ancillaries High voltage interlock Switch high power output Monitor cell voltages Monitor stack voltage Monitor stack current 10

11 Control Subsystem Functional Block Diagram 11

12 Control Subsystem Software Requirements Brief overview of software implementation strategy 12

13 Control Subsystem Application Layer Top level state machine Control software has multiple operating states. Transitions between states are largely driven by external CAN commands Internal error handling and external notification 13

14 Future of Control and Software Challenges and opportunities for developing 26 compatible systems 14

15 Dr R Clague October 2015 ralph.clague@intelligent-energy.com 2014 Intelligent Energy Limited The information in this document is the property of Intelligent Energy Limited and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Intelligent Energy Limited. This information is given in good faith based upon the latest information available to Intelligent Energy Limited, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Intelligent Energy Ltd or any of its subsidiary or associated companies. 15