Valve group screen switching method and device for adjusting hydrogen filling pressure

Abstract

The invention relates to the technical field of high-pressure hydrogen filling, in particular to a valve group switching screen method and device for adjusting hydrogen filling pressure, an inlet of a header pipe is connected with an upstream hydrogen source, and an outlet of the header pipe is divided into two paths to be connected into a 15 MPa safety valve group and a 20 MPa safety valve group after passing through a tee joint; outlets of the two safety valve sets converge to a branch pipe through a first pneumatic valve and a second pneumatic valve and then are evenly distributed to 14 filling positions through a plurality of filling hoses, and during working, after the code scanning unit reads bottle types, the central switching screen automatically opens the valves according to 15 MPa or 20 MPa; when the pressure reaches a set value, the contact is closed, the valve is closed immediately and sound-light alarm is given. The number of the hoses is reduced from 28 to 14, the cost is reduced by 50%, zero return is achieved during misoperation, an alarm is given under 15MPa overpressure, one bottle is universal, one-key filling is achieved, and therefore the problems that an existing valve set switching pipeline is tedious and long, the cost is high, and misoperation is likely to happen when the hoses are manually selected are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of high-pressure hydrogen filling, and in particular to a valve group switching screen method and device for adjusting hydrogen filling pressure. Background Art

[0002] At present, the existing high-pressure hydrogen filling generally adopts the "14 stations on both sides, 15MPa and 20MPa dual hoses at each station" layout, which requires a total of 28 hoses, with complex pipelines and many leakage points; filling personnel need to manually identify the cylinder grade and select the corresponding hose, and the misconnection rate is high; the alarm system only covers 20MPa, and there is no alarm for 15MPa overpressure; two sets of independent pipelines and valves increase procurement and maintenance costs. Summary of the Invention

[0003] The purpose of the present invention is to provide a valve group switching screen method and device for adjusting the hydrogen filling pressure, aiming to solve the problems of the existing valve group switching pipeline being long and costly, and the manual selection of hoses being prone to misoperation.

[0004] To achieve the above objectives, in a first aspect, the present invention provides a valve group switching screen device for adjusting the hydrogen filling pressure, comprising a main pipe, a 15MPa safety valve group, a pneumatic valve 1, a 20MPa safety valve group, a pneumatic valve 2, a branch pipe, multiple filling positions, multiple filling hoses, a code scanning unit, and a central switching screen; The 15MPa safety valve group and the 20MPa safety valve group are respectively connected in parallel with the main pipe, the pneumatic valve 1 is connected to the 15MPa safety valve group and to the branch pipe, the pneumatic valve 2 is connected to the 20MPa safety valve group and to the branch pipe, the multiple filling positions are connected to the branch pipe through multiple filling hoses, the central switching screen is connected to the pneumatic valve 1 and the pneumatic valve 2, and to the code scanning unit.

[0005] Wherein, a mechanical interlock valve is provided between the 15MPa safety valve group and the 20MPa safety valve group, and the mechanical interlock valve is used to prevent the two groups of safety valves from opening at the same time.

[0006] The filling hose is a 316L stainless steel corrugated tube, and both ends of the filling hose are equipped with CGA-350 quick-connect connectors.

[0007] Among them, the central switching screen has a built-in PLC controller, an audible and visual alarm and a touch screen. The PLC controller is connected to the pneumatic valve 1 and the pneumatic valve 2, and is connected to the code scanning unit. The audible and visual alarm and the touch screen are respectively connected to the PLC controller.

[0008] Wherein, a temperature-compensated pressure sensor is provided on the main pipe, and the temperature-compensated pressure sensor is used to correct the pressure drift caused by the ambient temperature in real time.

[0009] Wherein, electric contact pressure gauges are provided at the connection points between the plurality of filling positions and the plurality of filling hoses, and the electric contact pressure gauges are used to detect the pressure value at the outlet of the filling hoses.

[0010] In a second aspect, a valve group switching screen method for adjusting hydrogen filling pressure is used in the valve group switching screen device for adjusting hydrogen filling pressure described in the first aspect, comprising the following steps: The PLC controller detects the status of all sensors, valves and alarms; The code scanning unit works to read the cylinder information; The PLC controller drives pneumatic valve 1 or pneumatic valve 2 based on the cylinder information to connect to the 15MPa safety valve group or the 20MPa safety valve group; Multiple electrical contact pressure gauges send back pressure values ​​in a 100ms cycle; Based on the pressure value, if the real-time pressure is ≥ the set value + 0.2MPa, the PLC controller immediately closes pneumatic valve 1 or pneumatic valve 2, triggers an audible and visual alarm, and synchronizes the alarm event and filling curve to the local and cloud.

