Hydrogen fuel cell test system and application method

Abstract

The invention discloses a hydrogen fuel cell test system and an application method, and the system comprises a test chamber which is internally provided with a plurality of test cavities for placing hydrogen fuel cells to be tested; the plurality of fuel cell acquisition wire harnesses are connected with the output end of the hydrogen fuel cell to be tested in each test cavity; the gas supply module is arranged at the periphery of the test chamber; the load is arranged at the periphery of the test chamber and is connected with each hydrogen fuel cell to be tested; the data acquisition module is used for acquiring environment information in each test cavity; the execution modules are arranged in the cavities and used for simulating the working environment; and an external control center. According to the testing system, through cooperative work of all the modules, the running states of the hydrogen fuel cell under different working conditions can be accurately simulated, and real-time detection and analysis of multiple parameters such as voltage, current, power, efficiency, gas flow, pressure and temperature of the fuel cell are achieved; and effective technical support can be provided for research and development, production and quality detection of the hydrogen fuel cell.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of battery testing. More particularly, the present application relates to a hydrogen fuel cell testing system and application method. BACKGROUND

[0002] As a high-efficiency and clean energy conversion device, hydrogen fuel cells have high energy density, zero emissions, rapid start-up, and other advantages, and have broad application prospects in the fields of automobiles, power generation, portable devices, etc. However, the performance of hydrogen fuel cells is affected by various factors, such as the purity, flow rate, and pressure of hydrogen and oxygen, reaction temperature, humidity, etc., so it is crucial to comprehensively and accurately test the performance of hydrogen fuel cells. Currently, existing hydrogen fuel cell testing systems have problems such as low testing accuracy, single function, complex operation, etc., and are difficult to meet the testing needs in the research and development and production processes of hydrogen fuel cells. For example, some testing systems cannot accurately control the flow rate and pressure of the gas, which affects the accuracy of the test results; some testing systems can only detect a few parameters and cannot fully reflect the performance of the fuel cell; and some testing systems are cumbersome to operate and require professional personnel to operate, which reduces the testing efficiency.

[0003] In addition, hydrogen fuel cells are increasingly widely used in the fields of transportation, portable devices, etc., and may face various impact conditions in the working process, such as collisions during vehicle travel, drops during equipment handling, etc., which can significantly affect the performance and safety of the battery. Therefore, it is crucial to comprehensively test the impact conditions of hydrogen fuel cells in the working environment. Currently, the testing of the impact performance of hydrogen fuel cells mainly uses physical testing or separate simulation methods. Although physical testing is true and reliable, it has problems such as high cost, long testing period, and difficulty in covering all extreme impact conditions; simulation can quickly simulate various impact conditions, but due to model simplification and parameter assumptions, the accuracy of the results cannot be guaranteed, and the correlation with physical test data is weak. In the prior art, there is a lack of an asynchronous testing system that effectively combines physical testing and simulation, which cannot fully utilize the advantages of both, and cannot meet the needs of precise testing of the impact resistance performance of hydrogen fuel cells.

[0004] Therefore, it is of great practical significance to develop a system and application method that has high testing accuracy, comprehensive functions, and convenient operation, and can realize asynchronous testing of physical and simulation. SUMMARY

[0005] An object of the present application is to solve at least the above problems and / or deficiencies, and to provide at least the advantages described later.

[0006] To achieve these objects and other advantages and in view of prior art, a hydrogen fuel cell testing system is provided, comprising:

[0007] a test chamber, in which a plurality of test cavities for placing hydrogen fuel cells to be tested are arranged;

[0008] a plurality of fuel cell collection harnesses connected with output ends of the hydrogen fuel cells to be tested in the test cavities;

[0009] a gas supply module arranged outside the test chamber and used for supplying hydrogen and oxygen to the hydrogen fuel cells to be tested;

[0010] a load arranged outside the test chamber and connected with the hydrogen fuel cells to be tested;

[0011] a data collection module used for collecting environmental information in the test cavities;

[0012] an execution module arranged in each cavity and used for simulating a working environment;

[0013] an external control center in communication connection with the gas supply module, the load, the data collection module and the execution module;

[0014] The external control center is provided with a data collection card, a data processing module for processing, analyzing and storing data output by the data collection card, and a control module for configuring working parameters and working states of the gas supply circulation module and the execution module.

[0015] Preferably, each test cavity is configured to include: the gas supply circulation module includes: a hydrogen supply unit, a hydrogen circulation unit, an oxygen supply unit, an oxygen circulation unit and a neutralization unit.

[0016] The hydrogen supply unit and the oxygen supply unit each include: a gas source and an air inlet pipeline in communication with an anode or a cathode inlet end of the fuel cell, and the air inlet pipeline is provided with a filter I or a dryer I, a mass flow meter, a pressure reducing valve, a pressure stabilizing valve and an air inlet valve.

