Real operation pem fuel cells HEALTH-state monitoring and ...

- Call topic: FCH-02-3-2014: Stationary FC system diagnostics: development of online monitoring and diagnostics systems for reliable and durable fuel cell system operation

- Project dates: 01/09/15 – 31/12/18- Total project budget: 2,358,736€- Coordinator: University of Salerno (I)

Single cell models

Non-dimensional Parameters (p theorem)

Impedance model

Single cell impedance data

PARAMETERS IDENTIFICATION

IMPEDANCE RECONSTRUCTION

Stack impedance

Stack information

Physical knowledge

Spectra acquired with EIS board and converter

Embedded On-line tool based on Electrochemical Impedance Spectroscopy (EIS) foradvanced Fuel Cells Monitoring, Diagnosis and Lifetime Tool (MDLT).

The tool performs EIS-based condition monitoring of FC stacks and isolates 5 stack faults.

The project HEALTH-CODE (Real operation pem fuel cells HEALTH-state monitoring and diagnosis based on dc-dc COnverter embeddeD Eis) has received funding from the Fuel Cells and Hydrogen 2 Joint Undertaking under grant agreement No 671486. This Joint Undertaking receives support from the European Unions’ Horizon 2020 research & innovation programme and N.ERGHY.

www.pemfc.health-code.eu

Real operation pem fuel cells HEALTH-state monitoring and diagnosis based on dc-dc COnverter embeddeD Eis

PROJECT OVERVIEW EIS SPECTRA MEASUREMENTS

DIAGNOSTIC ALGHORITM TOOLS TESTING

USEFUL GUIDELINES for companies to implement EIS board on industrial FC systems: • NEW DC/DC converter designed to interact

with the EIS board.• ADAPT AVAILABLE converter to allow the

communication with the EIS board.

2200+ EIS spectra for stacks (10%) and cells,25% in nominal and 75% in faulty operations

Nominal spectra set the monitoring reference

Faulty spectra drive the setting of faultsisolation algorithm

Air/Reformate O2/H2 Air/Reformate O2/H2

- fuel starvation- air/O2 starvation- flooding/drying- CO contamination (only air-fed)- sulphur poisoning (only air-fed)

Faults

IMPACTHEALTH-CODE outcomes will:- increase electrical efficiency and durability of the different fuel cells used for power production;- contribute to reduce degradation by implementing the monitoring and diagnostic tool;- lead to a reduction of total cost ownership (TCO) by increasing the FC system efficiency;- contribute to improve grid stability in the future by applying stationary fuel cells together with energy

storage; the EPS backup system has grid interface for H2 & O2 production and can support grid balancing.

Ballard Europe µ-CHP system

DC/DC converter

15 A 25 A 40 A0

0.1

0.2

0.3

0.4

0.5

RmRct,aRct,c

Change detection check with nominal behaviourEIS spectrum

acquired on-board

Parameters extraction with

model fitting

15 A 25 A 40 A0

0.1

0.2

0.3

0.4

0.5

RmRct,aRct,c

1

0

1

Fault Pattern

FAULT ISOLATION:F2

FSM ECM PARAMETERSRm Rct,a Rct,c Ca Q φ Rd τ

FAU

LTS

F1 0 0 1 - - - - -

F2 1 0 1 - - - - -

F3 - - - - - - - -

Equivalent Circuit Modelling

III] Classification & Decision making

Algorithm Learning : Off-line FDI : Off-line validation & On-board application

2 3 4 5 6 7 8-1

-0.5

0

0.5

1

1.5

EIS learning data set New EIS measurement

2.5 3 3.5 4 4.5 5 5.5-0.8

-0.6

-0.4

-0.2

0

0.2

0.4

0.6

0.8

1

I] Automated features-selection I1: Normalization I2: Variance-Correlative Coef. analysis I3: Space dimension selection

Features’ Normalization

II] Fuzzy clustering

Clusters’ definition

00.2

0.40.6

0.81

00.2

0.40.6

0.81

0

0.5

1

1.5

f1

FDI results

f2

f3

SOH Assessment Save data file

Data file

Fuzzy Clustering approach

Adaptive Neuro Fuzzy Inference System Active Diagnosis

Cell voltage increase >5mV

Air Bleed surge routine

Yes No

CO poisoning

No CO poisoning

Alarm CO poisoning

EIS board cost < 500€ (3% of TCO)

Cell à Short stackà Full Stack

FCSTACK

GRID/LOAD

DC/DC CONVERTER

SYSTEM CONTROL UNIT

BOP

EIS BOARD

DIAGNOSIS

SoH& Lifetime

FC SYSTEM

SYSTEM MANAGEMENT

AND CONTROL UNIT

EPS backup/energy system

FCStack

EIS board proto 1

DC/DC converter

Power 1.3 kWCoolings Water cooled

Reactants Air & Reformate

Applications Residential µ-CHP

power 3 kWCoolings Water cooled

Reactants Oxygen & Hydrogen

Applications Backup electric powerH2 as energy buffer

Reformer

FC Stack

DC/AC Inverter

HeatIntegration

a b

LOAD

LOADSCALING-UP

INFO

BITRON EIS BoxSHAPE SMOOTHING SIGNIFICANT

EIS POINTS ECM FITTINGEIS SPECTRA

2 3 4Re(Z) [ *cm2]

-1.5

-1

-0.5

0

0.5

1

1.5

2

-Im(Z

) [*c

m2 ]

E0001 #S NOMINAL CONDITION 40A

EXPERIMENTAL DATA

2 3 4Re(Z) [ *cm2]

-1.5

-1

-0.5

0

0.5

1

1.5

2

-Im(Z

) [*c

m2 ]

E0001 #S NOMINAL CONDITION 40A

EXPERIMENTAL DATASHAPE SMOOTING

2 3 4Re(Z) [ *cm2]

-1.5

-1

-0.5

0

0.5

1

1.5

2

-Im(Z

) [*c

m2 ]

E0001 #S NOMINAL CONDITION 40A

EXPERIMENTAL DATAECM FITTING

2 3 4Re(Z) [ *cm2]

-1.5

-1

-0.5

0

0.5

1

1.5

2

-Im(Z

) [*c

m2 ]

E0001 #S NOMINAL CONDITION 40A

EXPERIMENTAL DATASHAPE SMOOTHINGSIGNIFICANT POINTS

EIS board (TRL 6)EIS board has been

prototyped (proto 2) ready to be engineered for

system embedding.

Converter (TRL 6) Conventional HW is

modified/re-engineered to allow flexibility and multiple

market choice for manufacturer strategies.

Algorithms (TRL 5) Detection and Isolation of 5 faults in stacks fed with Air+Reformate / O2+H2.