Electronic Control Unit for Fuel cell - Supercapacitors system: from design to implementation in low-consumption vehicles

This thesis encapsulates the collaborative efforts undertaken for the Team H2politO since March 2022, focusing on the design, build, and optimization of low consumption prototypes for annual participation in the Shell Eco-marathon, an esteemed international competition. Existing commercially available fuel cell control units, provided by fuel cell manufacturers, primarily cater to the control of individual fuel cell subsystems to ensure system operations, with limited flexibility in control management. Consequently, the necessity arose for the development of an Electronic Control Unit (ECU) capable of integrating fuel cell and supercapacitors stack to communicate via CANbus with other boards of the vehicle, adhering to diverse team specifications and competition regulations to enhance previous performance outcomes. The study, design, implementation, testing, and utilization of the properly made ECU board for the fuel cell and supercapacitor (FCSC) system have enabled precise control over crucial parameters essential for optimizing the system's efficiency. This includes the management of fan speed, purge frequency, and short-circuiting dynamics in real-time fuel cell conditions, aiming to optimize hydrogen consumption while ensuring operational integrity. Significant emphasis has been placed on the development of a programmable buck converter capable of dynamically adjusting charging current, regulation voltage, and supercapacitor connection configurations to adapt to varying race strategies and FCSC system conditions. The first board, focused on DC/DC converter functionality, yielded promising results during the SEM2023 competition, demonstrating enhanced performance and efficiency compared to previous iterations. Subsequently, a second board was developed to refine existing components and integrate missing features from the initial version, paving the way for a comprehensive third version aimed at further enhancing FCSC system control capabilities. Through iterative development and competition experiences, insights gained have informed ongoing refinement efforts, ensuring continued competitiveness in the Shell Eco-marathon and beyond.