An actively controlled fuel cell/battery hybrid to meet pulsed power demands

This paper presents the experimental results of an actively controlled fuel cell/battery hybrid power source topology that can be widely used in many applications, such as portable electronic devices, communication equipment, spacecraft power systems, and electric vehicles, in which the power demand is impulsive rather than constant. A step-down DC/DC power converter is incorporated to actively control the power flow between the fuel cell and the battery to achieve both high power and high energy densities. The results show that the hybrid power source can achieve much greater specific power and power density than the fuel cell alone. This paper first demonstrates that an actively controlled hybrid with a 35 W hydrogen-fueled polymer electrolyte membrane fuel cell and a lithium-ion battery pack of six cells yielded a peak power of 100 W, about three times as high as the fuel cell alone can supply, while causing a very limited (10%) weight increase to the whole system. After that, another hybrid source using a different battery array (eight cells) was investigated to further validate the control strategy and to show the flexibility and generality of the hybrid source design. The experimental data show that the hybrid source using an eight-cell battery supplied a peak power of 135 W, about four times that of the fuel cell alone. Finally, three power sources including the fuel cell alone and the two hybrids studied were compared in terms of specific power, power density, volume, weight, etc. The design presented here can be scaled to larger or smaller power capacities for a variety of applications.     

Optimized power management based on adaptive-PMP algorithm for a stationary PEM fuel cell/battery hybrid system

This research develops an efficient and robust polymer electrolyte membrane (PEM) fuel cell/battery hybrid operating system. The entire system possesses its own rapid dynamic response benefited from hybrid connection and power split characteristics due to DC/DC buck-boost converter. An indispensable energy management system (EMS) plays a significant role in achieving optimal fuel economy and in a promising running stability. EMS as an indispensable part plays a significant role in achieving optimal fuel economy and promising operation stability. This study aims to develop an adaptive supervisory EMS that comprises computer-aided engineering tools to monitor, control, and optimize the performance of the hybrid power system. A stationary fuel cell/battery hybrid operating system is optimized using adaptive-Pontryagin's minimum principle (A-PMP). The proposed algorithm depends on the adaptation of the control parameter (i.e., fuel cell output power) from the state of charge (SOC) and load power feedback. The integrated model simulated in a Matlab/Simulink environment includes the fuel cell, battery, DC/DC converter, and power requirements models by analyzing the three different load profiles. Real-time experiments are performed to verify the effectiveness of EMS after analyzing the simulated operating principle and control scheme.     

Development of solid oxide fuel cell and battery hybrid power generation system

Solid oxide fuel cell hybrid generation system is the best scheme for the load tracking of off-grid monitoring stations. But there are still potential problems that need to be addressed: preventing fuel starvation and ensuring thermal safety while meeting load tracking in hybrid power generation system. In order to solve these problems, a feasible hybrid power generation system structure scheme is proposed which combined SOFC subsystem and Li-ion battery subsystem. Then a model of the hybrid power generation system is built based on the proposed system structure. On this basis, an adaptive controller, include the adaptive energy management algorithm and current feedforward gas supply strategy, is applied to manage the power-sharing in this hybrid system as well as keep the system operating within the safety constraints. The constraints, including maintaining the bus voltage at the desired level, keeping SOFC operating temperature in safety, and mitigating fuel starvation are explicitly considered. The stability of the proposed energy management algorithm is analyzed. Finally, the developed control algorithm is applied to the hybrid power generation system model, the operation result proves the feasibility of the designed controller strategy for hybrid generation system and effectively prevent fuel starvation and ensure thermal safety.     

Performance simulation and analysis of a fuel cell/battery hybrid forklift truck

The performance of a forklift truck powered by a hybrid system consisting of a PEM fuel cell and a lead acid battery is modeled and investigated by conducting a parametric study. Various combinations of fuel cell size and battery capacity are employed in conjunction with two distinct control strategies to study their effect on hydrogen consumption and battery state-of-charge for two drive cycles characterized by different operating speeds and forklift loads. The results show that for all case studies, the combination of a 110 cell stack with two strings of 55 Ah batteries is the most economical choice for the hybrid system based on system size and hydrogen consumption. In addition, it is observed that hydrogen consumption decreases by about 24% when the maximum speed of the drive cycle is decreased from 4.5 to 3 m/s. Similarly, by decreasing the forklift load from 2.5 to 1.5 ton, the hydrogen consumption decreases by over 20%.     