[0017] The hydrogen circulation unit and the oxygen circulation unit each include: a buffer tank and an exhaust pipeline in communication with an anode or a cathode outlet end of the fuel cell, and the exhaust pipeline is provided with a gas collecting valve and a filter II or a dryer II, and each buffer tank is in communication with the gas inlet side of a corresponding mass flow meter through a corresponding branch I, and each branch I is provided with a control valve.

[0018] The hydrogen circulation unit and the oxygen circulation unit are in communication with the neutralization unit through a corresponding branch II, and the branch II is provided with a corresponding emergency exhaust valve and a corresponding control valve II.

[0019] Preferably, each test cavity is provided with a test table for placing the hydrogen fuel cell, and the test table is provided with a clamp for fixing the hydrogen fuel cell.

[0020] Preferably, the execution module comprises:

[0021] a heating and / or refrigeration unit for simulating the external environment temperature;

[0022] a humidification unit for simulating the external environment humidity;

[0023] a vibration unit arranged below the test bench for simulating the external environment disturbance;

[0024] a striking unit arranged above the test bench for simulating the external impact force;

[0025] wherein the striking unit comprises a power mechanism, an adjusting mechanism for adjusting the position and / or angle of the power mechanism, a plate striking head and / or a spike striking head connected to the output end of each power mechanism.

[0026] Preferably, the data acquisition module comprises:

[0027] a voltage sensor, a current sensor, and a power sensor connected to the fuel cell acquisition bundle for real-time detection of the voltage, current, and power of the hydrogen fuel cell;

[0028] a gas flow sensor and a gas pressure sensor arranged on the gas inlet pipeline for real-time detection of the flow and pressure of hydrogen and oxygen;

[0029] a temperature and humidity sensor arranged in the test chamber for real-time detection of the temperature and humidity of the test environment;

[0030] an infrared camera and / or an industrial camera arranged in the test chamber;

[0031] a stress sensor, a pressure sensor, and a displacement sensor arranged at multiple positions on the surface of the fuel cell under test for detecting the structural deformation of the battery;

[0032] a noise sensor arranged in the test chamber for detecting the operating noise of the hydrogen fuel cell.

[0033] Preferably, the external control center further comprises a simulation and emulation module for virtually simulating the working environment of the hydrogen fuel cell;

[0034] wherein the simulation and emulation module is connected to the data processing module and the control module, and is used for constructing a digital model of the hydrogen fuel cell, performing virtual working condition simulation, and interacting virtual and real data;

[0035] the simulation and emulation module comprises a three-dimensional modeling unit, a physical field simulation unit, a working condition simulation unit, a data interaction unit, a material attribute database, and a striking simulation unit;

[0036] The three-dimensional modeling unit is configured to construct a fuel cell geometric model and an internal structure model consistent with a real object.

[0037] The physical field simulation unit is configured to simulate physical processes of electrochemical reactions, heat transfer and mass transfer inside the battery.

[0038] The working condition simulation unit is configured to set virtual environment parameters and generate diversified virtual test working conditions.

[0039] The data interaction unit is configured to realize real-time transmission and associated storage of simulation data and real object test data.

[0040] The material attribute database is configured to store material mechanical performance parameters of each component of the battery.

[0041] The control module cooperates with the simulation controller, the simulation controller is configured to receive virtual parameter instructions of the simulation simulation module and convert them into real object test parameters executable by the PLC controller.

[0042] An application method of the hydrogen fuel cell test system, including working capacity test of the hydrogen fuel cell and working environment test of the hydrogen fuel cell, the working capacity test process includes:

[0043] System initialization: check whether each module is working normally, and initialize and set the control module, the data acquisition module and the data processing module;

[0044] Install the fuel cell: install the hydrogen fuel cell to be tested in the corresponding test cavity, fix the hydrogen fuel cell through the clamp, ensure the connection, connect the fuel cell with the external load;

[0045] Set the test parameters: set the flow and pressure of hydrogen and oxygen, the temperature and humidity of the test cavity, and the test time through the control module;

[0046] Start the test: the control module controls the hydrogen supply module and the oxygen supply module to supply hydrogen and oxygen to the test cavity, and the hydrogen fuel cell starts to occur electrochemical reaction;

[0047] Data detection and acquisition: the data acquisition module detects each parameter and running noise in the hydrogen fuel cell reaction process in real time, and transmits the data to the external control center through the data acquisition card;

[0048] Data processing and analysis: the data processing software of the external control center processes and analyzes the collected test data to generate a test report;

[0049] End the test: after the test time reaches the set value, the control module controls each supply module to stop gas supply, removes the tested hydrogen fuel cell, and closes the system.

