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- 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.