Fuel Cell Testing Methods and Recent Innovations

Efficiently detecting leaks in the hydrogen supply valve of a fuel cell system. The method involves checking for leaks in a fuel cell's hydrogen supply valve by supplying hydrogen to the valve while closed, then opening the cathode exhaust valve and running the blower to circulate oxygen. If the fuel cell stack voltage exceeds a predetermined threshold, it indicates a leaky hydrogen valve.

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Determining whether a vehicle's fuel cell hydrogen tanks are properly supplying fuel. It involves individually controlling tank valves to open, sensing hydrogen pressure in the supply line, and determining if the tanks opened properly based on pressure changes. If tanks fail to open, vehicle operation is adjusted to conserve fuel.

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Determining the starting state of a fuel cell system to predict potential reversible damage and initiate regeneration processes. The method involves introducing hydrogen to the anode chamber and measuring the voltage, evaluating if a threshold is reached. The starting state is determined based on whether the threshold is reached.

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A method and apparatus for simultaneous detection of multiple parameters of multiple fuel cell membrane electrode assemblies in a stack. The technique involves using different voltage excitations and micro-current excitations while controlling conditions like gas composition, temperature, to analyze parameters like hydrogen crossover current, catalyst surface area. This enables accurate and simultaneous testing of multiple fuel cell MEA parameters from the stack.

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Fault detection and response for hydrogen supply in a fuel cell system. The method uses pressure sensing and consumption estimation to diagnose issues like valve failure and leaks. It estimates hydrogen supply versus consumption and checks for abnormalities. Rapid pressure drops indicate valve failure. If supply-consumption mismatch exceeds a threshold, it detects a leak. Detected faults trigger corrective actions like entering an emergency mode, reducing load, or stopping the fuel cell for inspection.

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Detecting low-level fuel injector leakage in a fuel cell system to prevent uncontrolled hydrogen release and fuel cell damage. The system monitors pressure in the anode gas loop, predicts expected pressure reduction during closed injector operation, and compares it to the actual reduction. If pressure decreases slower than expected, a leaky injector is indicated. Remedial actions include warning of the fault, reducing hydrogen from fuel lines, and preventing restart.

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Detecting gas leaks from a fuel cell anode system during shutdown or startup periods. The method estimates the normal gas losses through permeation and reactions during these periods, and compares it to the actual gas loss. If the difference exceeds a threshold, it indicates an abnormal gas leak. This improves sensitivity to leaks by accounting for expected gas losses through seals and membranes.

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Diagnosing fuel cell stack failures in fuel cell electric vehicles to prevent damage due to abnormal hydrogen supply. The method involves using two hydrogen pressure sensors to detect if pressure is smooth. If the difference between sensor readings is large, it indicates hydrogen supply issues. The system shuts down if supply problems are detected, preventing stack damage.

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Estimating hydrogen crossover loss in a fuel cell system to detect pinholes or leaks. The method involves estimating the hydrogen crossover rate right after purging the anode channel, and comparing it to a reference value based on whether the fuel cell voltage is normal. A higher crossover rate with normal voltage indicates potential pinholes or leaks.

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Calibrating a pressure sensor offset in fuel cell systems by detecting a hydrogen pressure change at system start. When the fuel cell system starts and the hydrogen pressure rises, the pressure sensor offset is determined by using the time it takes the pressure to rise a set amount. This offset value is then used to adjust subsequent pressure readings. By detecting the offset when the system starts, it can be accurately calibrated without relying on external references like atmospheric pressure sensors.

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Estimating hydrogen concentration in a fuel cell to enable accurate control and maintenance of optimum hydrogen levels. The estimation is done by calculating the amount of gas crossover and purging from the anode over time, starting from an initial gas amount prediction.

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A method to accurately inspect the output of a fuel cell at low cost. It involves applying small measurement current to the anode and cathode of the fuel cell while maintaining voltage below the reduction potential of the electrode catalyst. Then changing the cathode gas from inert to oxygen-containing and measuring the output. This allows accurate measurement without applying full rated current.

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Method for controlling a fuel cell system that can diagnose whether hydrogen flows back into a stack enclosure during purging and condensate discharge, without the need to disassemble the stack enclosure and stack. The method involves detecting hydrogen inside the stack enclosure, stopping stack power generation if hydrogen is detected, purging hydrogen and discharging condensate, and then measuring hydrogen concentration inside the enclosure to determine if any backflow occurred.

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Determining the purity of hydrogen fuel being provided to a fuel cell stack and adapting the fuel cell system algorithms to account for the actual fuel purity. This involves comparing measured stack voltage/current to modeled values for pure hydrogen. If the comparison exceeds a threshold, it indicates impurities affecting performance. The hydrogen concentration is then adjusted down to a lower purity level to use in the models. This prevents issues like starvation or damage from inaccurate hydrogen purity assumptions.

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Gas-loading and packaging solid materials for use in hydrogen fuel cells and low-energy nuclear reactions (LENRs). The gas-loading and packaging process allows for quantifiable, controllable, and sustainable loading of gases into solid materials by measuring mass increase. This enables consistent characterization and reuse of gas-loaded materials for fuel cell and LENR applications.

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