Predictive fuel cell and battery power management for high sustained load conditions

Patent metadata

Field	Value
Publication number	US-12358396-B2
Application number	US-202217676715-A
Country	US
Kind code	B2
Filing date	Feb 21, 2022
Priority date	Feb 21, 2022
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A fuel cell and battery power management system for a fuel cell-powered vehicle includes an electric traction motor, a traction battery in electrical communication with the electric traction motor, a fuel cell stack in electrical communication with the traction battery and the electric traction motor, and a vehicle control system. The vehicle control system is configured to operate the vehicle with at a first discharge power level and a first charging power level if fuel cell power is sufficient alone to navigate the uphill grade and to build up battery state of charge by charging the traction battery at a second charging power level when the vehicle is approaching an uphill grade if fuel cell power is not sufficient alone to navigate the uphill grade. The vehicle control system is further configured to initiate proactive depletion of the battery SOC to enable powertrain braking and to provide regenerative power.

First claim

What is claimed is:

1. A fuel cell and battery power management system for a vehicle comprising:
electric traction motor;
a traction battery in electrical communication with the electric traction motor, the traction battery having a battery state of charge;
a fuel cell stack in electrical communication with the traction battery and the electric traction motor; and
a vehicle control system configured to:
receive grade information from connectivity-based mapping data to determine an approaching uphill grade or downhill grade;
operate the vehicle with a first discharge power level from the traction battery and a first charging power level to the traction battery if fuel cell power is sufficient alone to navigate an approaching uphill grade;
build-up battery state of charge by charging the traction battery at a second charging power level if fuel cell power is not sufficient alone to navigate the approaching uphill grade, wherein the second charging power level is dynamically adjusted based on a predicted energy demand for the approaching uphill grade; and
initiate proactive depletion of the battery state of charge to enable powertrain braking by reducing the fuel cell power and supplying a battery discharge power up to a second discharging power level and/or shutting off the fuel cell when the vehicle is approaching a downhill grade, wherein the traction battery is proactively depleted if the vehicle is approaching a downhill grade to prioritize delivering negative powertrain torque over a duration of the downhill grade and reduce an amount of regenerative braking wherein are replaced with foundation brakes, ensuring the powertrain provides consistent negative powertrain torque and a consistent vehicle acceleration and deceleration feel.

2. The fuel cell and battery power management system of claim 1 , wherein the vehicle control system is further configured, when the vehicle is on an uphill grade, to provide fuel cell power and third discharging power level that provides battery power to support propulsion.

3. The fuel cell and battery power management system of claim 2 , wherein the vehicle control system is further configured, when the vehicle is on the uphill grade, to provide coaching to a driver through a human machine interface to reduce power demand if the battery state of charge after being increased is not sufficient to navigate the uphill grade.

4. The fuel cell and battery power management system of claim 3 , wherein the human machine interface is configured to proactively coach the driver to reduce the power demand to increase a likelihood of completing a trip if connectivity-based grade information suggests that battery assist may not be sufficient for the uphill grade.

5. The fuel cell and battery power management system of claim 4 , wherein the coaching includes suggestions for an alternative speed setting and/or suggestions for alternative routes.

6. The fuel cell and battery power management system of claim 5 , wherein the human machine interface is further configured to provide a warning about any potential power derate ahead.

7. The fuel cell and battery power management system of claim 1 , configured to:
provide regenerative power up to first regenerative power level when the vehicle is on the downhill grade and the battery state of charge is sufficient to provide regenerative power for a full distance of the downhill grade; and
provide regenerative power based on braking demand up to a second regenerative power level when the vehicle is on the downhill grade and the battery state of charge is not sufficient to provide regenerative power for the full distance of the downhill grade, first regenerative power level being greater than second regenerative power level.

8. The fuel cell and battery power management system of claim 1 , wherein if the vehicle is not approaching or on an uphill grade or a downhill grade, the vehicle control system is further configured to provide a division of power between the traction battery and fuel cell for powering the electric traction motor.

9. The fuel cell and battery power management system of claim 1 , wherein the vehicle control system is further configured to receive grade information that includes a prediction from connectivity-based information for a grade coming ahead.

10. The fuel cell and battery power management system of claim 1 , wherein the vehicle control system is configured to prioritize delivering negative powertrain lift pedal over a long duration and reduce regenerative braking to provide consistent negative powertrain torque and thus consistent vehicle acceleration/deceleration feel.

11. The fuel cell and battery power management system of claim 1 , wherein the vehicle control system is further configured to proactively deplete the traction battery if the vehicle is approaching a long downhill grade.

12. The fuel cell and battery power management system of claim 1 configured to provide negative powertrain torque.

13. The fuel cell and battery power management system of claim 12 , wherein the negative powertrain torque is provided as either lift pedal torque or regenerative braking.

14. A method for fuel cell and battery power management comprising:
receiving grade information from connectivity-based mapping data to determine an approaching uphill grade or downhill grade;
operating a vehicle with a first discharge power level from a traction battery and a first charging power level to the traction battery if fuel cell power is sufficient alone to navigate an approaching uphill grade;
building-up battery state of charge by charging the traction battery at a second charging power level if fuel cell power is not sufficient alone to navigate the approaching uphill grade, the second charging power level being greater than the first charging power level; and
initiating proactive depletion of a battery state of charge to enable powertrain braking by reducing the fuel cell power and supplying a battery discharge power up to a second discharging power level and/or shutting off the fuel cell when the vehicle is approaching a downhill grade, wherein the second charging power level is dynamically adjusted based on a predicted energy demand for the approaching uphill grade and wherein the traction battery is proactively depleted if the vehicle is approaching a downhill grade to prioritize delivering negative powertrain torque over a duration of the downhill grade and reduce an amount of regenerative braking wherein are replaced with foundation brakes, ensuring the powertrain provides consistent negative powertrain torque and a consistent vehicle acceleration and deceleration feel.

15. The method of claim 14 further comprising providing fuel cell power and third discharging power level that provides battery power to support propulsion when the vehicle is on an uphill grade.

16. The method of claim 15 further comprising providing coaching to a driver through a human machine interface to reduce power demand if the battery state of charge after being increased is not sufficient to navigate the uphill grade.

17. The method of claim 16 further comprising proactively coach the driver to reduce the power demand to increase a likelihood of completing a trip if connectivity-based grade information suggests that battery assist may not be sufficient for the uphill grade.

18. The method of claim 16 further comprising:
providing regenerative power up to first regenerative power level when the vehicle is on the downhill grade and the battery state of charge is sufficient to provide regenerative power for a

Assignees

• Ford Global Tech Llc

Inventors

• Gogna Naginder
• Meyer Jason
• Ortmann Walter Joseph
• Bower Jr Stanley L
• Johri Rajit

Classifications

• B60L58/30

  for monitoring or controlling fuel cells · CPC title

• B60L7/10 Primary

  Dynamic electric regenerative braking (B60L7/22 takes precedence) · CPC title

• B60W20/20

  Control strategies involving selection of hybrid configuration, e.g. selection between series or parallel configuration · CPC title

• B60L2240/642

  Slope of road · CPC title

• B60L2240/622

  by satellite navigation · CPC title