Fault diagnostic apparatus for a fuel cell electric vehicle and a method therefor

Patent metadata

Field	Value
Publication number	US-11923575-B2
Application number	US-202117470699-A
Country	US
Kind code	B2
Filing date	Sep 9, 2021
Priority date	Dec 7, 2020
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

Abstract

A fault diagnostic apparatus for a fuel cell electric vehicle and a method therefor are provided. The apparatus includes: a main relay connected to a fuel cell stack; a power converter connected to the main relay; a heater relay connected to the fuel cell stack and the main relay at one end and connected to a cathode oxygen depletion (COD) heater at the other end; and a fuel cell control unit (FCU) connected with the main relay, the power converter, and the heater relay. The FCU diagnoses a fault of the main relay based on an amount of change in stack voltage according to control to turn off and on the heater relay and a power of the power converter according to variable control of a voltage of the power converter, when the vehicle enters a shutdown sequence, and outputs the diagnosed result.

First claim

What is claimed is:

1. A fault diagnostic apparatus for a fuel cell electric vehicle, the fault diagnostic apparatus comprising:
a main relay connected to a fuel cell stack;
a power converter connected to the main relay;
a heater relay connected to the fuel cell stack and the main relay at one end and connected to a cathode oxygen depletion (COD) heater at the other end; and
a fuel cell control unit (FCU) connected with the main relay, the power converter, and the heater relay,
wherein the FCU diagnoses a fault of the main relay based on an amount of change in stack voltage according to control to turn off and on the heater relay and a power of the power converter according to variable control of a voltage of the power converter, when the vehicle enters a shutdown sequence, and outputs the diagnosed result.

2. The fault diagnostic apparatus of claim 1 , wherein the FCU monitors a stack voltage during a predetermined time from a time when the heater relay is turned on, when the vehicle enters the shutdown sequence, to determine whether exhaustion of the stack voltage is delayed.

3. The fault diagnostic apparatus of claim 1 , wherein the FCU detects a first stack voltage after turning off the heater relay, detects a second stack voltage after turning on the heater relay, and calculates the amount of change in stack voltage using the first stack voltage and the second stack voltage.

4. The fault diagnostic apparatus of claim 3 , wherein the FCU primarily determines the fault of the main relay when the amount of change in stack voltage is less than a reference amount of change.

5. The fault diagnostic apparatus of claim 4 , wherein the FCU determines an operation delay fault of the COD heater when the amount of change in stack voltage is not less than the reference amount of change.

6. The fault diagnostic apparatus of claim 1 , wherein the FCU variably controls an output voltage of the power converter to an upper limit voltage and a lower limit voltage.

7. The fault diagnostic apparatus of claim 6 , wherein the FCU detects a first power converter power, when the output voltage of the power converter is variably controlled to the upper limit voltage, detects a second power converter power, when the output voltage of the power converter is variably controlled to the lower limit voltage, and secondarily determines the fault of the main relay depending on whether the first power converter power and the second power converter power meet a main relay fault diagnosis condition.

8. The fault diagnostic apparatus of claim 7 , wherein the FCU determines a main relay fusion fault when the first power converter power is less than a first reference power and when the second power converter power is greater than the first reference power and is less than a second reference power.

9. The fault diagnostic apparatus of claim 8 , wherein the FCU determines an operation delay fault of the COD heater when the first power converter power is greater than or equal to the first reference power and when the second power converter power is less than or equal to the first reference power and is greater than or equal to the second reference power.

10. The fault diagnostic apparatus of claim 1 , wherein the power converter is implemented as a bidirectional high voltage DC-DC converter (BHDC).

11. A fault diagnostic method for a fuel cell electric vehicle including a fuel cell control unit (FCU) connected with a main relay of a fuel cell stack, a power converter, and a heater relay, the fault diagnostic method comprising:
detecting whether the vehicle enters a shutdown sequence;
diagnosing a fault of the main relay based on an amount of change in stack voltage according to control to turn off and on the heater relay and a power of the power converter according to variable control of a voltage of the power converter when the vehicle enters the shutdown sequence; and
outputting the result of diagnosing the fault of the main relay.

12. The fault diagnostic method of claim 11 , wherein the diagnosing of the fault of the main relay includes:
monitoring a stack voltage during a predetermined time from a time when the heater relay is turned on; and
determining whether exhaustion of the stack voltage is delayed based on the result of monitoring the stack voltage.

13. The fault diagnostic method of claim 11 , wherein the diagnosing of the fault of the main relay includes:
detecting a static voltage when the heater relay is turned off and on and calculating the amount of change in stack voltage;
determining whether the amount of change in stack voltage is less than a reference amount of change; and
primarily determining the fault of the main relay when the amount of change in stack voltage is less than the reference amount of change.

14. The fault diagnostic method of claim 13 , wherein the diagnosing of the fault of the main relay includes:
determining an operation delay fault of a COD heater when the amount of change in stack voltage is not less than the reference amount of change.

15. The fault diagnostic method of claim 11 , wherein the diagnosing of the fault of the main relay includes:
variably controlling an output voltage of the power converter to an upper limit voltage to detect a first power converter power;
variably controlling the output voltage of the power converter to a lower limit voltage to detect a second power converter power; and
secondarily determining the fault of the main relay when the first power converter power and the second power converter power meet a main relay fault diagnosis condition.

16. The fault diagnostic method of claim 15 , wherein the secondarily determining includes:
determining a main relay fusion fault when the first power converter power is less than a first reference power and when the second power converter power is greater than the first reference power and is less than a second reference power.

17. The fault diagnostic method of claim 15 , wherein the diagnosing of the fault of the main relay further includes:
determining an operation delay fault of a COD heater when the first power converter power and the second power converter power do not meet the main relay fault diagnosis condition.

Assignees

• Hyundai Motor Co Ltd
• Kia Corp

Inventors

• Kim Min Taek
• Ye Chang Hwan
• Kweon Soon Gil
• Park Hyo Jin

Classifications

• Y02E60/50

  Fuel cells · CPC title

• H01M8/04679 Primary

  of fuel cell stacks · CPC title

• B60L50/70

  using power supplied by fuel cells (in combination with batteries B60L50/75) · CPC title

• B60L58/34

  by heating · CPC title

• H01M8/04228

  during shut-down · CPC title