System and method for feedback-based reduction of system overdraw in a fuel cell system

Patent metadata

Field	Value
Publication number	US-12024060-B2
Application number	US-202117405776-A
Country	US
Kind code	B2
Filing date	Aug 18, 2021
Priority date	Aug 18, 2021
Publication date	Jul 2, 2024
Grant date	Jul 2, 2024

Abstract

A system for reducing overdraw of power in a vehicle includes a power source having a battery and a fuel cell circuit. The system further includes an ECU that transmits a power limit signal to a vehicle controller, the power limit signal corresponding to an instantaneous maximum amount of power of the power source. The ECU also determines a battery allowed power corresponding to an amount of power available to be drawn from the battery to cause the SOC of the battery to remain above a lower SOC threshold. The ECU also determines a current battery power draw from the battery corresponding to an instantaneous amount of power being drawn from the battery. The ECU is designed to reduce the instantaneous maximum amount of power in the power limit signal when the current battery power draw is greater than the battery allowed power, reducing the current battery power draw.

First claim

What is claimed is:

1. A system for reducing overdraw 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 circuit 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:
transmit a power limit signal to a vehicle ECU, the power limit signal corresponding to an instantaneous maximum amount of power that can be provided by the power source,
determine a battery allowed power corresponding to an amount of power available to be drawn from the battery to cause the SOC of the battery to remain above a lower SOC threshold,
determine a current battery power draw from the battery corresponding to an instantaneous amount of power being drawn from the battery, and
reduce the instantaneous maximum amount of power in the power limit signal in response to the current battery power draw being greater than the battery allowed power in order to reduce an amount of power requested by the vehicle ECU, in turn reducing the current battery power draw.

2. The system of claim 1 wherein the power source ECU is further configured to increase an amount of the electricity generated by the fuel cell circuit in response to the current battery power draw being greater than the battery allowed power.

3. The system of claim 1 wherein the power source ECU is further configured to utilize a proportional-integral-derivative (PID) controller to iteratively reduce the instantaneous amount of power in the power limit signal until the current battery power draw is equal to or less than the battery allowed power.

4. The system of claim 1 wherein reducing the instantaneous maximum amount of power in the power limit signal reduces the likelihood of the SOC of the battery dropping to or below the lower SOC threshold.

5. 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 the vehicle ECU that controls operation of the motor of the vehicle.

6. The system of claim 1 wherein the power source ECU is further configured to:
determine a battery charge limit corresponding to an instantaneous maximum amount of electrical power that can be used to charge the battery;
transmit a charge limit signal to the vehicle ECU, the charge limit signal indicating an instantaneous maximum amount of power that can be provided to the power source for charging the battery;
determine a current battery charge amount corresponding to an instantaneous amount of power being provided to the battery for storage; and
reduce the instantaneous maximum amount of power that can be provided to the power source for charging the battery in the charge limit signal in response to the current battery charge amount being greater than the battery charge limit.

7. The system of claim 6 wherein the power source ECU is further configured to decrease an amount of the electricity generated by the fuel cell circuit in response to the current battery charge amount being greater than the battery charge limit.

8. The system of claim 6 wherein reducing the instantaneous maximum amount of power that can be provided to the power source for charging the battery in the charge limit signal reduces the likelihood of the SOC of the battery reaching or exceeding an upper SOC threshold.

9. A system for reducing overdraw 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 circuit 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:
transmit a power limit signal to a vehicle ECU, the power limit signal indicating an instantaneous maximum amount of power that can be drawn from the power source;
determine an internal maximum allowed consumption corresponding to the instantaneous maximum amount of power that can be drawn from the power source;
determine a current power consumption corresponding to a total amount of power being drawn from the power source; and
reduce the instantaneous maximum amount of power in the power limit signal in response to the current power consumption being greater than the internal maximum allowed consumption to reduce an amount of power requested by the vehicle ECU.

10. The system of claim 9 wherein the power source ECU is further configured to increase an amount of the electricity generated by the fuel cell circuit in response to the current power consumption being greater than the internal maximum allowed consumption.

11. The system of claim 9 wherein the power source ECU is further configured to utilize a proportional-integral-derivative (PID) controller to iteratively reduce the instantaneous amount of power in the power limit signal until the current power consumption is equal to or less than the internal maximum allowed consumption.

12. The system of claim 9 wherein the power source ECU is further configured to:
determine a battery charge limit corresponding to an instantaneous maximum amount of electrical power that can be used to charge the battery;
transmit a charge limit signal to the vehicle ECU, the charge limit signal indicating an instantaneous maximum amount of power that can be provided to the power source for charging the battery;
determine a current battery charge amount corresponding to an instantaneous amount of power being provided to the battery for storage; and
reduce the instantaneous maximum amount of power that can be provided to the power source for charging the battery in the charge limit signal in response to the current battery charge amount being greater than the battery charge limit.

13. The system of claim 12 wherein the power source ECU is further configured to decrease an amount of the electricity generated by the fuel cell circuit in response to the current battery charge amount being greater than the battery charge limit.

14. A method for reducing overdraw of power from a vehicular power source, the method comprising:
storing, in a battery, energy;
generating, by a fuel cell circuit, electricity to be at least one of utilized by a motor or stored in the battery;
transmitting, by a power source electronic control unit (ECU), a power limit signal to a vehicle ECU, the power limit signal corresponding to an instantaneous maximum amount of power that can be provided by a power source that includes the battery and the fuel cell circuit;
determining, by the power source ECU, a battery allowed power corresponding to an amount of power available to be drawn from the battery to cause the SOC of the battery to remain above a lower SOC threshold;
determining, by the power source ECU, a current battery power draw from the battery corresponding to an instantaneous amount of power being drawn from the battery; and
reducing, by the power source ECU, the instantaneous maximum amount of power in the power limit signal in response to the current battery power draw being greater than the battery allowed power in order to reduce an amount of power requested by the vehicle ECU, in turn reducing the current battery power draw.

15. The method of claim 14 further comprising increasing, by the power source ECU, an amount of the electricity generated by the fuel ce

Assignees

• Toyota Eng & Mfg North America

Inventors

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

Classifications

• H01M2250/20

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

• H01M2220/20

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

• H01M16/006

  of fuel cells with rechargeable batteries · CPC title

• H01M10/44

  Methods for charging or discharging (circuits for charging H02J7/00) · CPC title

• H01M8/04947

  of auxiliary devices, e.g. batteries, capacitors · CPC title