System integration of a portable direct methanol fuel cell and a battery hybrid

This paper introduces a complete system-level design and integration of a portable direct methanol fuel cell (DMFC) system. We describe hardware and software design for the balance of plant (BOP) control, including a 32-bit microprocessor and electronics for actuators and sensors, focusing on reliable operation and protection of the DMFC system. Various BOP components are characterized to find the optimal design for better portability, reliability, and energy efficiency, and we suggest effective and robust design of control loops for them. We demonstrate a hybrid operation of the DMFC stack and Li-ion battery to maintain a constant stack output current regardless of the load current to maximize the performance. We emphasize the design of subsystems for power supply, measurement, actuator drive, and protection in detail. We verify the robust operation of BOP control against environmental changes such as orientation and pressure variations with an implemented control board.     

The study on the power management system in a fuel cell hybrid vehicle

This paper presents a model of a hybrid electric vehicle, based on a primary proton exchange membrane fuel cell (PEMFC) and an auxiliary Li-ion battery, and its dynamics and overall performance. The power voltage from the fuel cell is regulated by a DC/DC converter before integrating with the Li-ion battery, which provides energy to the drive motor. The driving force for propelling the wheels comes from a permanent magnet synchronous motor (PMSM); where the power passes through the transmission, shaft, and the differential.     

Experimental investigation on the dynamic performance of a hybrid PEM fuel cell/battery system for lightweight electric vehicle application

A hybrid system combining a 2 kW air-blowing proton exchange membrane fuel cell (PEMFC) stack and a lead–acid battery pack is developed for a lightweight cruising vehicle. The dynamic performances of this PEMFC system with and without the assistance of the batteries are systematically investigated in a series of laboratory and road tests. The stack current and voltage have timely dynamic responses to the load variations. Particularly, the current overshoot and voltage undershoot both happen during the step-up load tests. These phenomena are closely related to the charge double-layer effect and the mass transfer mechanisms such as the water and gas transport and distribution in the fuel cell. When the external load is beyond the range of the fuel cell system, the battery immediately participates in power output with a higher transient discharging current especially in the accelerating and climbing processes. The DC–DC converter exhibits a satisfying performance in adaptive modulation. It helps rectify the voltage output in a rigid manner and prevent the fuel cell system from being overloaded. The dynamic responses of other operating parameters such as the anodic operating pressure and the inlet and outlet temperatures are also investigated. The results show that such a hybrid system is able to dynamically satisfy the vehicular power demand.     

Power management strategy for vehicular-applied hybrid fuel cell/battery power system

In this paper, a control strategy for a hybrid PEM (proton exchange membrane) fuel cell/BES (battery energy system) vehicular power system is presented. The strategy, based on fuzzy logic control, incorporates the slow dynamics of fuel cells and the state of charge (SOC) of the BES. Fuel cell output power was determined according to the driving load requirement and the SOC, using fuzzy dynamic decision-making and fuzzy self-organizing concepts. An analysis of the simulation results was conducted using Matlab/Simulink/Stateflow software in order to verify the effectiveness of the proposed control strategy. It was confirmed that the control scheme can be used to improve the operational efficiency of the hybrid power system.     

Variable structure battery-based fuel cell hybrid power system and its incremental fuzzy logic energy management strategy

A hybrid power system consists of a fuel cell and an energy storage device like a battery and/or a supercapacitor possessing high energy and power density that beneficially drives electric vehicle motor. The structures of the fuel cell-based power system are complicated and costly, and in energy management strategies (EMSs), the fuel cell's characteristics are usually neglected. In this study, a variable structure battery (VSB) scheme is proposed to enhance the hybrid power system, and an incremental fuzzy logic method is developed by considering the efficiency and power change rate of fuel cell to balance the power system load. The principle of VSB is firstly introduced and validated by discharge and charge experiments. Subsequently, parameters matching of the fuel cell hybrid power system according to the proposed VSB are designed and modeled. To protect the fuel cell as well as ensure the efficiency, a fuzzy logic EMS is formulated via setting the fuel cell operating in a high efficiency and generating an incremental power output within the affordable power slope. The comparison between a traditional deterministic rules-based EMS and the designed fuzzy logic was implemented by numerical simulation in three different operation conditions: NEDC, UDDS, and user-defined driving cycle. The results indicated that the incremental fuzzy logic EMS smoothed the fuel cell power and kept the high efficiency. The proposed VSB and incremental fuzzy logic EMS may have a potential application in fuel cell vehicles.     

An energy management strategy based on dynamic power factor for fuel cell/battery hybrid locomotive

In order to efficiently absorb more regenerative braking energy which sustains much longer compared with the conventional vehicle, and guarantee the safety of the hybrid system under the actual driving cycle of locomotive, an energy management control based on dynamic factor strategy is proposed for a scale-down locomotive system which consists of proton exchange membrane fuel cell (PEMFC) and battery pack. The proposed strategy which has self-adaption function for different driving cycles aims to achieve the less consumption of hydrogen and higher efficiency of the hybrid system. The experimental results demonstrate that the proposed strategy is able to maintain the charge state of battery (SOC) better than Equivalent Consumption Minimization Strategy (ECMS), and the proposed strategy could keep the change trend of SOC, which the final SOC is closed to the target value regardless of the initial SOC of battery. Moreover, the hydrogen consumption has been reduced by 0.86g and the efficiency of overall system has been raised of 2% at least than ECMS under the actual driving cycle through the proposed strategy. Therefore, the proposed strategy could improve the efficiency of system by diminishing the conversion process of energy outputted by fuel cell.     

