CEA LIST P AN- H P AN- H Smart embedded Voltage Control Sensor for - - PowerPoint PPT Presentation

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CEA LIST P AN- H P AN- H Smart embedded Voltage Control Sensor for - - PowerPoint PPT Presentation

Jun 04, 2023 330 likes •509 views

CEA LIST P AN- H P AN- H Smart embedded Voltage Control Sensor for individual elements of o fuel cell stack FC_tools 09 Trondheim Francis ROY Alain GIRAUD francis.roy1@mpsa.com alain.giraud@cea.fr Direction de la Recherche et de

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Laboratoire d' Intégration des Systèmes et des Technologies

1

Alain GIRAUD

alain.giraud@cea.fr

CEA LIST

Smart embedded Voltage Control Sensor for individual elements of o fuel cell stack FC_tools 09 Trondheim Francis ROY

francis.roy1@mpsa.com

PAN-H PAN-H

Direction de la Recherche et de l’Innovation Automobile

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Laboratoire d' Intégration des Systèmes et des Technologies

2 FISYPAC project

FiSYPAC is the first project which leads to the vehicle integration of GENEPAC fuel cell stacks.

GENEPAC technology : high performances 1.5kW/L and 1kW/kg Technical Achievements : Speed:155 km/h H2 = 1,1kg/100km Autonomy :500 km

Vehicle architecture : Electrical motor Li-Ion battery (75-500kms) Charged by recovering energy High pressure storage tank 1.5kW/L 1kW/kg

FCS on-line features: 60°-85°C 20-140A 10-16 bars on H2 entrance 50% of humidity FISYPAC Life time improvement FISYPAC Staionary performance

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Laboratoire d' Intégration des Systèmes et des Technologies

3 Outline

Fisypac : the fuel cell control Specification of monitoring module Design of the module Test and validations New approach with sensors based on GMR Designs Tests and validations Conclusions

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Laboratoire d' Intégration des Systèmes et des Technologies

4 FISYPAC: the fuel cell control

Voltage control dispersion – 0,3V to 1,28V for an individual cell – 38,4V to 153,6V for the stack) Resolution – +/-1% from 60°C to 85°C (nominal temperature) => +/-10mV – +/-5% from -20°C to 60°C (intermediate) Alarm thresholds – 0,4V information / 0,3V emergency Control loop – 500ms Board mechanical constraints – Screwed on stack back-bone – No compatibility between electronic space common standards and Individual cell plug: minimum flat cable wiring – Arrangement to equilibrate flat cable wiring between cells and board Galvanic insulation – Simple opto electronic components assume 1500V galvanic insulation between stack (350V with large tolerance) and vehicle grounded units Board organization – Induced a splitting into three modules of the functions embedded on the board CAN networking – CAN 1 : for each fuel cell emergency frames with alarm and emergency bits positioned when thresholds are crossed – CAN 2 : for each fuel cell current voltage values

Data reading collected from cell wires coming from upper part A Data reading collected for cell wires coming from lower part B Reading and diagnosys system CAN_1 CAN_2 12V Treatments and Diagnosis module Opto coupling insulation Opto coupling insulation

A A B B

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Laboratoire d' Intégration des Systèmes et des Technologies

5 FISYPAC : transfer mechanism

Galvanic insulation fixed to 1500V between fuel cells and 12V battery Galvanic insulation fixed to 1500V between fuel cells and 12V battery Opto-electronic barrel Opto-electronic barrel

V/F conversion Counter First conversion: linearity, few influence of temperature 100100100 Second conversion: using counter functions of the computer Computer

  • analog signals are affected by emissivity and photo current restitution in

presence of temperature

  • binary signals are less sensible to opto barrel

Fuel Cell

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Laboratoire d' Intégration des Systèmes et des Technologies

6 FISYPAC: cell for measuring

Measured cell = PR(i+1) Ground PR(i) Supply cell = PR(i+20) AA extern supply AM extern ground AS converted cell voltage AC(i) shut down

Opto barrel Regulator Cell supply V/F conversion Opto barrel Opto barrel Regulator V/F conversion Measured cell Ground cell

Printed board mock-up

Cell supply Measured cell Ground cell

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Laboratoire d' Intégration des Systèmes et des Technologies

