Modular fuel cell system architecture and a control system for distributing power to the modules

Patent metadata

Field	Value
Publication number	US-12148962-B2
Application number	US-202117539774-A
Country	US
Kind code	B2
Filing date	Dec 1, 2021
Priority date	Dec 1, 2021
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

Systems and methods are provided for modularizing a system. Parallel power systems having electronically isolated high voltage systems facilitate modulization. A control system is provided that optimizes the distribution of a power demand and/or a torque request so as to keep the efficiency, durability, drivability and/or safety of the system within an optimum range. In some cases, the distribution of power is uneven, so as to extend the battery life, while in other cases, the power draw on battery systems are kept equal and constant so as to properly manage the state of charge of the parallel power systems. In still other cases, the chosen power distribution keeps the power demand and/or torque request between minimum and maximum levels/capacity, and the power distribution avoids on/off of an individual power system.

First claim

What is claimed is:

1. A modular system of a vehicle comprising:
a shaft; and
a plurality of parallel systems that are electrically isolated from one another, the plurality of parallel systems comprising:
a first parallel system for rotating the shaft, the first parallel system comprising a first motor coupled to the shaft to rotate the shaft, a first parallel system power generation module coupled to the first motor to drive the first motor, a fuel cell electrically connected to supply electrical power to the first motor, and a battery electrically connected to supply power to the first motor; and
a second parallel system to rotate the shaft, the second parallel system comprising a second motor coupled to the shaft for rotating the shaft, and a second parallel system power generation module coupled to the second motor to drive the second motor.

2. The modular system of claim 1 , further comprising:
an electrical control system that
receives input indicative of an amount of torque to request the modular system to produce; and
apportions generation of an amount of power between the plurality of parallel systems,

wherein the apportioning is performed based on individual states of individual parallel systems of the plurality of parallel systems; and
wherein the electrical control system comprises states in which the first parallel system provides a different amount of torque than the second parallel system.

3. The modular system of claim 1 , further comprising:
an electrical control unit comprising states in which a different percentage of a total power is requested from different parallel systems of the plurality of parallel systems, wherein the total power is a total power requested for driving the vehicle.

4. A modular system of a vehicle comprising:
a shaft;
an electrical control system; and
a plurality of parallel systems, the plurality of parallel systems comprising:
a first parallel system to rotate the shaft, the first parallel system comprising a first motor coupled to the shaft for rotating the shaft, a first parallel system power generation module coupled to the first motor to drive the first motor, a fuel cell electrically connected to supply electrical power to the first motor, and a battery electrically connected to supply power to the first motor; and
a second parallel system to rotate the shaft, the second parallel system comprising a second motor coupled to the shaft for rotating the shaft, and a second parallel system power generation module coupled to the second motor to drive the second motor;

wherein, when the electrical control system is activated, the electrical control system performs operations comprising:
receiving input indicative of an amount of torque to request the modular system to produce; and
apportioning generation of the amount of power between the plurality of parallel systems;

wherein the apportioning depends at least on individual states of individual parallel systems of the plurality of parallel systems; and
wherein the electrical control system comprises states that occur during normal operation in which the first parallel system is requested to provide a different mount of torque than the second parallel system.

5. The modular system of claim 4 , wherein the first parallel system further comprises:
a first-parallel system energy module of a first type, that supplies electrical power to the first motor; and
a first-parallel system energy module of a second type, that supplies electrical power to the first motor.

6. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to keep a current state of charge of batteries of the plurality of parallel systems above a threshold value.

7. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to keep a given power requested from a given parallel system of the plurality of parallel systems below an upper threshold that is based on a maximum available power of that is available, via the given parallel system, for driving the modular system.

8. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to keep a given power requested from a given parallel system of the plurality of parallel systems above a lower threshold.

9. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to equalize a power draw from each battery system of each parallel system with respect to one another, so as to extend battery life.

10. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to maintain a constant draw of power from each battery system of each parallel system, when the battery system is not being charged, so as to extend battery life.

11. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to equalize a draw of charge from each battery of each parallel system with respect to one another.

12. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to achieve a fuel efficiency that is higher than without the apportioning.

13. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to maintain a durability of the modular system that is better than without the apportioning.

14. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to keep the amount of cycling between turning on a given parallel system of the plurality of parallel systems and turning off the given parallel system to less than a threshold value.

15. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to maintain specified drivability requirements.

16. The modular system of claim 15 , wherein the drivability requirements include keeping vibrations less than a predefined threshold.

17. The modular system of claim 4 , wherein the apportioning comprises diverting power from a parallel system having a torque derating to a system that does not have a torque derating, so as to meet a requested torque.

18. The modular system of claim 4 , wherein the apportioning comprises diverting power from a parallel system having a motor that is running at a higher temperature than other motors of the modular system.

19. The modular system of claim 4 , the apportioning being determined to apportion power between the plurality of parallel systems in order to rotate the shaft outside of a specified frequency band that includes a resonant frequency of the modular system.

20. The modular system of claim 2 , wherein the apportioning comprises diverting power from a parallel system having a torque derating to a system that does not have a torque derating, so as to meet a requested torque.

Assignees

• Toyota Eng & Mfg North America

Inventors

• Bulpitt Christopher M
• Folick Daniel Charles
• Farnsworth Jared
• Sata Andrew
• Eitzer Arlo C
• Bower Laura E
• Lim Daniel K
• Sander Jonathan J
• Rippelmeyer Luke A
• Friedman Scott A
• Yokoo Takehito

Classifications

• Y02T90/40

  Application of hydrogen technology to transportation, e.g. using fuel cells · CPC title

• H01M2220/20

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

• H01M8/249

  comprising two or more groupings of fuel cells, e.g. modular assemblies · CPC title

• B60K1/00

  Arrangement or mounting of electrical propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) · CPC title

• B60L58/22

  Balancing the charge of battery modules · CPC title