Browse fuel cell inverters from leading suppliers on our marketplace!
The inverter, also known as an electric motor controller, is normally connected to a CAN communication line, from where a torque or speed setpoint is demanded – normally from a higher control loop: vehicle control unit for traction applications, or even fuel cell control unit for fuel cell systems. Therefore, depending on the selected control method for a specific application, the inverter can work as a motor speed controller or as a motor torque controller.
The fuel cell system inverter algorithms receive the torque or speed setpoints and transduce them into a current setpoint for each phase. As the inverter is designed to operate the motor within safe and efficient conditions, the algorithms take various inputs into consideration, such as the DC voltage level, motor position, the stator temperature and the temperature of the inverter itself.
No, electric motor controllers can also been called “inverters”. The “inverter” is electrically connected between the high voltage battery (DC bus) and the electric motor, and it is designed to convert the energy stored in the battery from DC current into AC current.
For many decades now, electric motors have become a very popular solution in different applications in many industries, in automotive applications, domestic applications and in many other sectors.
Since the introduction of the electric vehicle, electric motors have gained an even higher relevance as they are a key part of the powertrain, but also for auxiliary applications required in any vehicle: electric steering system, electric brake system, electric air conditioning system, among others. In fuel cell systems, electric motor controllers can be found in the air compressor, water pump and in recirculation pumps.
These elements driven by electric motors (Mainly AC motors) are responsible for the main energy consumption in vehicles, and they require a proper control to operate efficiently and safely.
Signal of an electric motor controllerIn fuel cell systems, the most challenging application in which an inverter is applied is to control the air compressor. The air compressor is used to supply the air that the stack requires to fulfill the chemical reaction and generate electricity. Depending on the fuel cell system power output and application, the inverter and the electric motor can reach power levels from a few watts up to a couple of tens of kilowatts. Thus, inverters normally have a high voltage DC input, and they require a liquid cooling circuit. Depending on the compressor size, the speed can vary from a few thousand RPM for the biggest ones, up to ~280,000 RPM for the smallest ones. These high-speed motors require specific control techniques and a dedicated inverter hardware to support this operational speed range.
Water pumps are used in fuel cell systems to remove the heat generated by the chemical reaction and control the system temperature. In fuel cell systems at least two coolant circuits or loops can be found: the power electronics loop and the stack loop.
The power electronics loop is dedicated to cool down the power electronics components such as the inverter, air compressor and other elements, whereas the stack loop is dedicated to cool down this one component only (the stack). The stack circuit requires deionized water, and therefore needs to be separated from other elements (especially power electronics). Ion filters must be used for the coolant.
In the fuel cell system, the recirculation pump is used to recirculate the excess hydrogen that did not react in the stack back to the stack’s hydrogen inlet line. This excess hydrogen is recuperated and the purpose of the pump is to push it back to the inlet to be consumed and generate electricity. To make this possible, the pump’s motor and inverter have to generate enough power to bring the hydrogen up to 1bar-2bar of absolute pressure downstream from the stack.
Get help, help others, let us build the hydrogen economy together. No spamming, no marketing, just tech!
Visit Hyfindr Tech CommunityThere are many types of electric motor controllers, as they are designed to control different types of motors. For fuel cell systems and EV applications three main types of electric motor controller are used:
This motor controller type can control 3 phase motors. Such inverters are used for applications from a few hundred volts up to 800 volts application. Typically, the power range can also go from several kilowatts up to 250 KW. They are used for:
Electric motor controllers with six phase outputs are normally used for traction applications, where higher current is needed. The motors requiring a six phase inverter normally use parallel windings or open winding topologies. The voltage range for this type of motor also reaches from low voltage applications all the way to power outputs of 400-500kW. These types of electric motors usually have lower speed range and higher torque output compared to 3-phase motors.
Air cooled systems: Air cooled systems require bigger volumes to ensure good heat dissipation and in consequence, these systems have lower power density. Normally, this solution is chosen for applications with low power requirements or where cost considerations prevail over system performance.
Liquid cooling: lliquid-cooled systems have better integration capabilities, as they are more compact in size for a given power delivery. This is the most popular solution for standard automotive or heavy-duty applications.
Watch more high-quality videos, such as Hyfindr Tech Talks and more …
Go to Hyfindr on YoutubeFrom the system integration point of view, there are always many elements and components that have to be connected and “make them work”. Specifically, the inverter has many interfaces:
All these inverter “touch points” are a challenge for any system integrator, as they must not only integrate this component, but also many others to be integrated at the same time within a vehicle or a bigger system.
