Fuel Cell Integrated Power Electronics Module (FCIPEM)

The Fuel Cell Integrated Power Electronics Module (FCIPEM) addresses the problem of economically meeting the power conversion needs of mobile generators and heavy-duty vehicles powered by hydrogen fuel cells. Reducing the cost of power converters can help achieve the goal of making fuel cell systems more affordable and expanding their use, which is a key requirement for achieving the potential environmental and sustainability benefits of hydrogen-based power systems. The problem is being addressed by developing a new multiport power converter that uses standardized components to convert power generated by fuel cells and multiple other resources such as battery energy storage systems, in a compact package that is less expensive and easier to integrate than current power converter products. The innovative FCIPEM design utilizes common power modules using new gallium nitride (GaN) semiconductors, whose advantages include high electron mobility and critical field strength. What was done in Phase I ľ RockeTruck and Research Institution partner Sandia National Laboratories (ôSandiaö) completed detailed analyses and trade studies that confirmed several key advantages of GaN-based devices, such as the ability to reduce the size and weight of heat sinks, inductors, and filter capacitors. Based on these studies and subsequent optimization analyses, RockeTruck produced the preliminary design of a new power converter that can output up to 42 kilowatts (kW) of three-phase 208-volt power, in a package substantially smaller than that of comparably rated converters using more conventional silicon-based devices. Phase II Plans ľ During Phase II, RockeTruck and Sandia will evaluate further enhancements to the FCIPEM design, including a ôflying capacitorö topology that can boost output power and voltage, build a prototype converter based on the evolved FCIPEM design, and then test the new converter under real-world operating conditions. To support this testing, RockeTruck will integrate at least one FCIPEM converter into a ôMobile Fuel Cell Generatorö (MFCG) and test the MFCG in numerous locations throughout Southern California, including disadvantaged and low-income communities. By reducing converter acquisition and integration costs, FCIPEM will significantly reduce the cost of building fuel cell-powered generators such as RockeTruckĺs MFCG, improving their commercial viability. Through its use of common components, FCIPEM will also be adaptable to applications requiring power conversion from other large direct current (DC) power sources such as solar photovoltaic systems, battery energy storage systems, and wind turbines. In the longer term, FCIPEM variants can be used as traction inverters as well as DC-to-DC converters in heavy-duty fuel cell vehicles, including an aerodynamic Class 8 fuel cell truck RockeTruck has designed.