Abstract: A device (100) comprises a fuel cell system (110) having a fuel cell (110a) and a fuel cartridge (110b) to generate energy and charge a battery, a power storage and management system having a Lithium-ion battery interfaced with the management system to protect the battery, a control and protection system having Maximum Power Point Tracking (MPPT) (126) for optional charging using solar or grid power and an input-output interface to supply power to plurality of devices, wherein the fuel cell system (110) generates multiple voltage levels for power supply system to work at extreme temperatures and altitudes for providing multiple DC and AC power.
[001]The present invention relates to a device and method for generating, storing and distributing power.
BACKGROUND OF THE INVENTION
[002] Usually fuel cell systems provide a compelling solution as a portable power source, due to their portability and low carbon footprint However, the fuel cell systems often require long startup times to bring the fuel cells and fuel cartridges up to operational temperatures. These long startup times are generally prohibitive to wide consumer adoption of fuel cell systems as power sources. Especially, with the ubiquity of pre¬existing power sources, such as wall outlets connected to an electrical grid. However, since pre-existing power sources tend to be immobile and not easily portable, it can be desirable for users to utilize pre-existing power sources in certain settings and the fuel cell system in others.
[003] These fuel cells are also not compatible to work in extremely harsh weather conditions and various terrains and altitudes. Additionally, these also do not provide multiple voltages producing both AC and DC power.
[004] Thus, there is a need to mitigate the above-mentioned drawbacks and provide an improved system and method of allowing and leveraging multiple power source usage.
OBJECTS OF THE INVENTION
[005] It is an object of the present invention to provide a high capacity fuel-cell based power storage device capable of generating and supplying power.
[006] It is another object of the present invention to provide a ruggedized device capable of withstanding harsh climate conditions and altitudes.
[007] It is yet another object of the present invention to provide energy from green fuel resulting m pollution free energy.
[008] It is yet another object of the present invention to provide priority to a charging source in case of availability of multiple charging sources.
[009] It is still another object of the present invention to provide power in multiple voltage level.
SUMMARY OF THE INVENTION
[0010] According to an exemplary embodiment of the present invention, a device comprises a fuel cell system having a fuel cell and a fuel cartridge to generate energy and charge a battery, a power storage and management system having a Lithium-ion battery interfaced with the management system to protect the battery, a control and protection system having Maximum Power Point Tracking (MPPT) for optional charging using solar or grid power and an input-output interface to supply power to plurality of devices, wherein the fuel cell system generates multiple voltage levels for power supply system to work at extreme temperatures and altitudes for providing multiple DC and AC power.
[0011] According to an embodiment of the present invention, the power storage and management system protects the battery from overcharging, short circuit, deep discharge, overcurrent and controls the current during charging and discharging of the battery.
[0012] According to an embodiment of the present invention, the control and protection system further comprises at least one DC-DC converter, at least one DC-AC inverter, a overheat protection unit and a temperature control circuit.
[0013 ] According to an embodiment of the present invention, the Charging Priority Manager (CPM) monitors the status of the battery and assigns priority to a charging source with at least two charging sources available to the battery
[0014] According to an embodiment of the present invention, the power storage and
management system comprises a microcontroller (MCU) in communication with a
plurality of Field Effect Transistors (FETs) to monitor battery array state and transmits
Pulse Width Modulation (PWM) signal to a FET driver to control the charging current of the battery.
[0015] According to an embodiment of the present invention, the Microcontroller (MCU) is configured to transmit a stop signal to the FET driver if array voltage or battery current exceeds above or decreases below a predetermined temperature.
[0016] According to an embodiment of the present invention, the device further comprises a temperature controller to maintain the internal temperature using insulation.
[0017] Accordmg to an exemplary embodiment of the present invention, a method for controlling the charging and discharging of battery, the method comprising the steps of receiving, from at least one power source, power supply to charge the battery, monitoring and controlling, using power storage and management system, health status, current, voltage and temperature of the battery, generating multiple voltage levels for power supply system and supplying multi-port DC and AC power output.
[0018] According to an embodiment of the present invention, temperature and current of the battery and the one or more components are regulated in case the temperature and current exceeds or decreases the pre-defined threshold value.
[0019] According to an embodiment of the present invention, a charging source is assigned to a battery wherein at least two charging sources are available for charging the battery.