[0011] The present invention provides a valve group switching screen device for adjusting hydrogen filling pressure. The inlet of the main pipe is connected to an upstream hydrogen source with a design pressure of 20 MPa. The outlet is divided into two paths after a tee: one path is connected to a 15 MPa safety valve group, and the other path is connected to a 20 MPa safety valve group. The outlets of the two safety valve groups are combined into a branch pipe through the pneumatic valve 1 and the pneumatic valve 2, and then evenly distributed to 14 filling positions through multiple filling hoses. During operation, after the code scanning unit reads the bottle type, the central switching screen automatically opens the valve at 15 MPa or 20 MPa. When the pressure reaches the set value, the contacts close, the valve is immediately closed, and an audible and visual alarm is issued. The steel cylinder arrives → scan the code → select the valve by PLC → fill → close the valve in case of overpressure → upload data. 28 hoses are reduced to 14, reducing costs by 50%. Misoperation is reset to zero, and an alarm is issued in case of overpressure of 15 MPa. This enables one-bottle-universal, one-touch filling, thereby solving the problems of the existing valve group switching pipelines being lengthy and costly, and the manual selection of hoses being prone to misoperation. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0013] Figure 1It is a schematic diagram of a valve group switching screen device for adjusting hydrogen filling pressure provided by the present invention.

[0014] Figure 2 The present invention provides a flow chart of a valve group switching screen method for adjusting hydrogen filling pressure.

[0015] In the figure: 1-main pipe, 2-15MPa safety valve group, 3-pneumatic valve 1, 4-20MPa safety valve group, 5-pneumatic valve 2, 6-branch pipe, 7-filling position, 8-filling hose, 9-code scanning unit, 10-central switching screen, 11-mechanical interlock valve, 12-PLC controller, 13-sound and light alarm, 14-touch screen, 15-temperature compensated pressure sensor, 16-electric contact pressure gauge. DETAILED DESCRIPTION

[0016] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0017] See also Figure 1 In a first aspect, the present invention provides a valve group switching screen device for adjusting hydrogen filling pressure, comprising a main pipe 1, a 15MPa safety valve group 2, a pneumatic valve 1 3, a 20MPa safety valve group 4, a pneumatic valve 2 5, a branch pipe 6, multiple filling positions 7, multiple filling hoses 8, a code scanning unit 9, and a central switching screen 10; The 15MPa safety valve group 2 and the 20MPa safety valve group 4 are respectively connected in parallel with the main pipe 1, the pneumatic valve 1 3 is connected to the 15MPa safety valve group 2 and to the branch pipe 6, the pneumatic valve 2 5 is connected to the 20MPa safety valve group 4 and to the branch pipe 6, the multiple filling positions 7 are connected to the branch pipe 6 through the multiple filling hoses 8, the central switching screen 10 is connected to the pneumatic valve 1 3 and the pneumatic valve 2 5, and is connected to the code scanning unit 9.

[0018] In this embodiment, the inlet of the main pipe 1 is connected to an upstream hydrogen source with a design pressure of 20 MPa. The outlet is divided into two routes through a tee: one connected to a 15 MPa safety valve group 2, and the other to a 20 MPa safety valve group 4. The outlets of the two safety valve groups converge into a branch pipe 6 through pneumatic valves 1 and 2, 5, and are then evenly distributed to 14 filling stations 7 via multiple filling hoses 8. During operation, a barcode scanning unit 9 reads the bottle type, and a central switching screen 10 automatically opens the valve at 15 MPa or 20 MPa. When the pressure reaches the set value, the contacts close, immediately closing the valve and issuing an audible and visual alarm. The process involves: bottle arrival → scan barcode → PLC valve selection → filling → valve closure in case of overpressure → data upload. This reduces the number of hoses from 28 to 14, reducing costs by 50%. Misoperation errors are reset to zero, and an alarm is issued in the event of an overpressure of 15 MPa. This allows for one-bottle, one-touch filling, eliminating the problems of existing valve group switching systems, which are lengthy and costly, and prone to manual misoperation.

[0019] Furthermore, a mechanical interlock valve 11 is provided between the 15 MPa safety valve group 2 and the 20 MPa safety valve group 4. The mechanical interlock valve 11 is used to prevent the two groups of safety valves from opening at the same time.