A new topology of fuel cell hybrid power source for efficient operation and high reliability

This paper analyzes a new fuel cell Hybrid Power Source (HPS) topology having the feature to mitigate the current ripple of the fuel cell inverter system. In the operation of the inverter system that is grid connected or supplies AC motors in vehicle application, the current ripple normally appears at the DC port of the fuel cell HPS. Consequently, if mitigation measures are not applied, this ripple is back propagated to the fuel cell stack. Other features of the proposed fuel cell HPS are the Maximum Power Point (MPP) tracking, high reliability in operation under sharp power pulses and improved energy efficiency in high power applications. This topology uses an inverter system directly powered from the appropriate fuel cell stack and a controlled buck current source as low power source used for ripple mitigation. The low frequency ripple mitigation is based on active control. The anti-ripple current is injected in HPS output node and this has the LF power spectrum almost the same with the inverter ripple. Consequently, the fuel cell current ripple is mitigated by the designed active control. The ripple mitigation performances are evaluated by indicators that are defined to measure the mitigation ratio of the low frequency harmonics. In this paper it is shown that good performances are obtained by using the hysteretic current control, but better if a dedicated nonlinear controller is used. Two ways to design the nonlinear control law are proposed. First is based on simulation trials that help to draw the characteristic of ripple mitigation ratio vs. fuel cell current ripple. The second is based on Fuzzy Logic Controller (FLC). The ripple factor is up to 1% in both cases.     

Power management system for a fuel cell/battery hybrid vehicle incorporating fuel cell and battery degradation

Optimization of fuel cell/battery hybrid vehicle systems has primarily focused on reducing fuel consumption. However, it is also necessary to focus on fuel cell and battery durability as inadequate lifespan is still a major barrier to the commercialization of fuel cell vehicles. Here, we introduce a power management strategy which concurrently accounts for fuel consumption as well as fuel cell and battery degradation. Fuel cell degradation is quantified using a simplified electrochemical model which provides an analytical solution for the decay of the electrochemical surface area (ECSA) in the fuel cell by accounting for the performance loss due to transient power load, start/stop cycles, idling and high power load. The results show that the performance loss based on remaining ECSA matches well with test data in the literature. A validated empirical model is used to relate Lithium-ion battery capacity decay to C-rate. Simulations are then conducted using a typical bus drive cycle to optimize the fuel cell/battery hybrid system. We demonstrate that including these degradation models in the objective function can effectively extend the lifetime of the fuel cell at the expense of higher battery capacity decay resulting in a lower average running cost over the lifetime of the vehicle.     

Design, building and testing of a stand alone fuel cell hybrid system

This paper designs, sizes, builds and tests a stand alone fuel cell hybrid system made up of a fuel cell stack and a battery bank. This system has been sized to supply a typical telecommunication load profile, but moreover, the system can supply other profiles. For this purpose, a modular low cost electronic load bank has been designed and built. This load bank allows the power demand to be chosen by selecting different solid state relays. Moreover, a virtual instrument based on NI Labview^® has been designed to select the load power demand from the computer.     

Fuel cell/battery passive hybrid power source for electric powertrains

The concept of passive hybrid, i.e. the direct electrical coupling between a fuel cell system and a battery without using a power converter, is presented as a feasible solution for powertrain applications. As there are no DC/DC converters, the passive hybrid is a cheap and simple solution and the power losses in the electronic hardware are eliminated. In such a powertrain topology where the two devices always have the same voltage, the active power sharing between the two energy sources can not be done in the conventional way. As an alternative, control of the fuel cell power by adjusting its operating pressure is elaborated. Only pure H₂/O₂ fuel cell systems are considered in this approach. Simulation and hardware in the loop (HIL) results for the powertrain show that this hybrid power source is able to satisfy the power demand of an electric vehicle while sustaining the battery state of charge.     

A review of fuel cell based hybrid power supply architectures and algorithms for household appliances

Nowadays, renewable power system solutions are widely investigated for residential applications. Grid-connected systems including energy storage elements are designed. Advanced research is actually focused on improving the reliability and energy density of renewable systems reducing the whole utility cost. Source and load modeling, power architectures and algorithms are only a few topics to be addressed. Designers have to carefully deal with each subtopic prior to design efficient renewable energy systems. In the literature, each topic is separately discussed and the lack of a unique reference guide is clear to power electronics designers. In this paper, each design step including source and load modeling, hybrid supply architectures and power algorithms, is carefully addressed. A review of existing solutions is presented. The correlation between each topic is deeply analyzed. Guidelines for system design are given. This paper can be referenced as a detailed review of renewable energy system design issues and solutions.     

