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Abstract—This paper proposes robust control and power
management strategies for a 6kW stationary fuel cell hybrid
power system. The system consists of two 3kW PEMFC modules,
a Li-Fe battery set and electrical components to form a parallel
hybrid power system that is designed for telecom base stations
to supply uninterruptible power during emergency power
failures. The study is carried out in three steps: the PEMFC
modules control, power management, and system integration.
First, we apply robust control to regulate the hydrogen flow
rates of the PEMFC modules to increase system stability,
performance, and efficiency. Second, we design a parallel power
train that consists of two PEMFC modules and one Li-Fe
battery set for uninterruptible power supply (UPS) requirement.
When the main power is shut down, the Li-Fe battery will
activate PEMFC modules. Then the PEMFC modules provide
steady power at low current loadings. At high loading, both
PEMFC modules and the Li-Fe battery set will simultaneously
provide electricity. Lastly, we integrate the system for
experimental verification. Based on the results, the proposed
robust control and power management are deemed effective in
improving stability, performance and efficiency of the
stationary power system.
I. INTRODUCTION
s an alternative energy source, the proton exchange
membrane fuel cell (PEMFC) has drawn much attention
because of its advantageous properties, such as low operating
temperature, high efficiency, and environmental-friendly.
Gorgun [1] described a PEM electrolyzer as a dynamic model
that considered water phenomena, electro-osmotic drag and
diffusion, and voltage ancillary. Bao et al. [2] developed a
nonlinear PEMFC model and further linearized it for linear
control design. Woo and Benziger [3] designed a
proportional-integral-derivative (PID) controller that
regulated the hydrogen flow rate for optimal performance.
Vega-Leal et al. [4] developed a multivariable system that
Manuscript received October 28, 2012. This work was supported in part
by the Taiwan National Science Council under Grant
100-2622-E-002-027-CC3
Yi-Fu Kuo is with the Mechanical Engineering Department of National Taiwan University, Taiwan. (e-mail: [email protected])
Po-Cheng Kuo is with the Mechanical Engineering Department of
National Taiwan University, Taiwan. (e-mail: [email protected]). Hsueh-Ju Chen is with the Mechanical Engineering Department of
National Taiwan University, Taiwan. (e-mail: [email protected]).
Chung-Huang Yu is with the Department of Physical Therapy & Assistive Technology, National Yang-Ming University, Taipei, Taiwan (e-mail:
Fu-Cheng Wang is with the Mechanical Engineering Department of National Taiwan University, No.1, Sec. 4, Roosevelt Road, Taipei 10617,
Taiwan. (corresponding author phone: +886-2-33662680; fax:
+886-2-23631755; e-mail: [email protected]).
controlled the air and hydrogen flow rates to optimize net
power. Wang et al. [5–9] applied robust control that regulated
the oxygen and hydrogen flow rates to provide steady voltage
and to reduce hydrogen consumption. Andreasen et al. [10] applied proportional-integral (PI) temperature control to
achieve fuel cell system efficiency of 45 percent.
There are four main application fields for PEMFC,
namely transportation, niche markets, portable power, and
stationary power generation [11]. In this paper, we discuss the
application of stationary power, which include backup power,
auxiliary power unit (APU), uninterruptible power supply
(UPS), and combined heat & power system (CHP) [11]. Choi
et al. [12] focused on designed considerations of replacing
conventional UPS power sources by fuel-cells. Corbo et al.
[13] analyzed the application of a 20kW PEMFC stack to
both stationary power and automotive systems. Zhan et al. [14]
developed an hybrid intelligent UPS system that comprises a
PEMFC and a battery. Tao et al. [15] proposed a
line-interactive fuel-cell powered UPS system that composed
of a three-port bidirectional converter, a fuel cell, a
super-capacitor, and a grid-interfacing inverter. This paper
discusses the application of a 6kW PEMFC hybrid backup
power system for UPS of telecom base stations, where an
unexpected power disruption might cause injuries, fatalities,
serious business disruption, and data loss. Compared to
traditional UPS with combustion engines backup power,
battery-based UPS are adopted to improve system
performance and environment friendliness. However, the
operating time of batteries is limited by their capacities.