[0020] According to an embodiment of the present invention, the internal temperature is maintained using a temperature controller by dissipating excess heat.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0022] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0023] Fig. 1 illustrates a functional block representation of the fuel-cell based device according to an embodiment of the present invention;
[0024] Fig. 2 illustrates a standalone charging model according to an embodiment of the present invention;
[0025] Fig. 3 illustrates internal schematics of a power storage and battery management system according to an embodiment of the present invention;
[0026] Fig. 4 illustrates a hybrid-charging model according to an embodiment of the present invention;
[0027] Fig. 5 illustrates an internal schematic of a Maximum Power Point Tracking system according to an embodiment of the present invention;
[0028] Fig. 6 illustrates an alternate hybrid-charging model according to an embodiment of the present invention;
[0029] Fig. 7 illustrates a logic flow diagram of a charging priority manager according to an embodiment of the present invention;
[0030] Fig. 8 illustrates the functional block diagram of Power output in various mode according to an embodiment of the present invention.
illustrates internal schematics of a battery management system according to an embodiment of the present invention;
[0031] Fig. 9 illustrates mechanical design of an en closer according to an embodiment of the
[0032] Fig. 10 illustrates top view of an encloser according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] As used in the description herein and throughout the claims that follow, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.
[0034] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future.
[0035] Fig. 1 illustrates a functional block representation of the fuel-cell based device (100) comprising four functional parts, namely, a Fuel cell (110a) system (110), a power storage and Battery Management System (BMS) (114), a control and protection system and an Input-Output system.
[0036] A modular fuel-cell based generator cum storage cum distribution device has the capability to produce AC as well as DC power 24x7. There are three main features, i.e. the device (100) is designed to generate energy 24x7 in extreme weather and climatic conditions in any terrain, it provides power in multiple voltage level i.e. 24V DC/12VDC/230V AC and it generates energy from green fuel (Methanol) hence energy generation is almost pollution free.
,S
[0037] The Fuel cell system (110) contains fuel cell (110a) and a fuel (Metlianol) cartridge (110b) and being a smart system, it generates energy and charges a battery as per requirement. The Power storage and BMS has a Li-Ion battery of rating 24V/50Ah interfaced with 24V/30A BMS that protects the battery from overcharging, short circuit, deep discharge and over current. It also controls the current during charging and discharging of battery. The Control and protection system contain Maximum Power Point Tracking (MPPT) (126) for optional charging from solar or grid power i.e. DC IN port (130) of the device (100). It contains DC-DC converter (120), DC-AC inverter, a Charging Priority Manager (CPM) (116), and overheat protection and temperature control circuit (128). The Input-Output system includes input and output port which helps in power interface with different devices.
[0038] Fig. 2 illustrates a standalone charging model, i.e. using only fuel cell (110a), depending on the priority already set for charging the battery by the CPM. The fuel cell (110a) generates power to charge the battery after receiving a command from CPM. The fuel cell (110a) starts and stops automatically as soon as the battery gets empty or full respectively. At the same time, the BMS monitors the battery health status and keeps safety protection switched on.
[0039] Fig. 3 illustrates internal schematics of a power storage and battery management system (114). An internal Microcontroller (MCU) of the BMS continuously monitors an Array parameter of the battery pack, whenever any external DC power gets connected with PACK+ and PACK- terminal of the BMS (Fuel cell power) the coupled Field Effect Transistors (FETs) array (Jl, J2, J3) control the charging current flowing from external source to Battery pack. The current conductivity of the FETs is controlled through FETs driver which is further controlled by the self-inbuilt MCU. The MCU always monitors the voltage state of the battery array and accordingly it sends Pulse Width Modulation (PWM) signal to the FET driver to control the charging current of the battery.
[0040] Several safety interrupt signals are embedded into the MCU, thus, by getting these signals from the MCU, it sends a stop signal to the FET driver and stops the FETs
from charging the current to the battery array. These interrupts are as below:
* Interrupt 1: If temperature of the battery array exceeds from +70° C and below
-10DC, the MCU sends stop signal to the FET driver to stop charging current.
« Interrupt 2: if the battery current exceeds 100A, the MCU sends stop signal to the FET driver to stop charging current.
• Interrupt 3: If any array voltage of the battery gets out of range from
recommended voltage, the MCU sends stop signal to the FET driver to stop
charging or discharging current.
