Statement of the problem The Fuel Cell Integrated Power Electronics Module (FCIPEM) project addresses urgent needs to promote standardization and manufacturing of power electronics for heavy-duty fuel cell applications. A key barrier to developing cost-effective fuel cell-based power systems is the complexity and cost of integrating DC-to-DC converters and DC-to-AC power inverters. Commercial off-the-shelf DC-to-DC converters can convert fuel cells voltages, typically 280 to 400 volts DC, to higher voltages, but are currently highly specialized and expensive, particularly at the higher power levels required for larger generators and heavy-duty vehicle propulsion. In addition, modern fuel cell-based system architectures typically require multiple power conversion devices, adding to system complexity and cost. How this problem is being addressed The overall objective of the FCIPEM project is to standardize power electronics modules so critical components can be used across multiple applications, thereby enabling higher manufacturing volumes, interchangeability of parts, and lower costs. Availability of a single multiport converter that supports DC-to-DC conversion and DC-AC inverter functions, and that can deliver power to both high-voltage traction motors and low-voltage accessories, will drive down the cost of integrating mobile power generators and vehicle propulsion systems using fuel cells. To achieve this, the FCIPEM will utilize a modular design with interchangeable plug n play components that can be easily inserted and removed from a common backplane, enabling a standardized platform, supported by an inventory of plug-in devices to support a broad variety of fuel cells, battery pack designs, and fuel cell drive architectures. What will be done in Phase I RockeTruck and Sandia National Laboratories will perform modeling and design analysis to develop an optimized design for a multiport converter with two stages, a DC-to-DC conversion stage and an active back end that converts DC to AC power. Trade studies will be performed in five key areas: Switching Devices, Filter Capacitors and Magnetic Components, Thermal Management, Electrical and Electronic Controls, and Structural & Mechanical Integration. Once the optimal FCIPEM design is selected, RockeTruck's team will develop detailed plans for manufacturing and validation of a prototype FCIPEM system during Phase II. Commercial Applications and Other Benefits The planned FCIPEM advances will enhance the commercial viability of a broad range of fuel cell applications by helping to make fuel cell-based power generators simpler and more affordable. Lowering the total cost of ownership of such systems will help accelerate adoption of fuel cells for heavy-duty vehicles, creating a compelling commercial opportunity based on offering the first practical zeroemission propulsion solution for long-haul trucking. Lower cost fuel cell systems will also create commercial opportunities for developing lower cost, zero emission stationary and mobile generators, which will expand access to sustainable electric power and improve the resiliency of the U.S. electric power infrastructure. Key Words fuel cell, hydrogen, battery, inverter, DC-to-DC converter, standardization, zero emission transport, vehicle electrification, mobile power, backup power, uninterruptable power, emergency power, electricity resiliency. Summary for Members of Congress Achievement of equitable energy outcomes and expansion of the hydrogen economy will require technological advances to make fuel cell-based power systems simpler and more affordable. The proposed FCIPEM project will help achieve this by driving down the cost of procuring and integrating the power conversion devices required to efficiently deliver fuel cell power for transportation and electric power generation applications. This will reduce America's reliance on fossil fuels and result in significant reductions in emissions of toxic substances and greenhouse gases.
