System and method for controlling a fuel cell testing device Number:7,149,641 from the United States Patent and Trademark Office (PTO) owispatent

Title: System and method for controlling a fuel cell testing device

Abstract: A system and method in a data processor for controlling a controllable condition of a fuel cell via a control device is provided. The system and method involve (a) providing a script language comprising a control command type having an operating level field for receiving a selected operating level of the control device; (b) deriving a control command from the control command type by inserting the selected operating level of the control device into the operating level field of the control command; (c) writing a test script using the script language such that the test script includes the control command; (d) compiling the test script to provide a test program; and, (e) controlling the control device according to the test program.

Patent Number: 7,149,641 Issued on 12/12/2006 to Gopal,   et al.

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Inventors:	Gopal; Ravi B. (Oakville, CA), Wei; Yuehui (Mississauga, CA)
Assignee:	Hydrogenics Corporation (Mississauga, CA)
Appl. No.:	10/939,989
Filed:	September 14, 2004

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Related U.S. Patent Documents

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	Application Number	Filing Date	Patent Number	Issue Date
	10244609	Sep., 2002	6889147
	PCT/CA03/001117	Jul., 2003

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Current U.S. Class:	702/108
Current International Class:	G06F 19/00 (20060101)
Field of Search:	702/108

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Primary Examiner: Nghiem; Michael
Assistant Examiner: Lau; Tung S.
Attorney, Agent or Firm: Bereskin & Parr

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Parent Case Text

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RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 10/244,609, filed Sep. 17, 2002 now U.S. Pat. No. 6,889,147 and a continuation of PCT Patent Application No. PCT/CA03/001117, filed on Jul. 24, 2003.

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Claims

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The invention claimed is:

1. A system for testing a fuel cell, the system comprising: (a) testing means having a control device for controlling a controllable condition of the fuel cell; (b) a user interface for providing a script language comprising a control command type having an operating level field for receiving a selected operating level of the control device, wherein a test script is writeable using the script language such that the test script includes a control command of the control command type, the control command being derivable from the control command type by inserting the selected operating level of the control device into the operating level field of the control command; (c) a compiler for compiling the test script to provide a test program; and, (d) a system manager for controlling the control device according to the test program.

2. The system as defined in claim 1 wherein the compiler is operable to compile the test script to provide the test program by converting the selected operating level defined in the operating level field of the control command to a device operating level for controlling the control device to operate at the selected operating level.

3. The system as defined in claim 1 wherein the testing means comprises a plurality of control devices for controlling a plurality of controllable conditions of the fuel cell; the script language comprises a plurality of device identifiers for identifying the plurality of control devices, each control device in the plurality of control devices being identifiable by an associated device identifier in the plurality of device identifiers; the control command type comprises a device identification field for receiving the associated device identifier for a selected control device; and, the test script is writeable using the script language such that the test script includes a plurality of control commands of the control command type; and each control command in the test script includes, (i) in the operating level field of the control command, the selected operating level of the selected control device, and, (ii) in the device identification field, the associated device identifier for the selected control device.

4. The system as defined in claim 1 wherein the testing means comprises a plurality of control devices for controlling a plurality of controllable conditions of the fuel cell; the script language comprises a plurality of device identifiers for identifying the plurality of control devices, each control device in the plurality of control devices being identifiable by an associated device identifier in the plurality of device identifiers; the script language comprises a plurality of control command types, each control command type in the plurality of control command types having (i) an associated operating level field for receiving the selected operating level of a selected control device controlled by the control command, and (ii) a device identification field for receiving the associated identifier of the selected control device; and, the test script is writeable using the script language to include a plurality of control commands of the plurality of control command types such that each control command in the plurality of control commands defines, (i) in the operating level field of the control command, the selected operating level of the selected control device, and, (ii) in the device identification field, the associated device identifier for the selected control device.

5. The system as defined in claim 4 wherein the plurality of control devices comprises at least one flow controller for controlling at least one of an anode gas flow and a cathode gas flow; the plurality of control command types comprises a set_flow control command type, wherein the operating level field of the set_flow control command type is operable to receive a selected flow control level, and the device identification field of the set_flow control command type is operable to receive the associated device identifier of a selected flow controller in the at least one flow controller; and, the plurality of control commands includes a set_flow control command of the set_flow control command type.