[0041] Fig. 4 illustrates a hybrid-charging model in which the battery is charging through the Fuel cell (110a) and an external source i.e. Solar power, grid power or a 24 V DC source (130). The Charging Priority Manager (CPM) (116) manages the setting of priority of charging source, where more than one charging source is available. It is embedded with Maximum Power Point Tracking (MPPT) system (126) which detects the combinational of Voltage (V) X Current (I) so that maximum power (P) can be delivered to charge the battery.
[0042] Fig. 5 illustrates an internal schematic of a Maximum Power Point Tracking (MPPT) system (126) wherein Microcontroller in the form of voltage and current parameter senses solar power. It logically controls the current flow to the BMS through PWM signal to the FET and it deliver Vxl =Pmax to charge the battery through the BMS. It tracks the maximum power by its high-level logical programming inside the microcontroller. Apart from this, it also simulates errors and shows them in the form of indication by LED blinking. Accordingly, Fig. 6 illustrates an alternate hybrid-charging model in which when an external DC source gets connected, the MPPT (126) gets switched-off and the BMS gets power for charging from the external source.
[0043] Fig. 7 illustrates a logic flow diagram of the Charging Priority Manager (CPM) (116) that is responsible for setting the priority of chargmg source if more than one charging source is available as per the logic. According to the logic, CPM always monitors the status of battery and sends the start and stop command to Fuel cell (110a). Solar is
always in ON mode; hence CPM is only responsible for starting and stopping the fuel
Solar source is available or not. In case where Solar source is available, it stops the fuel cell (110a) and continues to charge the battery from solar. Where solar is not available, the fuel cell (110a) is used to charge the battery. According to an embodiment of the present invention, in a case where power is more than 50 percent, the fuel cell (110a) is used even if the solar is available. Thus, the battery is charged with solar as well as with Fuel cell (110a) till battery reaches up to 50 percent and follows the above-mentioned after 50 percent.
[0044] Fig. 8 illustrates internal schematics of a battery management system (114) in which a user can utilize the stored power to operate the concerned device (100) in 24V DC/12V DC/ 5V DC voltage level and 230V AC level. The stored power from the battery can be utilized through the BMS and DC-DC as well as DC-AC converters (122). The BMS protects the battery from over charging, deep discharging, short circuit and overheating through continuous monitoring of Array voltage, battery current and battery temperature. Apart from this, a safety and control circuit monitor the temperature of DC-DC converter (120) and inverter and prevents the same from overheating. Hence, user gets controlled multiport output i.e. 24V DC/12VDC/230V AC.
[0045] The internal MCU of the BMS continuously monitors an array parameter of the battery pack, whenever any external DC power gets connected with PACK+ and PACK-terminal of the BMS (DC IN OF MAGMA port) and the coupled FETs array (Ji, J2, J3) control the charging current flowing from external source to the Battery pack. The current conductivity of the FETs is controlled through the FETs driver which is further controlled by self-inbuilt MCU. The MCU always monitors the voltage state of the battery array and accordingly it sends PWM signal to the FET driver to control the charging current of the battery. Some safety interrupts signals are also imbedded into the MCU and by getting these signals, it sends stop signal to the FET driver to stop charging current to the battery array. The interrupts are as below:
• Interrupt 1: If temperature of the battery array exceeds from +70° C and below -10°C, the MCU sends stop signal to the FET driver to stop charging current.
0
• Interrupt 2: If battery current exceeds 100A, the MCU sends stop signal to the FET driver to stop the charging current.
® Interrupt 3: If any array voltage of the battery gets out of range from recommended voltage, the MCU sends stop signal to the FET driver to stop charging or discharging current.
[0046] According to an embodiment of the present invention, the system enclosed with a mechanical designed encloser provides insulation from external environment and helps to control the internal temperature of nearby devices along with the operational temperature which makes the system more reliable even in very harsh temperature condition, i.e. -SOT to +70°C.
[0047] Fig. 9 illustrates a mechanical design of an encloser and Fig. 10 illustrates the top view of an encloser. The encloser is made with small air bubbles which provides first level of insulation. Then, two layers of Armaflex are layered inside the encloser which maintains the temperature inside the encloser equivalent to that of operational temperature. A temperature controller with fan is also embedded inside the encloser to control and drain the excess heat out of the encloser.
q
We Claim:
A device (100) comprising:
a fuel cell system (110) having a fuel cell (110a) and a fuel cartridge (110b) to generate energy and charge a battery;
a power storage and management system having a Lithium-ion battery interfaced with the management system to protect the battery;
a control and protection system having Maximum Power Point Tracking (MPPT) (126) for optional charging using solar or grid power; and
an input-output interface to supply power to plurality of devices,
wherein the fuel cell system (110) generates multiple voltage levels for power supply system to work at extreme temperatures and altitudes for providing multiple DC and AC power.
