Power management system for a fuel cell/battery hybrid vehicle incorporating fuel cell and battery degradation

Optimization of fuel cell/battery hybrid vehicle systems has primarily focused on reducing fuel consumption. However, it is also necessary to focus on fuel cell and battery durability as inadequate lifespan is still a major barrier to the commercialization of fuel cell vehicles. Here, we introduce a power management strategy which concurrently accounts for fuel consumption as well as fuel cell and battery degradation. Fuel cell degradation is quantified using a simplified electrochemical model which provides an analytical solution for the decay of the electrochemical surface area (ECSA) in the fuel cell by accounting for the performance loss due to transient power load, start/stop cycles, idling and high power load. The results show that the performance loss based on remaining ECSA matches well with test data in the literature. A validated empirical model is used to relate Lithium-ion battery capacity decay to C-rate. Simulations are then conducted using a typical bus drive cycle to optimize the fuel cell/battery hybrid system. We demonstrate that including these degradation models in the objective function can effectively extend the lifetime of the fuel cell at the expense of higher battery capacity decay resulting in a lower average running cost over the lifetime of the vehicle.     

Experimental investigation on the dynamic performance of a hybrid PEM fuel cell/battery system for lightweight electric vehicle application

A hybrid system combining a 2 kW air-blowing proton exchange membrane fuel cell (PEMFC) stack and a lead–acid battery pack is developed for a lightweight cruising vehicle. The dynamic performances of this PEMFC system with and without the assistance of the batteries are systematically investigated in a series of laboratory and road tests. The stack current and voltage have timely dynamic responses to the load variations. Particularly, the current overshoot and voltage undershoot both happen during the step-up load tests. These phenomena are closely related to the charge double-layer effect and the mass transfer mechanisms such as the water and gas transport and distribution in the fuel cell. When the external load is beyond the range of the fuel cell system, the battery immediately participates in power output with a higher transient discharging current especially in the accelerating and climbing processes. The DC–DC converter exhibits a satisfying performance in adaptive modulation. It helps rectify the voltage output in a rigid manner and prevent the fuel cell system from being overloaded. The dynamic responses of other operating parameters such as the anodic operating pressure and the inlet and outlet temperatures are also investigated. The results show that such a hybrid system is able to dynamically satisfy the vehicular power demand.     

Modeling and thermal management of proton exchange membrane fuel cell for fuel cell/battery hybrid automotive vehicle

The proton exchange membrane fuel cell (PEMFC) stack is a key component in the fuel cell/battery hybrid vehicle. Thermal management and optimized control of the PEMFC under real driving cycle remains a challenging issue. This paper presents a new hybrid vehicle model, including simulations of diver behavior, vehicle dynamic, vehicle control unit, energy control unit, PEMFC stack, cooling system, battery, DC/DC converter, and motor. The stack model had been validated against experimental results. The aim is to model and analyze the characteristics of the 30 kW PEMFC stack regulated by its cooling system under actual driving conditions. Under actual driving cycles (0–65 kW/h), 33%–50% of the total energy becomes stack heat; the heat dissipation requirements of the PEMFC stack are high and increase at high speed and acceleration. A PID control is proposed; the cooling water flow rate is adjusted; the control succeeded in stabilizing the stack temperature at 350 K at actual driving conditions. Constant and relative lower inlet cooling water temperature (340 K) improves the regulation ability of the PID control. The hybrid vehicle model can provide a theoretical basis for the thermal management of the PEMFC stack in complex vehicle driving conditions.     

Fuel cell-battery hybrid powered light electric vehicle (golf cart): Influence of fuel cell on the driving performance

A light electric vehicle (golf cart, 5 kW nominal motor power) was integrated with a commercial 1.2 kW PEM fuel cell system, and fuelled by compressed hydrogen (two composite cylinders, 6.8 L/300 bar each). Comparative driving tests in the battery and hybrid (battery + fuel cell) powering modes were performed. The introduction of the fuel cell was shown to result in extending the driving range by 63–110%, when the amount of the stored H₂ fuel varied within 55–100% of the maximum capacity. The operation in the hybrid mode resulted in more stable driving performances, as well as in the increase of the total energy both withdrawn by the vehicle and returned to the vehicle battery during the driving. Statistical analysis of the power patterns taken during the driving in the battery and hybrid-powering modes showed that the latter provided stable operation in a wider power range, including higher frequency and higher average values of the peak power.     

