Dynamic fuel processor mechanization and control

A fuel processing system for a fuel cell comprising:

• a fuel processor having a fuel inlet receiving a fuel and an outlet discharging a reformate containing hydrogen, said fuel processor operable to break down said fuel to form said reformate;
• a fuel metering device providing fluid communication between a fuel supply and said fuel inlet to selectively input said fuel to said fuel processor;
• a valve in fluid communication with said outlet;
• a controller modulating said valve to control a flow rate of said reformate discharged from said fuel processor;
• and
• a flow rate sensor in fluid communication with an air inlet of said fuel processor for generating a control signal as a function of a flow rate of said air provided to said fuel processor, said controller using said control signal to modulate said valve.

A fuel processing system for a fuel cell comprising:

• a fuel processor having an inlet receiving at least one input stream and an outlet discharging a reformate containing hydrogen, said fuel processor operable to form said reformate;
• said input stream having a control device to selectively input said input stream to said fuel processor;
• a valve in fluid communication with said outlet;
• a controller modulating said valve to control a flow rate of said reformate discharged from said fuel processor, which cooperates with said control device to provide an increasing back-pressure in said fuel processor when said valve is at least partially closed whereby said fuel processor acts as a storage buffer;
• a fuel cell stack having an anode inlet in fluid communication with said valve, said fuel cell stack operable to generate electrical energy and an anode exhaust from said reformate;
• and
• a stack sensor for generating a control signal based on at least one of a stack voltage signal and a stack cell voltage variation signal, said controller using said control signal to modulate said valve.

A control system for a fuel processor of a fuel cell stack, comprising:

• a water metering device that controls water provided to said fuel processor;
• a fuel metering device that controls fuel provided to said fuel processor;
• an air flow rate sensor that generates an air flow rate signal based on air flowing to said fuel processor;
• a valve located between said fuel processor and said fuel cell stack;
• and
• a controller that controls said valve, said water metering device and said fuel metering device based on said air flow rate signal.

A fuel processing system for a fuel cell stack, comprising:

• a water metering device that controls water provided to said fuel processor;
• a fuel metering device that controls fuel provided to said fuel processor;
• a stack sensor that generates one of a stack voltage signal and a stack cell voltage variation signal;
• a valve located between said fuel processor and said fuel cell stack;
• and
• a controller that controls said valve, said water metering device and said fuel metering device based on said one of said stack voltage signal and said stack cell voltage variation signal.

A fuel processing system for a fuel cell stack, comprising:

• a water metering device that controls water provided to said fuel processor;
• a fuel metering device that controls fuel provided to said fuel processor;
• a valve located between said fuel processor and said fuel cell stack;
• a pressure differential sensor connected to an inlet and an outlet of said valve that generates a pressure differential signal;
• and
• a controller that controls said valve, said water metering device and said fuel metering device based said pressure differential signal.

A fuel processing system for a fuel cell stack, comprising:

• a water metering device that controls water provided to said fuel processor;
• a fuel metering device that controls fuel provided to said fuel processor;
• a valve located between said fuel processor and said fuel cell stack;
• a flow rate sensor connected between said valve and said fuel cell stack for providing a stack flow rate signal;
• and
• a controller that controls said valve, said water metering device and said fuel metering device based said stack flow rate signal.

A method of controlling a fuel processor for a fuel cell stack, comprising:

• providing a fuel cell stack and a fuel processor;
• metering water provided to said fuel processor;
• metering fuel provided to said fuel processor;
• sensing a flow rate of air to said fuel processor;
• providing a valve between said fuel processor and said fuel cell stack;
• and
• controlling said valve, said water metering device and said fuel metering device based on said air flow rate.

A method of controlling a fuel processor for a fuel cell stack, comprising:

• providing a fuel cell stack and a fuel processor;
• metering water provided to said fuel processor;
• metering fuel provided to said fuel processor;
• sensing at least one of stack voltage and stack cell voltage variation;
• providing a valve between said fuel processor and said fuel cell stack;
• and
• controlling said valve, said water metering device and said fuel metering device based on said at least one of said stack voltage and said stack cell voltage variation.

A method of controlling a fuel processor for a fuel cell stack, comprising:

• providing a fuel cell stack and a fuel processor;
• metering water provided to said fuel processor;
• metering fuel provided to said fuel processor;
• providing a valve between said fuel processor and said fuel cell stack;
• monitoring a pressure differential between an inlet and an outlet of said valve;
• and
• controlling said valve, said water metering device and said fuel metering device based on said pressure differential.

A method of controlling a fuel processor for a fuel cell stack, comprising:

• providing a fuel cell stack and a fuel processor;
• metering water provided to said fuel processor;
• metering fuel provided to said fuel processor;
• providing a valve between said fuel processor and said fuel cell stack;
• monitoring gas flow rate between an outlet of said valve and said fuel cell stack;
• and
• controlling said valve, said water metering device and said fuel metering device based on said gas flow rate.