Techno-economic study of off-grid hybrid photovoltaic/battery and photovoltaic/battery/fuel cell power systems in Kunming,China

The objective of this study is to evaluate the technical and economic feasibility of stand-alone hybrid photovoltaic (PV)/battery and PV/battery/fuel cell (FC) power systems for a community center comprising 100 households in Kunming by using the Hybrid Optimization Model for Electric Renewable (HOMER) software. HOMER is used to define the optimum sizing and techno-economic feasibility of the system equipment based on the geographical and meteorological data of the study region. In this study, different hybrid power systems are analyzed to select the optimum energy system while considering total net present cost (NPC) and levelized cost of energy (COE). The results showed that the optimal hybrid PV/battery system comprised 500 kW PV modules, 1200 7.6-kWh battery units, and 500 kW power converters. The proposed system has an initial cost of $6,670,000, an annual operating cost of $82,763/yr, a total NPC of $7,727,992, and a levelized COE of $1.536/kWh. While the PV/battery/FC power system is possible, the cost increases were due to the investment cost of the FC system. The optimal PV/battery/FC system has an initial cost of $6,763,000, an annual operating cost of $82,312/yr, a total NPC of $7,815,223, and a levelized COE of $1.553/kWh.     

Experimental investigation on the online fuzzy energy management of hybrid fuel cell/battery power system for UAVs

The hybrid powerplant combining a fuel cell and a battery has become one of the most promising alternative power systems for electric unmanned aerial vehicles (UAVs). To enhance the fuel efficiency and battery service life, highly effective and robust online energy management strategies are needed in real applications.In this work, an energy management system is designed to control the hybrid fuel cell and battery power system for electric UAVs. To reduce the weight, only one programmable direct-current to direct-current (dcdc) converter is used as the critical power split component to implement the power management strategy. The output voltage and current of the dcdc is controlled by an independent energy management controller. An executable process of online fuzzy energy management strategy is proposed and established. According to the demand power and battery state of charge, the online fuzzy energy management strategy produces the current command for the dcdc to directly control the output current of the fuel cell and to indirectly control the charge/discharge current of the battery based on the power balance principle.Another two online strategies, the passive control strategy and the state machine strategy, are also employed to compare with the proposed online fuzzy strategy in terms of the battery management and fuel efficiency. To evaluate and compare the feasibility of the online energy management strategies in application, experiments with three types of missions are carried out using the hybrid power system test-bench, which consists of a commercial fuel cell EOS600, a Lipo battery, a programmable dcdc converter, an energy management controller, and an electric load. The experimental investigation shows that the proposed online fuzzy strategy prefers to use the most power from the battery and consumes the least amount of hydrogen fuel compared with the other two online energy management strategies.     

Development of an optimal charging algorithm of a Ni-MH battery for stationary fuel cell/battery hybrid system application

When installed in stationary fuel cell/battery hybrid systems, sealed nickel-metal hydride (Ni-MH) battery packs have low rates of charging behavior at high temperatures. They can also be charged with surplus power from fuel cell system when they are part of a small-capacity fuel cell/battery hybrid system. Test results indicate that when subjected to high temperatures and low rates of charging current, a Ni-MH battery experiences a sharp reduction in discharge capacity but does not experience an increase in voltage. To solve these problems, we have applied a new charging algorithm based on this pulse charging method to a Ni-MH battery. The pulse charging method reduces the charging time by 2 hrs and has a charging efficiency of over 97%. The charging current factor (β) in this pulse charging method should influenced the controlling the charging rate to the battery with applied voltages. The results show a 27% increase in efficiency with the new charging method compared to the system efficiency of the conventional constant-voltage charging method. Such a pulse charging method is expected to increase the lifespan of a Ni-MH battery by inhibiting gas generation.     

Energy control of supercapacitor/fuel cell hybrid power source

This paper deals with a flatness based control principle in a hybrid system utilizing a fuel cell as a main power source and a supercapacitor as an auxiliary power source. The control strategy is based on regulation of the dc bus capacitor energy and, consequently, voltage regulation. The proposed control algorithm does not use a commutation algorithm when the operating mode changes with the load power variation and, thus, avoids chattering effects. Using the flatness based control method, the fuel cell dynamic and its delivered power is perfectly controlled, and the fuel cell can operate in a safe condition. In the hybrid system, the supercapacitor functions during transient energy delivery or during energy recovery situations. To validate the proposed method, the control algorithms are executed in dSPACE hardware, while analogical current loops regulators are employed in the experimental environment. The experimental results prove the validity of the proposed approach.