[0020] In this embodiment, the mechanical interlock valve 11 is a cam-linked mechanism installed between two pneumatic valves. When pneumatic valve 1 (15 MPa) is open, the cam forcibly depresses the connecting rod of pneumatic valve 2 (5), keeping it closed, and vice versa. This completely eliminates the risk of simultaneous conduction of two circuits due to PLC program anomalies or solenoid valve adhesion, achieving zero false operation. Requiring no additional sensors, the purely mechanical structure offers high reliability and a low failure rate.

[0021] Furthermore, the filling hose 8 is a 316L stainless steel corrugated tube, and both ends of the filling hose 8 are equipped with CGA-350 quick-connect connectors.

[0022] In this embodiment, the filling hose 8 has a pressure resistance of ≥35 MPa and a bend radius of 50 mm. The CGA-350 male / female quick-connect connectors at both ends feature self-locking steel balls and an insertion and removal force of ≤80 N, enabling single-handed operation. The filling hose 8 is high-pressure and corrosion-resistant, with a service life of ≥100,000 insertions and removals. Its quick-connect structure reduces the time required to change between bottles from 30 seconds to 5 seconds, improving filling efficiency.

[0023] Furthermore, the central switching screen 10 has a built-in PLC controller 12, an audible and visual alarm 13 and a touch screen 14. The PLC controller 12 is connected to the pneumatic valve 1 3 and the pneumatic valve 2 5, and is connected to the code scanning unit 9. The audible and visual alarm 13 and the touch screen 14 are respectively connected to the PLC controller 12.

[0024] In this embodiment, the PLC controller 12 has a scan cycle of 100ms; the touch screen 14 displays the pressure curve of each station in real time; the sound and light alarm 13 provides a 90dB beep and a red flashing LED. By switching between 15MPa and 20MPa with one button, manual intervention is eliminated; alarm information is stored locally and uploaded to the Ethernet network for cloud tracing; maintenance personnel can view historical curves and fault logs through the touch screen 14, reducing downtime and maintenance time by 60%.

[0025] Furthermore, a temperature-compensated pressure sensor 15 is provided on the main pipe 1 , and the temperature-compensated pressure sensor 15 is used to correct the pressure drift caused by the ambient temperature in real time.

[0026] In this embodiment, the temperature-compensated pressure sensor 15 has an accuracy of 0.25% FS, provides full temperature compensation from -40°C to +85°C, and a 4-20mA output connected to the PLC's AI module. The PLC adjusts the setpoint in real time based on a preset temperature-pressure compensation algorithm. Under operating conditions with a 30°C temperature difference between day and night, the pressure error of the temperature-compensated pressure sensor 15 is reduced from ±0.5MPa to ±0.05MPa, improving filling accuracy by an order of magnitude and eliminating the need for seasonal calibration.

[0027] Furthermore, electrical contact pressure gauges 16 are provided at the connection points between the plurality of filling positions 7 and the plurality of filling hoses 8 , and the electrical contact pressure gauges 16 are used to detect the pressure value at the outlet of the filling hose 8 .

[0028] In this embodiment, the electric contact pressure gauge 16 has a range of 0-25MPa and is equipped with two sets of micro switches with a contact capacity of 5A / 250VAC. The 4-20mA signal is connected to PLCAI, and two sets of passive contacts are connected to PLCDI. The electric contact pressure gauge 16 provides both continuous measurement and switch alarms, saving a pressure transmitter and a pressure switch, reducing costs by 30%. The two independent contacts at 15MPa and 20MPa levels achieve "one bottle, one threshold" accurate alarms with a false alarm rate of <0.1%. See also Figure 2 In a second aspect, a valve group switching screen method for adjusting hydrogen filling pressure is used in the valve group switching screen device for adjusting hydrogen filling pressure described in the first aspect, comprising the following steps: S1: PLC controller 12 detects the status of all sensors, valves and alarms; Specifically, after powering on, the PLC controller 12 first performs a 500ms self-test cycle: it reads the 4-20mA signal from the temperature-compensated pressure sensor 15 to determine if the range is within 3.8mA–20.2mA; uses the valve position feedback switch to check the "on / off" status of pneumatic valve 1 3 and pneumatic valve 2 5; checks the buzzer coil resistance (normally 26Ω±2Ω at 24VDC) and the continuity of the LED circuit of the sound and light alarm 13; and checks the RS-485 heartbeat frame of the barcode scanning unit 9. If there is no response within 200ms, a communication fault is reported. If all items pass, the touch screen 14 displays "Self-test OK"; otherwise, a fault code is displayed and the next step of filling is prohibited.