6. The system as defined in claimed 5 wherein the script language further comprises a stoichiometric relational command type having a stoichiometry-defining field for receiving a selected stoichiometric ratio and a device identification field for receiving the associated device identifier for a selected flow controller; the test script is writeable using the script language such that the test script includes a stoichiometric relational command of the stoichiometric relational command type wherein the stoichiometric relational command is derivable from the stoichiometric relational command type by inserting (i) the selected stoichiometric ratio into the stoichiometry-defining field, and (ii) the associated device identifier for the selected flow controller into the device identification field; and, the system manager is operable to determine an associated flow control level for the selected flow controller based on at least one variable, the at least one variable including the selected stoichiometric ratio.

7. The system as defined in claimed 6 wherein the at least one variable further includes a load current of the fuel cell.

8. The system as defined in claim 4 the plurality of control devices comprises at least one temperature controller; the plurality of control command types comprises a temperature control command type, wherein the operating level field of the temperature control command type is operable to receive a selected temperature control level, and the device identification field of the temperature control command type is operable to receive the associated device identifier of a selected temperature controller in the at least one temperature controller; and, the plurality of control commands includes a temperature control command of the temperature control command type.

9. The system as defined in claimed 4 wherein the plurality of control devices comprises at least one load controller for controlling a load on the fuel cell provided by a load box; the plurality of control command types comprises a load control command type, wherein the operating level field of the load control command type is operable to receive a selected load control level, and the device identification field of the load control command type is operable to receive the associated device identifier of a selected load controller of the at least one load controller; and, the plurality of control commands comprises a set_load control command for designating the load level.

10. The system as defined in claim 4 the plurality of control devices comprises at least one pressure controller; the plurality of control command types comprises a set_pressure control command type, wherein the operating level field of the set_pressure control command type is operable to receive a selected pressure control level, and the device identification field of the set_pressure control command type is operable to receive the associated device identifier of a selected pressure controller in the at least one pressure controller; and, the plurality of control commands comprises a set_pressure control command of the set_pressure control command type.

11. The system as defined in claim 4 wherein at least one control command type in the plurality of control command types further comprises an associated ramp field for receiving a ramp rate for changing the operating level of the selected control device defined in the associated operating level field; the test script is writeable using the script language such that the plurality of control commands comprises a ramp control command defining the ramp rate for changing the operating level of the selected control device defined in the associated operating level field.

12. The system as defined in claim 4 wherein the compiler is operable to convert the test script to the test program by, for each control command in the plurality of control commands, converting the selected operating level defined in the operating level field of the control command to a device operating level for controlling the control device identified by the associated device identifier to operate at the operating level specified in the operating level field of the control command.

13. The system as defined in claim 4 further comprising a script editor for writing the test script using the script language.

14. The system as defined in claim 13 wherein, when a control command type is selected from the plurality of control command types, the script editor is operable to provide a plurality of possible parameters for defining a control command of the control command type.

15. The system as defined in claim 14 wherein the plurality of possible parameters comprises a range of possible operating levels, such that when the control command type is selected from the plurality of control command types, the script editor provides the range of possible operating levels for selection of the selected operating level to be inserted into the associated operating level field of the control command.

16. A method in a data processor for controlling a controllable condition of a fuel cell via a control device, the method comprising: (a) providing a script language comprising a control command type having an operating level field for receiving a selected operating level of the control device; (b) deriving a control command from the control command type by inserting the selected operating level of the control device into the operating level field of the control command; (c) writing a test script using the script language such that the test script includes the control command; (d) compiling the test script to provide a test program; and, (e) controlling the control device according to the test program.

17. The method as defined in claim 16 wherein step (d) comprises converting the selected operating level defined in the operating level field of the control command to a device operating level for controlling the control device to operate at the selected operating level.

18. The method as defined in claim 16 wherein a plurality of controllable conditions of the fuel cell are controlled via a plurality of control devices; the script language comprises a plurality of device identifiers for identifying the plurality of control devices, each control device in the plurality of control devices being identifiable by an associated device identifier in the plurality of device identifiers; the control command type comprises a device identification field for receiving the associated device identifier for a selected control device; and, step (b) further comprises inserting the associated device identifier for the selected control device in the device identification field to derive the control command from the control command type.

19. The method as defined in claim 16 wherein a plurality of controllable conditions of the fuel cell are controlled via a plurality of control devices; the script language comprises a plurality of device identifiers for identifying the plurality of control devices, each control device in the plurality of control devices being identifiable by an associated device identifier in the plurality of device identifiers; the script language comprises a plurality of control command types, each control command type in the plurality of control command types having (i) an associated operating level field for receiving the selected operating level of a selected control device controlled by the control command, and (ii) a device identification field for receiving the associated identifier of the selected control device; and, step (b) further comprises deriving a plurality of control commands from the plurality of control command types by, for each control command in the plurality of control commands, inserting the selected operating level of the selected control device in the operating level field of the control command; and, inserting the associated device identifier for the selected control device in the device identification field.

