10 patents in this list

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Fuel cell simulation requires modeling complex multi-physics interactions across different temporal and spatial scales. Current models must account for electrochemical reactions, heat transfer, two-phase flow dynamics, and membrane transport phenomena—all while handling operating conditions that range from -40°C to 80°C and pressure variations from 1 to 3 atmospheres.

The fundamental challenge lies in balancing model fidelity with computational efficiency while capturing the coupled nature of transport phenomena, electrochemistry, and system-level dynamics.

This page brings together solutions from recent research—including reduced-order modeling techniques, multi-scale simulation frameworks, real-time predictive methods using IHOS (Integrated Homotopic Operating States), and degradation-conscious control strategies. These and other approaches help engineers optimize fuel cell designs and control strategies for real-world applications.

1. Proton Exchange Membrane Fuel Cell Simulation Model Calibration with Experimental Data for Performance Optimization

CATARC New Energy Vehicle Test Center (Tianjin) Co., Ltd., 2023

Optimizing the performance of proton exchange membrane fuel cells using a combination of simulation and experimentation. The optimization involves calibrating a simulation model with bench test data to accurately predict fuel cell output voltages. Standard operating conditions are identified through simulation that maximize a performance metric. The optimized simulation results are then verified against bench test data to validate the optimization. This allows finding optimal operating conditions for fuel cells that balance factors like humidity, temperature, and gas flow rates to improve performance.

2. Method for Structural Design of Flaky Fuel Assemblies Using Surrogate Modeling and Co-Simulation

DALIAN UNIVERSITY OF TECHNOLOGY, 2023

A method for optimizing the structure of flaky fuel assemblies used in nuclear reactors to improve performance and longevity. The method uses surrogate modeling and co-simulation to optimize fuel assembly design under multidisciplinary coupling conditions of flow, solid, and thermal characteristics. It involves creating a surrogate model using Kriging to predict assembly performance based on key design parameters. This is combined with optimization algorithms like adaptive simulated annealing, multi-island genetic algorithm, and others to efficiently find the optimal assembly structure. This addresses issues like uneven temperature distribution.

3. Method for Estimating True Flow Area in Variable-Area Injectors for Hydrogen Flow Control

GM GLOBAL TECHNOLOGY OPERATIONS LLC, 2023

A method for accurately controlling hydrogen flow in fuel cell systems with injectors that have variable flow areas. The method involves estimating the true flow area of the injector based on hydrogen consumption at steady state and the modeled flow rate. This estimated area is then used to adjust the hydrogen flow command, leak rate, and exhaust valve flow estimates. It compensates for injector flow variations to improve fuel cell performance and stability.

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4. Object-Oriented Simulation Framework for Gas Dynamics in Fuel Cell Systems

dSPACE digital signal processing and control engineering GmbH, 2022

Computer-based simulation of gas dynamics in fuel cell systems to optimize and understand performance. The simulation models the real fuel cell system using a customized object-oriented approach. The simulation defines classes representing container volumes and flow channels, with instances representing actual components in the fuel cell. The simulation connects the instances to mimic the fuel cell's container network. It then simulates thermodynamic parameters in the volumes using user-defined parameters. This allows dynamic, spatially-accurate simulation of pressure, temperature, and mass flow in the fuel cell's container network.

5. Fuel Cell Control System with Linear Time Varying Model Predictive Framework and Degradation-Conscious Optimization

THE REGENTS OF THE UNIVERSITY OF MICHIGAN, 2022

Degradation-conscious control for fuel cells that improves durability by formulating a linear time varying model predictive control (MPC) framework for fuel cells with special attention to membrane durability. The MPC uses a reduced-order model for water and heat transport in the fuel cell with linearized dynamics. It solves a quadratic optimization problem at each time step to determine operating conditions that meet power demand while avoiding degradation constraints.

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6. Fuel Cell Bipolar Plate with Dehomogenized Multi-Layer Fluid Flow Network Design

Toyota Motor Engineering & Manufacturing North America, Inc, 2022

Optimizing fluid flow networks in fuel cell bipolar plates using dehomogenization techniques to simultaneously design air, hydrogen, and coolant flow networks. The optimization involves iterative simulations and sensitivity analysis to find the optimal design that satisfies requirements for efficient fluid distribution in the fuel cell. The dehomogenization stage refines the discretization to extract intricate Turing flow channels. The optimization applies design variables to the air and hydrogen layers, with the coolant layer being a function of those variables. This allows simultaneous optimization of all three layers.

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7. Fuel Cell Plates with Modeled Flow Networks and Iterative Channel Structure Optimization

Toyota Motor Engineering & Manufacturing North America, Inc, 2022

Designing fuel cell plates with optimized flow networks to minimize flooding and maximize power generation. The method involves predicting liquid and vapor regions in the fuel cell channels using a model. Then, simultaneous optimization of the air, hydrogen, and coolant layers using the predicted regions. This iterative process refines the channel structures to prevent flooding while maintaining uniform cooling and reaction.

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8. Method for Fuel Cell Input-Output Analysis Using Dimensional and Similarity Principles

Xi?an Jiaotong University, 2021

A method to analyze the input-output characteristics of fuel cells using similarity principles that reduces the number of experiments needed to understand fuel cell performance. The method involves applying dimensional analysis and the principle of similarity to analyze fuel cell models and equations. It converts dimensional physical quantities into dimensionless numbers that represent similar sets of working conditions. By changing the dimensionless numbers, you can verify the correction and reduce the number of experiments needed to understand fuel cell behavior.

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9. Interpolation-Based Real-Time Fuel Cell Stack Modeling Using Integrated Homotopic Operating States

TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA, INC., 2020

Real-time modeling of a fuel cell stack in a vehicle without the need for additional sensors. The method involves using an interpolation-based model called Integrated Homotopic Operating States (IHOS) to predict fuel cell stack behavior. The IHOS model interpolates output states based on input conditions instead of relying on a lookup table. It reduces storage, processing, and time compared to traditional lookup tables. The model is generated from a dataset of real fuel cell stack data, where each data point has conditions and an associated operating state. The model minimizes the dataset required for interpolation. The vehicle's electronic control unit uses the IHOS model to predict stack behavior without additional sensors.

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10. Time-Series Control Path Determination for Multi-Actuator Fuel Cell Systems Using Physics-Based Simulation

TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA, INC., 2020

Determining optimal time-series control paths for multiple actuators in a fuel cell system to achieve desired performance while avoiding issues like compressor surge. The method involves using a physics model of the fuel cell circuit to simulate and analyze control paths. By selecting and comparing multiple time-series actuator states, the best set that meets requirements is identified. This ensures synchronous actuator motion that avoids compressor surge and fuel cell drying.

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