Therefore, in this study, we integrate a PEMFC hybrid
backup power for continuous operation of UPS systems.
This paper is organized as follows: section II discusses the
dynamics of a 3kW PEMFC modules. Section III applies H∞
robust control to regulate the hydrogen flow rates of the
PEMFC to improve system performance. Section IV
proposes a 6kW PEMFC hybrid stationary power system that
satisfies the UPS requirements for telecom base stations.
Section V demonstrates system integration and experimental
verification. Lastly, we draw conclusions in Section VI.
II. PEMFC SYSTEM DESCRIPTION AND IDENTIFICATION
The proposed 6kW PEMFC UPS system consists of two
independent M-FieldTM
3kW PEMFC models. We first
consider an air-breathing 3kW PEMFC module, as shown in
Fig. 1, which is equipped with a hydrogen inlet and an outlet.
In addition, four 50W fans are used for air-cooling and
supplying oxygen. The stack is operated in a dead-end mode,
i.e., the hydrogen outlet is closed except for purging, in order
Control and Power Management of a Hybrid Stationary Fuel Cell
System
Yi-Fu Kuo, Po-Chen Kuo, Hsueh-Ju Chen, Chung-Huang Yu, and Fu-Cheng Wang
A
Proceedings of the 2013 IEEE/SICE InternationalSymposium on System Integration, Kobe InternationalConference Center, Kobe, Japan, December 15-17,
SP1-I.3
978-1-4799-2625-1/13/$31.00 ©2013 IEEE 144
to maintain necessary reactant in the system. During
experiments, the valve is purged for 0.5 s at an interval of 50 s.
The specifications of this PEMFC module are illustrated in
Table I.
Fig. 1. The M-Field 3kW PEMFC module.
TABLE I
STACK SPECIFICATIONS OF A M-FIELDTM
3KW PEMFC [16].
Number of cells 80
Maximum power DC 3.2kW (at DC75A) Input voltage 24VDC
Output voltage 42–80VDC
Size 80×46 ×40 cm^3
weight 40 kg Fuel inlet temperature -15→55 oC
Fuel inlet pressure 136kpa (0.36barg)
Air inlet temperature 10→50 oC
From the system point of view, the PEMFC module can
be depicted as the following single-input multi-output
system [7]:
2
( ) ,H
IG s N
V
(1)
where 2HN is the hydrogen flow rate and ( )G s is a 2×1
transfer function matrix, which represents the PEMFC
dynamics, where we can regulate the fuel cell voltage (V )
and current ( I ) outputs by controlling the hydrogen input.
Because most electrical devices require a steady voltage
supply, we can assume the output impedance as Ze (i.e., V=
Ze× I), and simplify Eq. (1) as a single-input single-output
(SISO) model:
2
( ) ,HV G s N (2)
whose output voltage can be controlled by regulating the
hydrogen flow rate [6]. To decide the transfer function
( )G s of (2), we generate chirp signals to control the
hydrogen flow rates, and measure the output voltage signals.
Applying the subspace state space system identification
(N4SID) algorithms [17, 18], we then obtain the state-space
models of the PEMFC. Based on the characteristics of the
PEMFC, we set the operating conditions as 59V, 55.8V,
53.6V and 50.8V with four different current loads: 20A,
30A, 40A, and 50A. Considering the system variations, we
repeat the experiments twice at each load and illustrate the
obtained system transfer functions in Table II. These
transfer functions will be used for robust control design in
Section III. TABLE II
TRANSFER FUNCTIONS OF THE PEMFC.
20A01 20A022 2
2.355 0.357 2.342 0.464920A : ,
0.7334 0.00096 0.7971 0.00126
s sG G
s s s s
30A01 30A022 2
1.764 0.06668 1.851 0.419530A : ,
0.6097 0.00026 0.6816 0.00016
s sG G
s s s s
40A01 40A022 2
2.072 0.5781 2.021 0.180240A : ,
1.239 0.003012 0.9912 0.00094
s sG G
s s s s
50A01 50A022 2
2.059 0.1174 2.192 0.23950A : ,
1.319 0.0007 1.471 0.00147
s sG G
s s s s
III. ROBUST CONTROL DESIGN
In this section, we introduce robust control algorithms
and design a H∞ controller for the PEMFC module. Suppose a
nominal plant 0G has a normalised left coprime factorization
of 1
0G M N , where ,M N RH and * *MM NN I .