7 FISYPAC : scanning, treatment and transfer

Prototyping board (as near as possible final embedded board)

– ARM MAC7111 (automotive guarantees) – I/O, timers – CAN – JTAG probe for downloading and debugging – Development PC with debuggind, dowlnoading, compiler and CAN interface

Binary to counted signals

– Best choice for timer conversion functions

Test bench

– combining mock-up with 12 measurements cells, prototype board and sell simulation (supply) – Embedded software nearby FISYPAC application

Results

– For each measured cell, linearity of computed data versus analog supply simulating cell voltage

  • External supply to replace fuel cell
  • 10mV increments to verify accuracy and

repeatability

– Computation to determine coefficients of linear function which identify the transfer response of measurement cell – Control of emergency thresholds – CAN frames organization (automotive protocol) ARM MAC7111 microcontroller Available I/O and counters 2 CAN drivers JTAG debug

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Laboratoire d' Intégration des Systèmes et des Technologies

8 Monitoring module : some results

500 1000 1500 2000 2500 3000 1000 2000 3000 4000 5000 6000 7000 Digital counting

Série1 Série2 Série3 Série7 Série9

Cell voltage (mV)

Mock-up validation

– Precision < 10mV effective – No significant variation du to temperature or batches dispersion – Efficient calibration

  • Convert. tension/fréquence AD654_circuit 1, régulateur LM

2936 et optocoupleur HCPL063L à différents paliers de température (tens. entrée conv. = 0,6V, tens. sortie opto. = 3,3V) 58550 58600 58650 58700 58750 58800 58850 5 10 15 20 25 Tension entrée régulateur (V) Fréquence sortie optocoupleu fréq.@ 85°C fréq.@ 60°C fréq.@ 20°C fréq.@ 0°C fréq.@

  • 20°C
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Laboratoire d' Intégration des Systèmes et des Technologies

9

Computed voltage

– Computed voltage restitute correct cell voltage – Occurrence of event (modification of threshold voltage, exchange of batteries – Without further temperature tests

200 400 600 800 1000 1200 1400 1 101 201 301 401 Scrutations

VOIE_0 VOIE_1 VOIE_2 VOIE_3 VOIE_4 VOIE_5 VOIE_6 VOIE_7 VOIE_8 VOIE_9 VOIE_10 VOIE_11

Computed cell voltage (mV)

New threshold (300mV)

200 400 600 800 1000 1200 1400 1 101 201 301 401 Scanning loop

VOIE_0 VOIE_1 VOIE_2 VOIE_3 VOIE_4 VOIE_5 VOIE_6 VOIE_7 VOIE_8 VOIE_9 VOIE_10 VOIE_11

Computed cell voltage (mV)

Changing of battery n°10

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Laboratoire d' Intégration des Systèmes et des Technologies

10 FISYPAC : final board

Prototype board

– Design based of 12 cells mock- ups – Use of printed boards layers to equilibrate charge of the pile and access to the counters of treatment module – calibration of all elements – Final validation of embedded software (automotive protocol PSA) – Test and validation at LITEN facility – Test and validation in-situ in automotive conditions

  • In lab conditions
  • On-going on road conditions

Automatic purge of cells CAN connectors JTAGconnec tors Full remote

  • n-

line monitoring Futur on-line monitoring

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Laboratoire d' Intégration des Systèmes et des Technologies

11

640 660 680 700 720 740 760 780 800 820 40 80 120 160 200 240 Cell identifiers (pile FISYPAC)

  • 40
  • 20

20 40 60

carte banc delta

Computed cell voltage(mV) Difference (mV)

840 860 880 900 920 940 40 80 120 160 200 240 Cells identifers (FISYPAC stack)

  • 40
  • 20

20 40 60 80 100

prototype board PSA facility Difference

Computed voltage(mV) Diffrence(mV)

600 700 800 900 1000 20 40 60 80 100 120 Cell identifiant (carte 1) Computed cell voltage (mV)

Diagnosys board Flat cable to the stack Ombilic of flat cables

Tests on LITEN facility

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Laboratoire d' Intégration des Systèmes et des Technologies

12 FISYPAC: GMR technology

Features:

  • a current circulating into bias lines induces a magnetic field detected by

resistors which value depend of the magnetic field encountered (nanned GMR).

