System and method for reducing battery overconsumption in a fuel cell system

Patent metadata

Field	Value
Publication number	US-11987149-B2
Application number	US-202117405841-A
Country	US
Kind code	B2
Filing date	Aug 18, 2021
Priority date	Aug 18, 2021
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

A system for reducing overconsumption of power in a vehicle includes a power source including a battery having a state of charge (SOC), and a fuel cell stack that generates electricity. The system further includes an electronic control unit (ECU) coupled to the power source and designed to receive a power request corresponding to a requested amount of power from the power source. The ECU is further designed to determine a fuel cell power amount corresponding to an amount of the electricity generated by the fuel cell stack to achieve the requested amount of power. The ECU is further designed to determine an overconsumption event when a current power consumption corresponding to a total amount of power being drawn from the power source is greater than the power request. The ECU is further designed to increase the fuel cell power amount in response to determining the overconsumption event.

First claim

What is claimed is:

1. A system for reducing overconsumption of power from a vehicular power source, the system comprising:
a power source including:
a battery configured to store energy and having a state of charge (SOC), and
a fuel cell stack configured to generate electricity at least one of to be utilized by a motor or to be stored in the battery; and

a power source electronic control unit (ECU) coupled to the power source and configured to:
receive a power request corresponding to a requested amount of power from the power source,
determine a fuel cell power amount corresponding to an amount of the electricity generated by the fuel cell stack to achieve the requested amount of power,
determine an overconsumption event when a current power consumption corresponding to a total amount of power being drawn from the power source is greater than the requested amount of power of the power request due to a miscommunication between the power source and one or more vehicle components causing the power request, and
increase the fuel cell power amount in response to determining the overconsumption event.

2. The system of claim 1 wherein the power source ECU is further configured to iteratively increase the fuel cell power amount until the fuel cell power amount is equal to the current power consumption.

3. The system of claim 1 wherein the battery is further configured to output supplemental power that supplements the fuel cell power amount to cause the power source to meet the current power consumption when the current power consumption is greater than the requested amount of power of the power request.

4. The system of claim 3 wherein the power source ECU is further configured to determine the overconsumption event in response to the SOC of the battery decreasing.

5. The system of claim 1 further comprising at least one sensor configured to detect power data corresponding to the total amount of power being drawn from the power source, wherein the power source ECU is further configured to determine the overconsumption event by comparing the detected power data to the power request.

6. The system of claim 1 wherein the power source ECU is further configured to:
determine a battery power output amount;
determine a total calculated power being drawn from the power source by adding the battery power output amount to the fuel cell power amount; and
determine the overconsumption event by comparing the total calculated power to the power request.

7. The system of claim 1 wherein the system is configured to be implemented in a vehicle manufactured separately from the system such that the power source ECU is configured to communicate with and receive the power request from a vehicle ECU that controls operation of the motor of the vehicle.

8. The system of claim 1 wherein increasing the fuel cell power amount in response to determining the overconsumption event reduces the likelihood of the SOC of the battery reaching or dropping below a lower SOC threshold.

9. The system of claim 1 wherein the power source ECU is further configured to cause the fuel cell stack to output the fuel cell power amount.

10. A system for reducing overconsumption of power from a vehicular power source, the system comprising:
a motor configured to convert electricity into mechanical power;
a power source including:
a battery configured to store energy and having a state of charge (SOC), and
a fuel cell stack configured to generate electricity at least one of to be utilized by the motor or to be stored in the battery;

a vehicle electronic control unit (ECU) coupled to the motor and configured to control operation of the motor and to generate a power request corresponding to a requested amount of power from the power source; and
a power source ECU coupled to the power source and the vehicle ECU and configured to:
receive the power request from the vehicle ECU,
determine a fuel cell power amount corresponding to an amount of the electricity generated by the fuel cell stack to achieve the requested amount of power,
determine an overconsumption event when a current power consumption corresponding to a total amount of power being drawn from the power source is greater than the requested amount of power of the power request due to a miscommunication between the power source and the motor, and
increase the fuel cell power amount in response to determining the overconsumption event.

11. The system of claim 10 wherein the battery is further configured to output supplemental power that supplements the fuel cell power amount to cause the power source to meet the current power consumption when the current power consumption is greater than the requested amount of power of the power request, and the power source ECU is further configured to determine the overconsumption event in response to the SOC of the battery decreasing.

12. The system of claim 10 further comprising at least one sensor configured to detect power data corresponding to the total amount of power being drawn from the power source, wherein the power source ECU is further configured to determine the overconsumption event by comparing the detected power data to the power request.

13. The system of claim 10 wherein the power source ECU is further configured to:
determine a battery power output amount;
determine a total calculated power being drawn from the power source by adding the battery power output amount to the fuel cell power amount; and
determine the overconsumption event by comparing the total calculated power to the power request.

14. A method for reducing overconsumption of power from a vehicular power source, the method comprising:
storing, in a battery, energy;
generating, by a fuel cell stack, electricity to be at least one of utilized by a motor or stored in the battery, the battery and the fuel cell stack together being a power source;
receiving, by a power source electronic control unit (ECU), a power request corresponding to a requested amount of power from the power source;
determining, by the power source ECU, a fuel cell power amount corresponding to an amount of the electricity generated by the fuel cell stack to achieve the requested amount of power;
determining, by the power source ECU, an overconsumption event when a current power consumption corresponding to a total amount of power being drawn from the power source is greater than the requested amount of power of the power request due to a miscommunication between the power source and one or more vehicle components causing the power request; and
increasing, by the power source ECU, the fuel cell power amount in response to determining the overconsumption event.

15. The method of claim 14 wherein increasing the fuel cell power amount includes iteratively increasing the fuel cell power amount until the fuel cell power amount is equal to the current power consumption.

16. The method of claim 14 further comprising outputting, by the battery, supplemental power that supplements the fuel cell power amount to cause the power source to meet the current power consumption when the current power consumption is greater than the requested amount of power of the power request.

17. The method of claim 16 wherein determining the overconsumption event includes determining the overconsumption event in response to a state of charge (SOC) of the battery decreasing.

18. The method of claim 14 further comprising detecting, by at least one sensor, power data corresponding to the total amount of power being drawn from the power source, wherein

Assignees

• Toyota Eng & Mfg North America

Inventors

• Folick Daniel Charles
• Bulpitt Christopher M
• Farnsworth Jared
• Sata Andrew

Classifications

• B60L58/40 Primary

  for controlling a combination of batteries and fuel cells · CPC title

• G01R31/382

  Arrangements for monitoring battery or accumulator variables, e.g. SoC · CPC title

• H01M2250/20

  Fuel cells in motive systems, e.g. vehicle, ship, plane · CPC title

• B60L58/13

  Maintaining the SoC within a determined range · CPC title

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title