To overcome these issues and reduce time and effort needed for development it is very important to work with a development partner who not only has the expertise in inverters and motors, but who also understands the final application and the operating scenarios the overall system will be subjected to. It is therefore of paramount importance to work with a partner who can provide a turnkey solution. This solution should include tools to facilitate calibration and vehicle integration by incorporating self-calibration routines, or OTA (over-the-air) software updates.
Content contributed by EPowerlabs
EPowerlabs was born from the vision to contribute towards a more sustainable world by providing services to help industry players accelerate the adoption of electric mobility. The team is formed by a group engineers who have developed deep knowledge in leading automotive companies. The company has the mission to share this experience with clients through custom, agile and effective services. EPowerlabs has developed a variety of embedded hardware to meet the specific needs of each project. From small motor control units for bicycles and mopeds in different power ranges, to developments for automotive industry inverters up to 150kW.
Last update: 6.6.2022
hyfindr.com is your one-stop shop for hydrogen systems and components for the hydrogen fuel cell industry.
Do you want to list your component or product on hyfindr.com? Register your company here.
The structure of an electrical control panel is a combination of an enclosure and a back panel, similar to a breaker box in a home or office.
The enclosure is a metal box which varies in size and is typically made of aluminum or stainless steel. The number of doors (usually one or two) needed on the enclosure determines its size in most industrial applications. The enclosure will come with a UL safety rating (508A is typical) an IP rating, and/or a NEMA classification. These listings help users determine properties such as:
Indoor/outdoor use
Waterproof/water resistance
Dust/solid contaminants proofing
Hazardous conditions rating
Explosion-proof rating
These various classifications should be printed on a metal plate and attached to the enclosure for easy identification and reference.
A back panel is a metal sheet mounted inside the enclosure that provides structural support for DIN rail mounting and wiring ducts. DIN metal rails feature standardized dimensions and provide a mounting structure for electrical devices. Assembly Wiring ducts provide for the routing and organization of wires while also assisting in the control of electrical noise between devices inside the box.
Eight types of electrical components exist within an used electrical panel enclosure which define and organize the several different functions carried out by the panel. These components include:
Main circuit breaker. This is like the disconnect of the main electrical panel leading into a home or office. Miniature circuit breakers handle between 120V–480V in most industrial applications which established control over circuit components.
Surge arresters. This component prevents lightning strikes or utility power surges from damaging the electrical components inside the panel due to overvoltage.
Transformers. Depending on the incoming voltage, transformers may reduce voltage to 120V for various components or step down voltage to 24V in instances where incoming power is 120V.
Terminal blocks. These blocks help to organize and distribute the array of wires coming from various sources to different electrical devices.
Programmable Logic Controller (PLC). This is essentially a CPU contained inside the control panel. This unit is the brains of the control panel, providing monitoring and control of the various mechanical processes. In will include various inputs and outputs to and from mechanized functions of the production equipment.
Relays and contactors. These on/off switches control mechanized functions based on commands from the PLC. Smaller relays control functions like lights and fans. Larger relays, called contacts, control more advanced functions like motor controllers.
Network switches. The communication hub of the control panel, network switches facilitate communication between the PLC and the various network compatible devices on the production line.
Human Machine Interface (HMI). These components allow an operator to monitor or control certain functions of the machinery. Common HMIs include video monitors, joysticks, buttons, switches, and keyboards.
The design of a custom electrical control panel will depend upon the complexity of the system it operates. Designs can include a simple electrical relay system or a more complex PLC system with single or multiple PLC networks with IIoT or SCADA integrations. Indicators that your organization might need a custom panel design include a need for more advanced operation of various production operations; more cohesive, universal control of systems; and/or a need for improved HMI.
Maintenance is another key consideration for electrical control panels. Facilitating maintenance is a critical element in custom electrical control panel design. Maintenance elements should include:
Clearly labeled components, wiring, and terminals
Capability to monitor the status of the various electrical connections
Control of particulates and dust within the enclosure
Pest control measures
Electrical control panels are essential for industrial automation. They provide higher-level monitoring and control of the various functions of production machinery, allowing manufacturers to define, organize, and meet production objectives.
IndustLabs has more than 15 years of experience in the design and construction of electrical control panels serving industries such as:
Food & beverage
Oil & gas
Pharmaceutical
Power generation & power circuit components
Control Board Component
Manufacturing
Fluid handling
Material handling
We provide new installations and upgrades to existing systems. Contact us for more information concerning the electrical control panel solutions provided by IndustLabs.
Comments
Please Join Us to post.
0