Adaptive real-time optimal energy management strategy based on equivalent factors optimization for hybrid fuel cell system

Fuel cell, a new kind of energy supply equipment, has several advantages such as high efficiency, low noise, and no emission. Proton exchange membrane fuel cell (PEMFC) is considered to have the potential to take the place of the conventional engine on unmanned underwater vehicle (UUV). Besides the power sources in the hybrid power system, the energy management system (EMS) is crucial to operating performance. In this paper, an on-line adaptive equivalent hydrogen consumption minimization strategy (ECMS) is proposed to solve the problem of prior knowledge demand and poor adaptability of current energy management algorithms. In this presented method, a battery state of charge (SOC) constituted penalty term is designed to calculate the equivalent factor (EF), and then the equivalent factor obtained by optimization is substituted into the original objective equation to realize the real-time energy regulation. In this paper, a typical UUV load curve is used to verify the control effect under different working conditions, and the performance is compared with three conventional algorithms’. Simulation results show that the hydrogen consumption of proposed algorithm is close to the optimal solution obtained in offline environment, and it is reduced by more than 3.79% compared with the traditional online methods.     

Numerical modeling of a non-flooding hybrid polymer electrolyte fuel cell

Experimental results were recently reported regarding a novel “non-flooding” hybrid fuel cell consisting of proton exchange membrane (PEM) and anion exchange membrane (AEM) half-cells on opposite sides of a water-filled, porous intermediate layer. Product water formed in the porous layer, where it could permeate to the exterior of the cell, rather than at the electrodes. Although electrode flooding was mitigated, the reported power output was low. To investigate the potential for increased power output, a physicochemical charge transport model of the porous electrolyte layer is reported here. Traditional electrochemical modeling was generalized in a novel way to consider both ion transport and reaction in the aqueous phase and electronic conduction in the graphitic scaffold using a unified Poisson–Nernst–Planck framework. Though the model used no arbitrary or fitting parameters, the ionic resistance calculated for the porous layer agreed well with the highly non-Ohmic experimental values previously reported for the entire fuel cell. Interestingly, electronic charge carriers in the scaffold were found to obviate the need for counterion presence in this unique electrolyte structure. Still, the thickness- and temperature-dependent model results offer limited prospects for improving the power output.     

Dynamic modeling of a photovoltaic hydrogen fuel cell hybrid system

The objective of this paper is to mathematically model a stand-alone renewable power system, referred to as “Photovoltaic–Fuel Cell (PVFC) hybrid system”, which maximizes the use of a renewable energy source. It comprises a photovoltaic generator (PV), a water electrolyzer, a hydrogen tank, and a proton exchange membrane (PEM) fuel cell generator. A multi-domain simulation platform Simplorer is employed to model the PVFC hybrid systems. Electrical power from the PV generator meets the user loads when there is sufficient solar radiation. The excess power from the PV generator is then used for water electrolysis to produce hydrogen. The fuel cell generator works as a backup generator to supplement the load demands when the PV energy is deficient during a period of low solar radiation, which keeps the system's reliability at the same level as for the conventional system. Case studies using the present model have shown that the present hybrid system has successfully tracked the daily power consumption in a typical family. It also verifies the effectiveness of the proposed management approach for operation of a stand-alone hybrid system, which is essential for determining a control strategy to ensure efficient and reliable operation of each part of the hybrid system. The present model scheme can be helpful in the design and performance analysis of a complex hybrid-power system prior to practical realization.     

Thermal analysis and management of proton exchange membrane fuel cell stacks for automotive vehicle

The thermal management of a proton exchange membrane fuel cell (PEMFC) is crucial for fuel cell vehicles. This paper presents a new simulation model for the water-cooled PEMFC stacks for automotive vehicles and cooling systems. The cooling system model considers both the cooling of the stack and cooling of the compressed air through the intercooler. Theoretical analysis was carried out to calculate the heat dissipation requirements for the cooling system. The case study results show that more than 99.0% of heat dissipation requirement is for thermal management of the PEMFC stack; more than 98.5% of cooling water will be distributed to the stack cooling loop. It is also demonstrated that controlling cooling water flow rate and stack inlet cooling water temperature could effectively satisfy thermal management constraints. These thermal management constraints are differences in stack inlet and outlet cooling water temperature, stack temperature, fan power consumption, and pump power consumption.     