20. The method as defined in claim 19 wherein the plurality of control devices comprises at least one flow controller for controlling at least one of an anode gas flow and a cathode gas flow; the plurality of control command types comprises a set_flow control command type, wherein the operating level field of the set_flow control command type is operable to receive a selected flow control level, and the device identification field of the set_flow control command type is operable to receive the associated device identifier of a selected flow controller in the at least one flow controller; and, the plurality of control commands includes a set_flow control command of the set_flow control command type.

21. The method as defined in claimed 20 wherein the script language further comprises a stoichiometric relational command type having a stoichiometry-defining field for receiving a selected stoichiometric ratio and a device identification field for receiving the associated device identifier for a selected flow controller; the test script is writeable using the script language such that the test script includes a stoichiometric relational command of the stoichiometric relational command type wherein the stoichiometric relational command is derivable from the stoichiometric relational command type by inserting (i) the selected stoichiometric ratio into the stoichiometry-defining field, and (ii) the associated device identifier for the selected flow controller into the device identification field; and, the method further comprises determining an associated flow control level for the selected flow controller based on at least one variable, the at least one variable including the selected stoichiometric ratio.

22. The method as defined in claimed 21 wherein the at least one variable further includes a load current of the fuel cell.

23. The method as defined in claim 19 the plurality of control devices comprises at least one temperature controller; the plurality of control command types comprises a temperature control command type, wherein the operating level field of the temperature control command type is operable to receive a selected temperature control level, and the device identification field of the temperature control command type is operable to receive the associated device identifier of a selected temperature controller in the at least one temperature controller; and, the plurality of control commands includes a temperature control command of the temperature control command type.

24. The method as defined in claimed 19 wherein the plurality of control devices comprises at least one load controller for controlling a load on the fuel cell provided by a load box; the plurality of control command types comprises a load control command type, wherein the operating level field of the load control command type is operable to receive a selected load control level, and the device identification field of the load control command type is operable to receive the associated device identifier of a selected load controller of the at least one load controller; and, the plurality of control commands comprises a set_load control command for designating the load level.

25. The method as defined in claim 19 the plurality of control devices comprises at least one pressure controller; the plurality of control command types comprises a set_pressure control command type, wherein the operating level field of the set_pressure control command type is operable to receive a selected pressure control level, and the device identification field of the set_pressure control command type is operable to receive the associated device identifier of a selected pressure controller in the at least one pressure controller; and, the plurality of control commands comprises a set_pressure control command of the set_pressure control command type.

26. The method as defined in claim 19 wherein at least one control command type in the plurality of control command types further comprises an associated ramp field for receiving a ramp rate for changing the operating level of the selected control device defined in the associated operating level field; step (b) comprises deriving a ramp control command from the at least one control command type in the plurality of control command types by inserting the ramp rate for changing the operating level of the selected control device defined in the associated operating level field.

27. The method as defined in claim 19 wherein step (d) comprises converting the test script to the test program by, for each control command in the plurality of control commands, converting the selected operating level defined in the operating level field of the control command to a device operating level for controlling the control device identified by the associated device identifier to operate at the operating level specified in the operating level field of the control command.

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Description

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FIELD OF THE INVENTION

This invention relates to fuel cell testing systems. More particularly, the invention relates to a system for controlling the operation of fuel cell testing systems and for automating fuel cell tests.

BACKGROUND OF THE INVENTION

In recent years, research and development of fuel cells has increased dramatically. It is expected that these efforts will eventually yield commercially viable power systems that produce little pollution.

Fuel cells convert chemical energy stored in fuels into electrical energy. A fuel cell has an anode and a cathode. In some types of fuel cell, hydrogen atoms are introduced into the anode. Within the fuel cell, the hydrogen atoms are separated into electrons and protons (hydrogen ions). The hydrogen ions pass through a membrane to the cathode, where they are combined with oxygen to form water. The electrons cannot flow through the membrane resulting in an electrical potential between the anode and cathode. The electrons flow through an external load to the cathode. Thus, the external load consumes the potential generated by the cell. At the cathode, the hydrogen ions are oxidized to produce water. Theoretically, the only products of the fuel cell are the electrical power consumed by the load, heat and water. In reality, impurities in the hydrogen fuel, environmental conditions and other conditions can substantially effect the efficiency of the fuel cell and resulting in by-products and exhaust products other than heat and water.