The device (100) as claimed in claim 1, wherein the power storage and management system protects the battery from overcharging, short circuit, deep discharge, overcurrent and controls the current during charging and discharging of the battery.
The device (100) as claimed in claim 1, wherein the control and protection system further comprises at least one DC-DC converter (120), at least one DC-AC inverter, a overheat protection unit (128), a Charging Priority Manager (CPM) (116) and a temperature control circuit.
The device (100) as claimed in claim 3, wherein the Charging Priority Manager (CPM) (116) monitors the status of the battery and assigns priority to a charging source with at least two charging sources available to the battery.
The device (100) as claimed in claim 1, wherein the power storage and management system comprises a microcontroller (MCU) in communication with a plurality of Field Effect Transistors (FETs) to monitor battery array state and transmits Pulse Width Modulation (PWM) signal to a FET driver to control the charging current of the battery.
The device (100) as claimed in claim 5, wherein the Microcontroller (MCU) is configured to transmit a stop signal to the FET driver if array voltage or battery current exceeds above or decreases below a predetermined temperature.
The device (100) as claimed in claim 1, further comprising a temperature controller to maintain the internal temperature using insulation.
A method for controlling the charging and discharging of battery, the method comprising the steps of:
receiving, from at least one power source, power supply to charge the battery;
monitoring and controlling, using power storage and management system, health status, current, voltage and temperature of the battery;
generating multiple voltage levels for power supply system; and
supplying multi-port DC and AC power output.
The method as claimed in claim 8, further comprising the step of regulating temperature and current of the battery and the one or more components in case the temperature and current exceeds or decreases the pre-defined threshold value.
. The method as claimed in claim 8, further comprising the step of assigning a charging source wherein at least two charging sources are available for charging the battery.
. The method as claimed in claim 8, further comprising the steps of maintaining the internal temperature using a temperature controller by dissipating excess heat.
| # | Name | Date |
|---|---|---|
| 1 | 201911030746-Correspondence to notify the Controller [02-03-2025(online)].pdf | 2025-03-02 |
| 1 | 201911030746-IntimationOfGrant24-03-2025.pdf | 2025-03-24 |
| 1 | 201911030746-STATEMENT OF UNDERTAKING (FORM 3) [30-07-2019(online)].pdf | 2019-07-30 |
| 2 | 201911030746-FORM 1 [30-07-2019(online)].pdf | 2019-07-30 |
| 2 | 201911030746-PatentCertificate24-03-2025.pdf | 2025-03-24 |
| 2 | 201911030746-US(14)-HearingNotice-(HearingDate-04-03-2025).pdf | 2025-02-14 |
| 3 | 201911030746-CLAIMS [26-09-2024(online)].pdf | 2024-09-26 |
| 3 | 201911030746-DRAWINGS [30-07-2019(online)].pdf | 2019-07-30 |
| 3 | 201911030746-Written submissions and relevant documents [17-03-2025(online)].pdf | 2025-03-17 |
| 4 | 201911030746-DECLARATION OF INVENTORSHIP (FORM 5) [30-07-2019(online)].pdf | 2019-07-30 |
| 4 | 201911030746-Correspondence to notify the Controller [02-03-2025(online)].pdf | 2025-03-02 |
| 4 | 201911030746-COMPLETE SPECIFICATION [26-09-2024(online)].pdf | 2024-09-26 |