An energy management strategy based on dynamic power factor for fuel cell/battery hybrid locomotive

In order to efficiently absorb more regenerative braking energy which sustains much longer compared with the conventional vehicle, and guarantee the safety of the hybrid system under the actual driving cycle of locomotive, an energy management control based on dynamic factor strategy is proposed for a scale-down locomotive system which consists of proton exchange membrane fuel cell (PEMFC) and battery pack. The proposed strategy which has self-adaption function for different driving cycles aims to achieve the less consumption of hydrogen and higher efficiency of the hybrid system. The experimental results demonstrate that the proposed strategy is able to maintain the charge state of battery (SOC) better than Equivalent Consumption Minimization Strategy (ECMS), and the proposed strategy could keep the change trend of SOC, which the final SOC is closed to the target value regardless of the initial SOC of battery. Moreover, the hydrogen consumption has been reduced by 0.86g and the efficiency of overall system has been raised of 2% at least than ECMS under the actual driving cycle through the proposed strategy. Therefore, the proposed strategy could improve the efficiency of system by diminishing the conversion process of energy outputted by fuel cell.     

Energy management of PEM fuel cell/ supercapacitor hybrid power sources for an electric vehicle

This paper presents the utilization of a supercapacitor (SC) as an auxiliary power source in an electric vehicle (EV), composed of a proton electrolyte membrane fuel cell (PEMFC) as the main energy source. The main weak point of PEMFC is slow dynamics because one must limit the fuel cell current slope in order to prevent fuel starvation problems, to improve its performance and lifetime. The very fast power response and high specific power of a supercapacitor can complement the slower power output of the main source to produce the compatibility and performance characteristics needed in a propulsion system. DC-DC converters connected to the hybrid source ensure a constant voltage value in inverters inputs. After an architecture presentation of the hybrid energy source, two parallel-type configurations are explored in more detail. For each of them, the energy flow control and management, validated simulation shows the performance obtained in this configuration. The hybrid source management is based primarily on the intervention of the supercapacitor in fugitives' schemes such as slopes, different speeds and rapid acceleration. Secondly, the PEMFC intervenes to guarantee the power in permanent regime. Finally, simulation results considering energy management are presented and illustrated the hybrid energy source benefits.     

The computer-aided analysis for the driving stability of a plug-in fuel cell vehicle using a proton exchange membrane fuel cell

In order to analyze the driving stability of a plug-in fuel cell vehicle (PFCV), a computer-aided simulator for PFCVs has been developed. PFCVs have been introduced around the world to achieve early commercialization of an eco-friendly and highly efficient fuel cell vehicle. The plug-in option, which allows the battery to be recharged from the electricity grid, enables a reduction in size of the fuel cell system (FCS) and an improvement of its durability. As such, the existing limitations of the fuel cell - such as its high cost, poor durability, and the insufficient hydrogen infrastructure – can be overcome. During the design phase of PFCV development, simulation-based driving stability test is necessary to determine the sizes of the electric engine of the FCS and the battery. The developed simulator is very useful for analyzing the driving stability of the PFCV with respect to the capacities of the FCS and battery. The simulation results are in fact very close to those obtained from a real system, since the estimation accuracy of PFCV component models used in this simulator, such as the fuel cell stack, battery, electric vehicle, and the other balance of plants (BOPs), are verified by the experiments, and the simulator uses the newly-proposed power distribution control logic and the pre-confirmed real driving schedule. Using these results, we can study which one will be the best in terms of driving stability.     