[0029] S2 code scanning unit 9 works to read the cylinder information; Specifically, when the cylinder is pushed into place, the diffuse reflection photoelectric switch generates a position signal. The PLC triggers the code scanning unit 9 to transmit 30dBm radio frequency power to read the electronic tag on the bottle neck. If the tag fails, the system switches to QR code mode, and a handheld scanner is used to read it. Bits 9-10 of the cylinder information are the rated pressure field, which the PLC writes to an internal register and simultaneously displays on the touch screen 14.

[0030] S3: The PLC controller 12 drives the pneumatic valve 1 3 or the pneumatic valve 2 5 to connect with the 15MPa safety valve group 2 or the 20MPa safety valve group 4 based on the cylinder information; Specifically, if the cylinder information is identified as a 15 MPa cylinder, the controller energizes the electromagnetic coil of "Pneumatic Valve 1 3", and 0.6 MPa clean air pushes the cylinder, causing Valve 1 to open within 0.3 seconds, while ensuring that "Pneumatic Valve 2 5" is in the closed state; if the cylinder information is identified as a 20 MPa cylinder, the action is reversed, Valve 2 opens, and Valve 1 closes.

[0031] Each valve is equipped with a mechanical feedback switch, which must return an "open" signal within 1 second, otherwise the controller will power off and close the valve again and report a fault prompt.

[0032] S4: Multiple electrical contact pressure gauges 16 transmit pressure values ​​in a 100ms cycle; Specifically, each electric contact pressure gauge 16 sends a real-time pressure value of 4-20 mA back to the controller through a shielded line every 100 milliseconds; the controller reads all workstations in turn with a period of 100 milliseconds and stores the data in a real-time data area for subsequent judgment.

[0033] S5: Based on the pressure value, if the real-time pressure is ≥ the set value + 0.2 MPa, the PLC controller 12 immediately closes the pneumatic valve 1 3 or the pneumatic valve 2 5, and triggers the sound and light alarm, and synchronizes the alarm event and the filling curve to the local and cloud.

[0034] Specifically, the controller compares the real-time pressure with the corresponding set value: if the pressure of a certain workstation is ≥ the set value + 0.2 MPa, the following actions are immediately performed: the power supply of the corresponding solenoid valve is disconnected, the spring is reset, and the pneumatic valve is closed within 200 milliseconds; the sound and light alarm 13 is triggered, the on-site buzzer sounds 90 decibels and the red light flashes quickly; a "workstation × overpressure" prompt pops up on the touch screen 14; the event time, workstation number, bottle number, set value, and actual pressure are written to the local SD card and sent to the host computer / cloud via Ethernet every 500 milliseconds. The data is locally cached when the network is disconnected and automatically re-uploaded after the network is restored, so that offline data of more than 7 days is not lost.

[0035] Example: Scenario: A hydrogen refueling station fills 280 high-pressure hydrogen cylinders per day (including 120 15MPa cylinders and 160 20MPa cylinders).

[0036] Device layout: General Manager: 25mm×3mm316L seamless pipe, design pressure 20MPa, length 12m.

[0037] The 15MPa safety valve group is set to 15.0MPa, and the 20MPa safety valve group is set to 20.0MPa; the two groups of outlets are merged through a DN15 branch pipe and divided into 14 DN10 branches, corresponding to 14 filling positions.

[0038] Each workstation: 1.5m of 20MPa stainless steel corrugated hose with CGA-350 quick connectors at both ends; an electric contact pressure gauge installed at the hose outlet; an RFID reader fixed on the left side of the workstation.

[0039] Central switching screen: 7″ touch screen + S7-1200PLC; connected to the station control server via Ethernet.

[0040] Workflow: a) Self-test: After starting up every day, the PLC will complete the self-test of sensors, valves and alarms within 500ms, and the screen will display "Self-test OK".

[0041] b) Scan code: The cylinder is pushed into place and the RFID reads the bottle number and rated pressure fields.

[0042] c) Valve group switching: If it is a 15MPa bottle, the PLC drives pneumatic valve 1 to open and valve 2 to close; the opposite is true for 20MPa bottles.

[0043] d) Filling: Fill to 14.8MPa (15MPa bottle) or 19.8MPa (20MPa bottle) at the preset rate.

[0044] e) Overpressure protection: When the pressure at any station is ≥ the set value + 0.2MPa, the PLC closes the valve within 200ms, the buzzer sounds a 90dB alarm, and the event is written to the local SD card and uploaded to the cloud in real time.

[0045] Beneficial effects: 1. The present invention connects a 15MPa / 20MPa safety valve group in parallel with a 20MPa main pipe, and replaces the traditional 28 double hoses with a single branch pipe + 14 20MPa hoses. The pipeline length, leakage points, and the number of valves are reduced by about 50%, and the procurement and maintenance costs are reduced by 46%.

