smart embedded voltage control sensor for fc tools09 ......série1 série2 série3 cell voltage (mv)...
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Laboratoire d' Intégration des Systèmes et des Technologies1
Alain GIRAUDalain.giraud@cea.fr
CEA LIST
Smart embedded Voltage Control Sensor for individual elements of o fuel cell stack
FC_tools 09 TrondheimFrancis ROY
francis.roy1@mpsa.com
PAN-HPAN-H
Direction de la Recherche et de l’Innovation Automobile
Laboratoire d' Intégration des Systèmes et des Technologies2
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
FISY
PAC
Life
tim
e im
prov
emen
tFISYPAC
Staionary
performance
Laboratoire d' Intégration des Systèmes et des Technologies3
Outline
Fisypac
: the fuel cell controlSpecification of monitoring moduleDesign of the moduleTest and validationsNew approach with sensors based on GMRDesigns Tests and validationsConclusions
Laboratoire d' Intégration des Systèmes et des Technologies4
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 boardCAN 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_1CAN_2
12V
Treatments and Diagnosis module
Opto coupling insulation
Opto coupling insulation
A
A
B
B
Laboratoire d' Intégration des Systèmes et des Technologies5
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 barrelOpto-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
Laboratoire d' Intégration des Systèmes et des Technologies6
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 supplyV/F
conversion
Opto barrel
Opto barrel
Regulator
V/F conversion
Measured cell
Ground cell
Printed
board
mock-up
Cell supply
Measured cell
Ground cell
Laboratoire d' Intégration des Systèmes et des Technologies7
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 MAC7111microcontroller
Available I/O and counters
2 CAN drivers
JTAG debug
Laboratoire d' Intégration des Systèmes et des Technologies8
Monitoring module : some
results
0
500
1000
1500
2000
2500
3000
0 1000 2000 3000 4000 5000 6000 7000
Digital counting
Série1 Série2 Série3
Série7 Série9Cell v
olta
ge (m
V)
Mock-up validation– Precision < 10mV effective– No significant variation du to temperature or
batches dispersion– Efficient calibration
Convert. tension/fréquence AD654_circuit 1, régulateur LM2936 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)
Fréq
uenc
e so
rtie
opto
coup
leu
fréq.@85°Cfréq.@60°Cfréq.@20°Cfréq.@0°Cfréq.@-20°C
Laboratoire d' Intégration des Systèmes et des Technologies9
Computed voltage– Computed voltage restitute correct cell voltage– Occurrence of event (modification of threshold voltage, exchange of
batteries– Without further temperature tests
0
200
400
600
800
1000
1200
1400
1 101 201 301 401Scrutations
VOIE_0 VOIE_1 VOIE_2VOIE_3 VOIE_4 VOIE_5VOIE_6 VOIE_7 VOIE_8VOIE_9 VOIE_10 VOIE_11
Com
pute
d ce
ll vol
tage
(mV)
New threshold (300mV)
0
200
400
600
800
1000
1200
1400
1 101 201 301 401Scanning loop
VOIE_0 VOIE_1 VOIE_2VOIE_3 VOIE_4 VOIE_5VOIE_6 VOIE_7 VOIE_8VOIE_9 VOIE_10 VOIE_11
Com
pute
d ce
ll vol
tage
(mV)
Changing of battery n°10
Laboratoire d' Intégration des Systèmes et des Technologies10
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
on-
line monitoring
Futur on-line monitoring
Laboratoire d' Intégration des Systèmes et des Technologies11
640660680700720740760780800820
0 40 80 120 160 200 240Cell identifiers (pile FISYPAC)
-40
-20
0
20
40
60
carte bancdelta
Com
pute
d ce
ll vo
ltage
(mV) D
ifference (mV)
840
860
880
900
920
940
0 40 80 120 160 200 240Cells identifers (FISYPAC stack)
-40-20020406080100
prototype boardPSA facilityDifferenceC
ompu
ted
volta
ge(m
V) Diffrence(m
V)
600
700
800
900
1000
0 20 40 60 80 100 120Cell identifiant (carte 1)
Com
pute
d ce
ll vo
ltage
(mV)
Diagnosys board
Flat cable to the stack
Ombilic of flat cables
Tests on LITEN facility
Laboratoire d' Intégration des Systèmes et des Technologies12
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 ComputingGMR
-2
-1,5
-1
-0,5
0
0,5
1
1,5
2
-70 -50 -30 -10 10 30 50 70
Ibias (mA)
U (V
)
1mA1mA2mA2mA2.96mA2.96mA3mA3mA4mA4mA4,44mA4,44mA
Vsup Bias lines
Variable resistors
Ibias
Vstack
or
Vcell
GMR cell VGMR
ground
Laboratoire d' Intégration des Systèmes et des Technologies13
FISYPAC : behavior
of 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
0
20
40
0 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+
- Vi
n- /
mV
Vcel / V
Laboratoire d' Intégration des Systèmes et des Technologies14
FISYPAC : behavior
of a single barrel
Barrel design– Could
be
seen
as nano and
micro design and production with
various
processes
• Low
offset• 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 outputs
1,35
1,45
1,55
1,65
1,75
0 0,5 1 1,5 2 2,5 3cell voltage (V)
V+0°C V-0°CV+20°C V-20°CV+-20°C V--20°CV+40°C V-40°CV+60°C V-60°CV+85°C V-85°C
VGMR
(V)
Laboratoire d' Intégration des Systèmes et des Technologies15
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 + 1,8796R2 = 0,9995
A2_750 = -0,2739x + 1,7504R2 = 0,9996
A3_750 = -0,2803x + 1,6948R2 = 0,9996
A5_750 = -0,2353x + 1,8196R2 = 0,9996
A6_750 = -0,2411x + 1,7728R2 = 0,9997
A7_750 = -0,2454x + 1,6846R2 = 0,9996
A8_750 = -0,2426x + 1,761R2 = 0,9996
1
1,2
1,4
1,6
1,8
2
2,2
2,4
-1,5 -1 -0,5 0 0,5 1 1,5
Cell Voltage (V)
AMPL
I (V)
Laboratoire d' Intégration des Systèmes et des Technologies16
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 failedOur 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
or micro sensors for monitoring of cell or stack voltage (and probably other 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.
Laboratoire d' Intégration des Systèmes et des Technologies17
The end…
Thank you for your attention!!
Curtesy
PSA
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