Investigation and analysis of proton exchange membrane fuel cell dynamic response characteristics on hydrogen consumption of fuel cell vehicle

The number of working points and response speed are two essential characteristics of proton exchange membrane fuel cell (PEMFC). The improper setting of the number of working points and response speed may reduce the life of PEMFC and increase the hydrogen consumption of the vehicle. This paper explores the impact of the response speed as well as the working points of the PEMFC on the hydrogen consumption in the real-system level. In this paper a dynamic model of the PEMFC system is established and verified by experiments. The model is able to reflect the dynamic response process of PEMFC under a series different number of working points and different response speed. Based on the proposed model, the influence of working points and the response speed of PEMFC on the hydrogen consumption in the vehicle under different driving cycles is analyzed and summarized, for the first time, in the open literature. The results highlight that the hydrogen consumption will decreases in both cases that with the increase of working point number and increase of response speed. However, the reduction range of hydrogen consumption trends to smaller and may reach to an optimal level considering the trade-off between the hydrogen saving and the other costs, for example the control cost. Also, with a more complex driving cycle, the working points and response speed have a greater the impact on the hydrogen consumption in the vehicle applications.     

Transient power characteristic measurement of a proton exchange membrane fuel cell generator

An experimental study on the transient power characteristics of a fuel cell generator has been conducted. The generator is hybridized by a proton exchange membrane (PEM) as the main power source and a lithium-ion battery as the secondary power source. power-conditioning module consisting of a main bidirectional converter and an auxiliary converter has been designed to manage the hybrid power of the generator that copes with fast dynamics of variable loads. Sensors embedded in the generator have measured the electrical properties dynamically. It was found that the present power-conditioning scheme has well controlled the power flow between the fuel cell stack and the battery by regulating the power flow from or to the battery. In addition, the thermal management system using pulse width modulation (PWM) schemes could limit the operation temperature of the fuel cell generator in a designed range. Furthermore, the dynamics of electrical efficiency of the generator are found to be parallel with those of the net system power. Finally, the stability and reliability of the fuel cell generator is proven by the rational dynamic behaviors of thermal and electrical properties for over 30-h demonstration.     

Experimental investigation on water and heat management in a PEM fuel cell using response surface methodology

Water and heat management are the most critical issues for the performance of proton exchange membrane (PEM) fuel cells. They can be provided by keeping hydrogen flow rate, oxygen flow rate, cell temperature and humidification temperature under control. In this study, the effects of these parameters on the power density of proton exchange membrane (PEM) fuel cell which has 25 cm² active area have been examined experimentally using hydrogen on the anode side and oxygen on the cathode side. Response Surface Methodology (RSM) has been applied to optimize these operation parameters of proton exchange membrane (PEM) fuel cell. The test responses are the maximum output power density. ANOVA (analysis of variance) analyses are used to compute the effects and the contributions of the various factors to the fuel cell maximal power density. The use of this design shows also how it is possible to reduce the number of experiments. Hydrogen flow rate, oxygen flow rate, humidification temperature and cell temperature were the main parameters to have been varied between 2.5–5 L/min, 3–5 L/min, 40–70 °C and 40–80 °C in the analyses. The maximum power density was found as 241.977 mW/cm².     

An actively controlled fuel cell/battery hybrid to meet pulsed power demands

This paper presents the experimental results of an actively controlled fuel cell/battery hybrid power source topology that can be widely used in many applications, such as portable electronic devices, communication equipment, spacecraft power systems, and electric vehicles, in which the power demand is impulsive rather than constant. A step-down DC/DC power converter is incorporated to actively control the power flow between the fuel cell and the battery to achieve both high power and high energy densities. The results show that the hybrid power source can achieve much greater specific power and power density than the fuel cell alone. This paper first demonstrates that an actively controlled hybrid with a 35 W hydrogen-fueled polymer electrolyte membrane fuel cell and a lithium-ion battery pack of six cells yielded a peak power of 100 W, about three times as high as the fuel cell alone can supply, while causing a very limited (10%) weight increase to the whole system. After that, another hybrid source using a different battery array (eight cells) was investigated to further validate the control strategy and to show the flexibility and generality of the hybrid source design. The experimental data show that the hybrid source using an eight-cell battery supplied a peak power of 135 W, about four times that of the fuel cell alone. Finally, three power sources including the fuel cell alone and the two hybrids studied were compared in terms of specific power, power density, volume, weight, etc. The design presented here can be scaled to larger or smaller power capacities for a variety of applications.     