Assume a perturbed system G can be expressed as:
1
M NG M N
with N M
, and
,M N RH . Because coprime factorization of a system is
not unique, we can define the gap between a nominal plant
0G and a perturbed plant G as [19]:
The smallest value of N M
which
perturbs 0G into G , is called the gap between
0G and G , and is denoted as 0 ,G G .
Therefore, we can select a nominal plant 0G for the PEMFC
system, which minimizes the maximum gap between 0G and
the perturbed plants G , as follows:
0
0 0arg min max , , .i
i iG G
G G G G
(3)
Consider the system transfer functions of Table II, we
select 30A01G as the nominal plant, i.e.,
0 30A01G G , which
gives 0 , 0.2199iG G for all iG . The gap can be regarded
as the maximum system variation of the PEMFC, due to the
changes in operating conditions, such as temperature,
humidification, and current loads. A closed-loop system with
a perturbed system G and a controller K can be represented
as Fig. 3(a) and rearranged as Fig. 3(b). Therefore, using the
Small-Gain Theorem [20], the system is internally stable for
all perturbations [ ]N M with
if and only
if:
1
0 0
1.
KI G K I G
I
(4)
978-1-4799-2625-1/13/$31.00 ©2013 IEEE 145
(a) A closed-loop system with G and K.
(b) Rearrangement for the Small-Gain Theorem.
Fig. 3. The closed-loop control system.
Define the system’s stability margin 0 ,b G K as [18]:
-1
-1
0 0 0, - ,K
b G K I G K I GI
(5)
the closed-loop system is internally stable for all uncertainties
[ ]N M with
if and only if its stability
margin 0 ,b G K . Hence, the objective of controller
synthesis is to design a controller K for the nominal plant 0G
such that 0 , 0.2199b G K . Using the H loop-shaping
design techniques [21], as shown in Fig. 4, we set the
weighting functions as:
1 2
0.3 0.06, 1
sW W
s
,
to shape the plant as 2 0 1sG W G W . The weighting functions
are selected and iteratively verified by simulations and
experiments, in order to provide a high-gain at the
low-frequency range to improve system performance, and a
low-gain at the high-frequency range for robust stability.
Following the aforementioned procedures, the standard H
robust controller is designed as:
2
2
1.203 0.5017 0.0575,
0.5456 0.0692
s sK s
s s
which gives a stability bound of 0.5679. Because the
stability margin is greater than the system gap
0 , 0.2199iG G , the system stability is guaranteed. The
weighted controller 1 2K W K W is then implemented for
the PEMFC system, as illustrated in Fig. 4(b). We
implement the designed controller, and illustrate the test
results in Table III, where the hydrogen consumption is
reduced. The root mean square error (RMSE) is effectively
controlled within a reasonable range (<0.05V) by the
designed robust controller.
(a) Shape the open-loop plant 2 0 1sG W G W .
(b) Implemente the weighted controller 1 2K W K W .
Fig. 4. Loop-shaping design procedures.
TABLE III COMPARISON OF THE OPEN- AND CLOSED-LOOP CONTROL.
H2 consumption (L) in 5 min.
RMSE(V)
Closed-loop
Open-Loop Closed-Loop Improved (%)
20A 76.95 71.29 7.36% 0.0363
30A 104.44 98.60 5.59% 0.0475
40A 133.99 128.96 3.75% 0.0304
50A 162.92 156.96 3.66% 0.0272
IV. POWER MANAGEMENT
In this section, we design the power management
strategies for the 6kW stationary PEMFC hybrid system. A
classical UPS is shown in Fig. 5(a), where the main 220VAC
grid power is converted (by the switch module rectifier; SMR)
into 48VDC for the stations supplied, and charges the battery
set. When the grid power is shut down, the backup battery set
is used for uninterrupted operation. However, the operating
time of the classical UPS system is limited due to the limited
capacity of the battery set. Therefore, we construct a PEMFC
978-1-4799-2625-1/13/$31.00 ©2013 IEEE 146
UPS system, as illustrated in Fig. 5(b), which completes the
battery set with a 6kW PEMFC for continuous operation as
long as the hydrogen is continuously supplied.