| 5 | 201911030746-US(14)-HearingNotice-(HearingDate-04-03-2025).pdf | 2025-02-14 |
| 5 | 201911030746-DRAWING [26-09-2024(online)].pdf | 2024-09-26 |
| 5 | 201911030746-COMPLETE SPECIFICATION [30-07-2019(online)].pdf | 2019-07-30 |
| 6 | Abstract.jpg | 2019-08-17 |
| 6 | 201911030746-FER_SER_REPLY [26-09-2024(online)].pdf | 2024-09-26 |
| 6 | 201911030746-CLAIMS [26-09-2024(online)].pdf | 2024-09-26 |
| 7 | 201911030746-FORM-26 [26-09-2024(online)].pdf | 2024-09-26 |
| 7 | 201911030746-FORM 18 [26-07-2023(online)].pdf | 2023-07-26 |
| 7 | 201911030746-COMPLETE SPECIFICATION [26-09-2024(online)].pdf | 2024-09-26 |
| 8 | 201911030746-DRAWING [26-09-2024(online)].pdf | 2024-09-26 |
| 8 | 201911030746-FER.pdf | 2024-03-27 |
| 8 | 201911030746-OTHERS [26-09-2024(online)].pdf | 2024-09-26 |
| 9 | 201911030746-FER_SER_REPLY [26-09-2024(online)].pdf | 2024-09-26 |
| 9 | 201911030746-PETITION UNDER RULE 137 [26-09-2024(online)].pdf | 2024-09-26 |
| 9 | 201911030746-Proof of Right [26-09-2024(online)].pdf | 2024-09-26 |
| 10 | 201911030746-FORM-26 [26-09-2024(online)].pdf | 2024-09-26 |
| 10 | 201911030746-PETITION UNDER RULE 137 [26-09-2024(online)].pdf | 2024-09-26 |
| 10 | 201911030746-Proof of Right [26-09-2024(online)].pdf | 2024-09-26 |
| 11 | 201911030746-FER.pdf | 2024-03-27 |
| 11 | 201911030746-OTHERS [26-09-2024(online)].pdf | 2024-09-26 |
| 12 | 201911030746-FORM 18 [26-07-2023(online)].pdf | 2023-07-26 |
| 12 | 201911030746-FORM-26 [26-09-2024(online)].pdf | 2024-09-26 |
| 12 | 201911030746-PETITION UNDER RULE 137 [26-09-2024(online)].pdf | 2024-09-26 |
| 13 | 201911030746-FER_SER_REPLY [26-09-2024(online)].pdf | 2024-09-26 |
| 13 | 201911030746-Proof of Right [26-09-2024(online)].pdf | 2024-09-26 |
| 13 | Abstract.jpg | 2019-08-17 |
| 14 | 201911030746-COMPLETE SPECIFICATION [30-07-2019(online)].pdf | 2019-07-30 |
| 14 | 201911030746-DRAWING [26-09-2024(online)].pdf | 2024-09-26 |
| 14 | 201911030746-FER.pdf | 2024-03-27 |
| 15 | 201911030746-COMPLETE SPECIFICATION [26-09-2024(online)].pdf | 2024-09-26 |
| 15 | 201911030746-DECLARATION OF INVENTORSHIP (FORM 5) [30-07-2019(online)].pdf | 2019-07-30 |
| 15 | 201911030746-FORM 18 [26-07-2023(online)].pdf | 2023-07-26 |
| 16 | 201911030746-CLAIMS [26-09-2024(online)].pdf | 2024-09-26 |
| 16 | 201911030746-DRAWINGS [30-07-2019(online)].pdf | 2019-07-30 |
| 16 | Abstract.jpg | 2019-08-17 |
| 17 | 201911030746-COMPLETE SPECIFICATION [30-07-2019(online)].pdf | 2019-07-30 |
| 17 | 201911030746-FORM 1 [30-07-2019(online)].pdf | 2019-07-30 |
| 17 | 201911030746-US(14)-HearingNotice-(HearingDate-04-03-2025).pdf | 2025-02-14 |
| 18 | 201911030746-Correspondence to notify the Controller [02-03-2025(online)].pdf | 2025-03-02 |
| 18 | 201911030746-STATEMENT OF UNDERTAKING (FORM 3) [30-07-2019(online)].pdf | 2019-07-30 |
| 18 | 201911030746-DECLARATION OF INVENTORSHIP (FORM 5) [30-07-2019(online)].pdf | 2019-07-30 |
| 19 | 201911030746-Written submissions and relevant documents [17-03-2025(online)].pdf | 2025-03-17 |
| 19 | 201911030746-DRAWINGS [30-07-2019(online)].pdf | 2019-07-30 |
| 20 | 201911030746-PatentCertificate24-03-2025.pdf | 2025-03-24 |
| 20 | 201911030746-FORM 1 [30-07-2019(online)].pdf | 2019-07-30 |
| 21 | 201911030746-STATEMENT OF UNDERTAKING (FORM 3) [30-07-2019(online)].pdf | 2019-07-30 |
| 21 | 201911030746-IntimationOfGrant24-03-2025.pdf | 2025-03-24 |
| 1 | 201911030746ferE_22-03-2024.pdf |