[0046] 2. Mechanical interlock valve ensures that the two safety valves will never open at the same time, eliminating the risk of false operation.

[0047] 3. 316L corrugated hose + CGA-350 quick-connect connector reduces the single-bottle connection time from 30s to 5s, and the plug-in and unplug life is ≥100,000 times.

[0048] 4. The PLC controller + touch screen + code scanning unit realizes automatic bottle type recognition and one-click filling, with zero manual intervention; the temperature compensation sensor reduces the pressure error from ±0.5MPa to ±0.05MPa under a temperature difference of ±30℃, eliminating seasonal calibration.

[0049] 5. The electric contact pressure gauge provides both 4-20mA continuous measurement and 15MPa / 20MPa two-level contact alarm. A single gauge replaces the traditional dual gauges, reducing costs by another 30%.

[0050] 6. When the pressure is ≥ the set value + 0.2MPa, the PLC closes the valve within 200ms and triggers a 90dB sound and light alarm. Events and curves are uploaded to the cloud in real time, shortening downtime for maintenance by 60%.

[0051] 7. The present invention realizes "one bottle for all, one-click filling, two-level safety, and cloud traceability", which completely solves the problems of the existing technology such as long pipelines, high costs, manual errors and no alarm at 15MPa.

[0052] The above disclosure is only a preferred embodiment of the valve group switching screen method and device for adjusting the hydrogen filling pressure of the present invention. Of course, this cannot be used to limit the scope of rights of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above embodiments and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A valve group switching screen device for adjusting hydrogen filling pressure, characterized in that: It includes main pipe, 15MPa safety valve group, pneumatic valve 1, 20MPa safety valve group, pneumatic valve 2, branch pipe, multiple filling positions, multiple filling hoses, code scanning unit and central switching screen; The 15MPa safety valve group and the 20MPa safety valve group are respectively connected in parallel with the main pipe, the pneumatic valve 1 is connected to the 15MPa safety valve group and to the branch pipe, the pneumatic valve 2 is connected to the 20MPa safety valve group and to the branch pipe, the multiple filling positions are connected to the branch pipe through multiple filling hoses, the central switching screen is connected to the pneumatic valve 1 and the pneumatic valve 2, and to the code scanning unit.

2. The valve group switching screen device for adjusting hydrogen filling pressure according to claim 1 is characterized in that: A mechanical interlock valve is provided between the 15MPa safety valve group and the 20MPa safety valve group, and the mechanical interlock valve is used to prevent the two groups of safety valves from opening at the same time.

3. The valve group switching screen device for adjusting the hydrogen filling pressure according to claim 1 is characterized in that: The filling hose is a 316L stainless steel corrugated tube, and both ends of the filling hose are equipped with CGA-350 quick-connect connectors.

4. The valve group switching screen device for adjusting the hydrogen filling pressure according to claim 1 is characterized in that: The central switching screen has a built-in PLC controller, an audible and visual alarm, and a touch screen. The PLC controller is connected to the pneumatic valve 1 and the pneumatic valve 2, and is connected to the code scanning unit. The audible and visual alarm and the touch screen are respectively connected to the PLC controller.

5. The valve group switching screen device for adjusting hydrogen filling pressure according to claim 1 is characterized in that: The main pipe is provided with a temperature-compensated pressure sensor, which is used to correct the pressure drift caused by the ambient temperature in real time.

6. The valve group switching screen device for adjusting hydrogen filling pressure according to claim 1 is characterized in that: Electrical contact pressure gauges are provided at the connection points between the plurality of filling positions and the plurality of filling hoses, and the electrical contact pressure gauges are used to detect the pressure value at the outlet of the filling hoses.

7. A valve group switching screen method for adjusting hydrogen filling pressure, used in the valve group switching screen device for adjusting hydrogen filling pressure according to any one of claims 1 to 6, characterized in that: The following steps are involved: The PLC controller detects the status of all sensors, valves and alarms; The code scanning unit works to read the cylinder information; The PLC controller drives pneumatic valve 1 or pneumatic valve 2 based on the cylinder information to connect to the 15MPa safety valve group or the 20MPa safety valve group; Multiple electrical contact pressure gauges send back pressure values ​​in a 100ms cycle; Based on the pressure value, if the real-time pressure is ≥ the set value + 0.2MPa, the PLC controller immediately closes pneumatic valve 1 or pneumatic valve 2, triggers an audible and visual alarm, and synchronizes the alarm event and filling curve to the local and cloud devices.

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