A typical fuel cell is capable of producing only a small electrical potential between its anode and cathode--generally about 1 volt. To produce a useful potential individual cells are assembled in series into fuel cell stacks. Typically, a test is conducted on such a fuel cell stack.

Fuel cell stacks must be tested under different and varied conditions to mirror the conditions in which they will be used in practical devices such as motor vehicles. This includes long term test during which conditions change. The development of fuel cells requires substantial testing and several testing systems or "test stations" have been developed for this purpose.

These testing stations allow many conditions of a fuel cell stack, its environment, fuel sources and other conditions to be controlled. Known testing stations allow these conditions to be controlled manually--a target value is set for each condition and automated equipment within the test station attempts to achieve the target value. For example, during a particular test, three target conditions relating to a hydrogen gas supply at the anode fuel supply for a fuel cell may be that it should be supplied at a pressure of 300 kPa, 83.degree. C., and at a rate of 300 lpm (liters per minute). Typical fuel cell testing stations include pumps and flow controllers to achieve the desired pressure and flow rates and heating and/or cooling equipment to achieve the desired temperatures to control the flow rate. Similar characteristics of the cathode gas mixture, the load applied to the fuel cell and other conditions are similarly controllable.

Typically, fuel cell test stations have software control systems. It is preferable that the software has a simple and flexible architecture that allows the control system to be varied and configured easily.

Furthermore, it is desirable that the control system allows fuel cell stacks to be tested substantially automatically. In addition, the control system preferably allows the test or the control system itself to be modified easily--preferably even during a test through modification of the automated test and/or by manually changing the test conditions.

SUMMARY OF THE INVENTION

This invention provides a control system for monitoring and controlling the operation of a fuel cell testing system. The control system itself includes a server that incorporates a system manager and a set of driver applications. Each driver application communicates with a corresponding control module. The control modules in turn communicate with elements of the fuel cell testing system. Each such element may either be controlled or monitored or both by the control module to which it is coupled. For example, flow control elements may be monitored to determine the amount of liquid or gas that is currently flowing through them, and may also be controlled to set the amount of liquid or gas that it will pump.

The driver applications are created and launched by the system manager and they communicate with the system manager through a mapped file created and made available by the system manager. The mapped file contains a record for every controllable or monitorable element in the fuel cell testing system. Elements that are both controllable and monitorable are treated as having separate controllable and monitorable characteristics and each such characteristic has a separate record in the mapped file.

The record for each controllable or monitorable characteristic of an element is identified in the mapped file with a unique tag name. Tags that are associated with a controllable element are referred to as control tags. Tags that are associated with a monitorable element are referred to as data tags.

Tags may be associated by various signal types depending on the nature of the device being controlled or monitored. For example, a valve or switch that may be simply closed or open receives a digital control value to either turn it on or off. The valve or switch can also be queried to determine a digital data value to determine if it is open or closed. The switch has a control tag that is used to transmit the digital control value and has a data tag that is used to query its current state.

In contrast, a flow controller which can be set to allow different controllable amounts of liquid or gas to flow through it will typically receive an analog control value, which defines the amount of gas or liquid that should flow through it. Correspondingly, a flow controller can be queried to determine an analog data value which indicates the amount of liquid or gas that is presently flowing through it. In an alternative embodiment of the present invention a device such as a flow controller having many settings may also receive a digital value consisting of more than one bit that defines a particular setting from the group of settings. For example, an eight bit word may be sent as a control value to instruct the full controller to allow the better gas to flow out one of 256 levels.

Coupled to the system manager is at least one user application that is not part of the first embodiment of the present invention but may be prepared by a user in order to control the operation and procedures of a fuel cell test. The system manager communicates with the driver applications and the one or more user applications through a mapped file. The system manager creates the mapped file and makes it accessible to each driver application and each user application. The mapped file contains tag records and also some system activity info, such as task activity flags that allow the system manager to control the activity of the entire testing system.

Driver applications read the control values of the specific tags and record the present control values. Typically a control module will use a different range of signals to control a physical device then the numerical operating range of that device. For example, a control system may be configured to transmit a signal between 0 to 20 volts to operate a flow controller that is capable of flowing between 0 and 500 standard liters per minute (slpm). The relationship between the 0 and 20 volt input control value range and the 0 and 500 slpm operating level range