Multiple model predictive control for a hybrid proton exchange membrane fuel cell system

This paper presents a hierarchical predictive control strategy to optimize both power utilization and oxygen control simultaneously for a hybrid proton exchange membrane fuel cell/ultracapacitor system. The control employs fuzzy clustering-based modeling, constrained model predictive control, and adaptive switching among multiple models. The strategy has three major advantages. First, by employing multiple piecewise linear models of the nonlinear system, we are able to use linear models in the model predictive control, which significantly simplifies implementation and can handle multiple constraints. Second, the control algorithm is able to perform global optimization for both the power allocation and oxygen control. As a result, we can achieve the optimization from the entire system viewpoint, and a good tradeoff between transient performance of the fuel cell and the ultracapacitor can be obtained. Third, models of the hybrid system are identified using real-world data from the hybrid fuel cell system, and models are updated online. Therefore, the modeling mismatch is minimized and high control accuracy is achieved. Study results demonstrate that the control strategy is able to appropriately split power between fuel cell and ultracapacitor, avoid oxygen starvation, and so enhance the transient performance and extend the operating life of the hybrid system.     

Energy management of a fuel cell hybrid ultra-energy efficient vehicle

This paper focuses on energy management in an ultra-energy efficient vehicle powered by a hydrogen fuel cell with rated power of 1 kW. The vehicle is especially developed for the student competition Shell Eco-marathon in the Urban Concept category. In order to minimize the driving energy consumption a simulation model of the vehicle and the electric propulsion is developed. The model is based on vehicle dynamics and real motor efficiency as constant DC/DC, motor controllers and transmission efficiency were considered. Based on that model five propulsion schemes and driving strategies were evaluated. The fuel cell output parameters were experimentally determined. Then, the driving energy demand and hydrogen consumption was estimated for each of the propulsion schemes. Finally, an experimental study on fuel cell output power and hydrogen consumption was conducted for two propulsion schemes in case of hybrid and non-hybrid power source. In the hybrid propulsion scheme, supercapacitors were used as energy storage as they were charged from the fuel cell with constant current of 10 A.     

An overview: Current progress on hydrogen fuel cell vehicles

The harmful consequences of pollutants emitted by conventional fuel cars have prompted vehicle manufacturers to shift towards alternative energy sources. Currently, fuel cells (FCs) are commonly regarded as highly efficient and non-polluting power sources capable of delivering far greater energy densities and energy efficiency than conventional technologies. Proton exchange membrane fuel cells (PEMFC) are viewed as promising in transportation sectors because of their ability to start at cold temperatures and minimal emissions. PEMFC is an electrochemical device that converts hydrogen and oxidants into electricity, water, and heat at various temperatures. The pros and cons of the technology are discussed in this article. Various fuel cell types and their applications in the portable, automobile, and stationary sectors are discussed. Additionally, recent issues associated with existing fuel cell technology in the automobile sector are reviewed.     

Experimental study of the start-up of a fuel cell stack for backup power application

The transient response of proton exchange membrane fuel cells during start-up is an important issue for backup power systems which require a very short start-up time in order to limit the use of batteries during a blackout. The start-up procedure of a ten cells stack was studied: in the first stage the cathode channel initially filled with nitrogen was supplied with oxygen in open circuit then in the second stage it was connected to the load. The influences of the current time-profile (step or ramp), the cell voltage at the connection and the gas flow rates on the voltage variation were investigated. It was found that the voltage value during the filling of the cathode is not sufficient to determine which fraction of the cathode was filled with oxygen. In most cases, high oxygen flow rates allow reducing the start-up time of the stack. Furthermore, for fixed current density and stoichiometric coefficients it was found that a minimum start-up time exits. The analysis of transient response to current steps showed that around 70% of the maximum electrical power was available less than 2 s after the beginning of the start-up procedure.     

Development of a proton exchange membrane fuel cell cogeneration system

A proton exchange membrane fuel cell (PEMFC) cogeneration system that provides high-quality electricity and hot water has been developed. A specially designed thermal management system together with a microcontroller embedded with appropriate control algorithm is integrated into a PEM fuel cell system. The thermal management system does not only control the fuel cell operation temperature but also recover the heat dissipated by FC stack. The dynamic behaviors of thermal and electrical characteristics are presented to verify the stability of the fuel cell cogeneration system. In addition, the reliability of the fuel cell cogeneration system is proved by one-day demonstration that deals with the daily power demand in a typical family. Finally, the effects of external loads on the efficiencies of the fuel cell cogeneration system are examined. Results reveal that the maximum system efficiency was as high as 81% when combining heat and power.