The detailed structure of the 6kW PEMFC hybrid backup
power system is shown in Fig. 6, in which the parameters are:
Q : PEMFC module hydrogen flow rate.
, : PEMFC module output voltage and current.
, : Battery set output voltage and current.
, :DC DC converter input voltage and current.
,
j
FCj FCj
BATT BATT
Cij Cij
Coj Coj
j
V I j
V I
V I j
V I
: DC DC converter output voltage and current.
, : Balance of plant BOP voltage and current.BOPj BOPj
j
V I
where j=1,2.
(a) The classical UPS structure.
(b) The PEMFC UPS structure.
Fig. 5. The UPS system structure.
Fig. 6. The 6kW PEMFC hybrid power system.
TABLE IV
System hardware.
System parts Company/
type
Specification
PEMFC modules M-Field/
LPH8020
As illustrated in Table 1.
Li-Fe battery set A123/ ANR26650
Nominal voltage nV =52.8V,
Nominal capacity nQ =23Ah
DC buses Nell/
NKJ240
Maximum reverse voltage RPMV
=600V,
Maximum forward current fI =240A
DC-DC converters PSP/
SN:0020-D
Input: 45~85V(3kW)
Ouput1: 51V(adjustable) Ouput2: 24V
Load AMREL/
PLW9k
Mode: CC,CV,CP,CR
Pmax:9kW
The hybrid system consists of three parts: two PEMFC
modules (the main source, where module-1 is a new module
and module-2 is a two-year-old module), a Li-Fe battery set
(auxiliary source) and electrical components. The power
management strategies can be described as follow:
1. When the grid power is available, the station loading is
supplied by SMR 48VDC output and the battery set is
charged by charger.
2. If the grid power is shut down, the battery set , BATTI
will provide electricity ( , , , ) for station
loadings and start up BOPs ( , , , ) to
activate the PEMFC modules.
3. After the PEMFC modules reach steady states (normally
within 1 minute), they will provide electricity
( , , , ) in parallel with the battery set: At low
current loadings ( > and > ), the PEMFC
modules provide electricity alone. At high current loadings
( = = ), both the PEMFC modules and battery set
provide electricity for station loads.
4. When the station load is low (<35A), the PEMFC
module-1 will charge the battery set directly until its voltage
is equal or higher than 54V, considering the discharging
curve of the battery set of Fig. 7. The charging method is
near to constant current charge.
5. For safety, the security protection will be activated by the
following four conditions:
(1) gas pressure protection: the input pressure of hydrogen
flow should be greater than 0.1 barg and less than 0.5
barg.
(2) temperature protection: the temperature of the
input/output flow should be less than 50 C / 70 C .
(3) PEMFC module output protection:
( 45 85, 0< 60FCj FCjV I ).
(4) Battery protection: ( 46 54BATTV ).
Table IV illustrates the system hardware: two M-field
PEMFC modules as main sources, an A123 Li-Fe battery set
as the auxiliary source, DC buses and DC-DC converters for
power managements.
978-1-4799-2625-1/13/$31.00 ©2013 IEEE 147
Fig. 7. The discharging curves of the battery set.
V. EXPERIMENT
In this section, we will integrate the aforementioned system,
as shown in Fig. 8, for experimental verification and
calculate the system efficiency. Refer to Fig. 6, we define
the system energy levels as follow:
1: ,
2 : ,
3 : ,
,
e
s
e
s
e
s
e
s
e
s
t
FCj FCj FCjt
t
BATT BATT BATTt
t
Cij Cij Cijt
t
Coj Coj Cojt
t
BOPj BOPj BOPjt
Level E V I dt
E V I dt
Level E V I dt
Level E V I dt
E V I dt
(6)
where j=1,2. Note that Level 1 includes the output energy of
two PEMFC modules and the Li-Fe Battery set. Level 2
comprises the input energy of all DC-DC converters. Level 3
contains the output energy of all DC-DC converters. Using
the experiment parameters of Table V, we show the
experimental responses in Fig. 9, and illustrate the statistic
data in Table VI.