  • The magnetic field is not affected by the insulation layers between bias lines

and GMR resistor, which allows an intrinsic galvanic insulation

  • The linearity of the conversion is very efficient

Individual fuel cell Bias current Amplifiers 100100100 CA/N Computing GMR

  • 2
  • 1,5
  • 1
  • 0,5

0,5 1 1,5 2

  • 70
  • 50
  • 30
  • 10

10 30 50 70

Ibias (mA) U (V) 1mA 1mA 2mA 2mA 2.96mA 2.96mA 3mA 3mA 4mA 4mA 4,44mA 4,44mA

Vsup

Bias lines Variable resistors

Ibias

Vstack

  • r

Vcell

GMR cell

VGMR

ground

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Laboratoire d' Intégration des Systèmes et des Technologies

13 FISYPAC : behavior

  • f a single GMR cell

Behavior of a single GMR

– Very linear comportment of cell voltage conversion – Inherent low offset – Sensitivity to temperature

  • Appears as homogeneous and

linear

  • Computed correction

(treatment module)

  • Compensation by technology
  • Not possibility to evaluate lot

effect production

– Next step, design of a barrel

Single GMR cell

Bias line and cell voltage simulation

Amplification

  • 40
  • 20

20 40 0,5 1 1,5 2 2,5 3

VIN+ - VIN-(mV à 20°C) VIN+ - VIN-(mV à 40°C) VIN+ - VIN-(mV à 60°C) VIN+ -VIN- (mV à 85°C) VIN+ - VIN-(mV à 0°C) VIN+ - VIN- (mV à -20°C)

ESSAI

Vin+ - Vin- / mV Vcel / V

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Laboratoire d' Intégration des Systèmes et des Technologies

14 FISYPAC : behavior

  • f a single barrel

Barrel design

– Could be seen as nano and micro design and production with various processes

  • Low
  • ffset
  • Few drifts observed

in tempature environments

  • Some

drifts on bias resistors

– No dispersion on the barrel

Insulation difficulties

Barrel of 8 GMR cells Bias lines GMR

  • utputs

1,35 1,45 1,55 1,65 1,75 0,5 1 1,5 2 2,5 3 cell voltage (V)

V+0°C V-0°C V+20°C V-20°C V+-20°C V--20°C V+40°C V-40°C V+60°C V-60°C V+85°C V-85°C

VG MR (V)

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Laboratoire d' Intégration des Systèmes et des Technologies

15 FISYPAC: the GMR module

Design of an hybrid model

– GMR barrel – Discrete instrumentation stage

Packaging

– Multilayer – Interconnection

Results

– Linearity – Existing offset – Accuracy

GMR barrel

A1_750 = -0,2834x + 1,8796 R2 = 0,9995 A2_750 = -0,2739x + 1,7504 R2 = 0,9996 A3_750 = -0,2803x + 1,6948 R2 = 0,9996 A5_750 = -0,2353x + 1,8196 R2 = 0,9996 A6_750 = -0,2411x + 1,7728 R2 = 0,9997 A7_750 = -0,2454x + 1,6846 R2 = 0,9996 A8_750 = -0,2426x + 1,761 R2 = 0,9996 1 1,2 1,4 1,6 1,8 2 2,2 2,4

  • 1,5
  • 1
  • 0,5

0,5 1 1,5 Cell Voltage (V)

AMPLI (V)

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Laboratoire d' Intégration des Systèmes et des Technologies

16 To conclude

Applications involving a large number of cells or stacks needs an efficient and faithful smart embedded control board to deal with emergency technics when single or multiple cells become degraded or failed Our on-line monitoring tools are involved in an automotive application? Validation for validation is on-going. Recent GMR technology offers an appreciable opening to modern nano

  • r micro sensors for monitoring of cell or stack voltage (and probably
  • ther parameters not yet tracked). The prototype board will be soon

produced and validate on 200-400 cells stacks. Nevertheless, as for electronic technologies, such an innovative approach will deal with industries interest only when technologies become stable with a significant life-time. This will be done for designers and founders when an identified volume market will be appreciate.

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Laboratoire d' Intégration des Systèmes et des Technologies

17 The end…

Thank you for your attention!!

Curtesy PSA