Fig. 8 Integration of 6kW PEMFC hybrid backup power system.
TABLE V
EXPERIMENT PARAMETERS.
Operating parameter
Input
Pressure 5 barg
Temperature 25 o C
Voltage 24V
Output Purge volume 3000L(open loop) Load-meter 40A→60A→80A→100A, (100s each)
Measure signal
NI DAQ
sampling
time=0.01s
Flow rate: Q j( j=1,2)
Level 1: , , , FCj FCj BATT BATTV I V I ( j=1,2)
Level 2: , Cij CijV I ( j=1,2)
Level 3: , , , Coj Coj BOPj BOPjV I V I ( j=1,2)
Fig. 9 System current and power response.
TABLE VI Statistic data of Fig. 9 [12].
Energy (kJ) Closed-loop
Level 1
1FCE 780.80
2FCE 561.45
BATTE 336.09
Level 2 1CiE 1037.06
2CiE 620.11
Level 3
1CoE 924.79
2CoE 527.00
1BOPE 32.80
2BOPE 21.74
(%)e 89.75
.(%)hyd 77.48
(%)total 73.59
For quantitative comparison, we define several system
efficiencies as in the following. First, we define the net power
efficiency (%)e as:
1 2 1 2
1 2
3(%) 100%,
1
Co Co BOP BOP
e
FC FC BATT
E E E ELevel
Level E E E
(7)
which represents the percentage of utilized energy from Level
1 to Level 3. Second, we define the hydrogen efficiency as
[8]:
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
48
50
52
54
56
Time(hrs)
Voltage(V
)
Discharge curve Li-Fe Batteries 48V23Ah with BMS
0 2 4 6 8 10 12 14 16 18
48
50
52
54
56
Capacity(Ah)
Voltage(V
)0.5C
1C
1.5C
2C
Load-meter
FC
Module-2
BreakerConverter2
Lead-Acid Batteries
Diode
ComputerLi-Fe
Batteries
FC
Module-1
Converter1
0 50 100 150 200 250 300 350 4000
20
40
60
80
Level 1
Current(A)-Time(s) plot
0 50 100 150 200 250 300 350 4000
20
40
60
80
Level 2
0 50 100 150 200 250 300 350 4000
20
40
60
80
Level 3
time(s)
0 50 100 150 200 250 300 350 4000
1
2
3
4Power(kW)-Time(s) plot
0 50 100 150 200 250 300 350 4000
1
2
3
4
0 50 100 150 200 250 300 350 4000
1
2
3
4
time(s)
Ci1
Ci2
FC1
FC2
BATT
Co1
Co2
BOP1
BOP2
978-1-4799-2625-1/13/$31.00 ©2013 IEEE 148
2
.
2
(%) 100%,Th
hyd Exp
H
H (8)
where 2
ThH and 2
ExpH are the theoretical and practical
hydrogen consumption, respectively. The theoretical
hydrogen consumption 2
ThH is defined as [9]:
2 ,2
Th I n tH R
F
(9)
in which I is the current load, n is the number of cells, t is the
time interval, F is the Faraday constant (F=96,485 C/mole )
and R is the mass of per mole hydrogen (R= 2.0158 g/mole ).
Lastly, we define the total system efficiency as:
1 2 .( )total e hydr r
(10)
1 21 2
1 2 1 2
, BATT FC FC
FC FC BATT FC FC BATT
E E Er r
E E E E E E
(11)
where 1r and 2r are the battery energy ratio and the PEMFC
energy ratio, respectively, of Level 1. As shown in Table VI,
we achieve a net power efficiency of about =89.75%e and a
hydrogen efficiency .hyd 77.48% by the closed-loop
control strategies, which makes the total system efficiency
total 73.59%.
VI. CONCLUDING REMARKS
This paper has demonstrated the control and power
management of a 6kW stationary fuel cell hybrid system. We
first modeled and controlled a 3kW PEMFC module, and then
designed the PEMFC hybrid power system for UPS for
telecommunication stations. This system was integrated for
experimental verification, and shown to improve the system
efficiencies. Based on the results, the proposed robust control
and power management was deemed effective for the
PEMFC stationary system.
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