[0050] Preferably, the working environment test includes: a standard test of synchronous testing of temperature and / or humidity in the hydrogen fuel cell working environment by physical object and simulation, and the process includes:

[0051] S01, system initialization and model building: obtaining physical object parameters in the current working state of each module, and building a hydrogen fuel cell digital model through a three-dimensional modeling unit of a simulation simulation module;

[0052] S02, virtual working condition setting: setting at least three groups of differentiated virtual test parameters I in the simulation simulation module through a working condition simulation unit, the virtual test parameters I including material properties, structure parameters, virtual environment temperature and / or humidity, and gas flow pressure;

[0053] S03, physical test parameter matching: the simulation controller automatically matches the gas flow pressure of the hydrogen supply unit and the oxygen supply unit and the operating parameters of the test cavity based on the virtual test parameters I, and the execution module controls the temperature and humidity inside the test cavity based on the operating parameters;

[0054] S04, synchronous testing: the simulation simulation module directly performs virtual testing based on the virtual test parameters I to obtain simulation data I, while the PLC controller starts the physical testing process based on the physical testing parameters output by the simulation controller, and the data acquisition module synchronously collects to obtain physical testing data I, and stores the physical testing data I through the data interaction unit;

[0055] S05, data interaction and analysis: the data processing module calls the physical testing data I and the simulation data I from the data interaction unit, performs comparative analysis, and calculates the deviation rate;

[0056] S06, model iteration optimization: adjusting the physical field parameters and model boundary conditions of the simulation simulation module according to the deviation rate, and repeating steps S02-S05 until the virtual and physical testing data error is ≤5%;

[0057] S07, test report generation: integrating all test data and analysis results to generate a comprehensive test report containing virtual-real performance mapping relationship and key parameter sensitivity analysis.

[0058] Preferably, the working environment test further includes: a non-standard test I of asynchronous testing of impact in the hydrogen fuel cell working environment by physical object and simulation, and the working process of the non-standard test I includes:

[0059] S11, system initialization: checking whether each module is working normally, initializing and setting the control module, the data interaction unit and the data analysis module, and establishing the associated parameters of the physical testing and the simulation simulation;

[0060] S12, model construction and parameter setting: a three-dimensional modeling unit of the simulation simulation module constructs a hydrogen fuel cell digital model, and material attribute parameters are imported from a material attribute database; a working condition simulation unit sets virtual test parameters II, which include impact parameters of the impact unit, virtual environment temperature and / or humidity, gas flow pressure, and asynchronous time difference and test sequence of physical testing and simulation simulation, the impact parameters include impact force, angle, and action time;

[0061] S13, simulation simulation: the simulation simulation module directly performs virtual testing based on the virtual test parameters II to simulate the battery response and external structure change of the hydrogen fuel cell digital model under the corresponding impact parameters, to obtain simulation data II, the simulation data II is stored through the data interaction unit, and the safety factor of the hydrogen fuel cell under the corresponding impact parameters is evaluated through the data analysis module, if the safety factor is within the predetermined threshold range, then S14 is entered, otherwise the impact parameters are reset in S12;

[0062] S14, physical impact test: according to the set asynchronous parameters, after simulation simulation, the control module controls the impact unit to apply impact to the physical hydrogen fuel cell according to the set impact parameters, the data acquisition module synchronously detects the performance parameters and structure state during and after impact to obtain physical test data II, and the physical test data II is stored through the data interaction unit;

[0063] S15, data interaction and analysis: the data processing module calls the physical test data II and the simulation data II from the data interaction unit, performs comparative analysis, calculates the deviation rate to evaluate the performance attenuation and structure damage of the battery after impact;

[0064] S16, model iteration optimization: according to the analysis result, the impact parameters or model parameters are adjusted, and steps S12-S15 are repeated until the virtual and physical test data error is ≤1%;

[0065] S17, test report generation: integrate all test data and analysis results to generate a test report containing battery impact resistance performance evaluation and structure weak point analysis.

[0066] Preferably, the working environment test further comprises a non-standard test II for testing external vibration in the working environment of the hydrogen fuel cell, and the working process of the non-standard test II comprises:

[0067] S21, system initialization and model construction: obtain physical parameters in the current working state of each module, and construct a hydrogen fuel cell digital model through a three-dimensional modeling unit of the simulation simulation module;

[0068] S22, virtual working condition setting: at least three groups of different virtual test parameters III are set in the simulation module, including material properties, structure parameters, virtual environment temperature and / or humidity, gas flow pressure, vibration parameters;

[0069] S23, physical test parameter matching: the simulation controller automatically matches the gas flow pressure of the hydrogen supply unit and the oxygen supply unit and the operating parameters of the test cavity based on the virtual test parameters III, and the execution module regulates the temperature and humidity inside the test cavity based on the operating parameters, and sets the working parameters of the vibration unit;

[0070] S24, synchronous testing: the simulation module runs the virtual test working condition to obtain simulation data III, and the PLC controller starts the physical test process based on the physical test parameters output by the simulation controller, and the data acquisition module synchronously collects to obtain physical test data III, and stores the physical test data I through the data interaction unit;

[0071] S25, data interaction and analysis: the data processing module calls the physical test data III and the simulation data III from the data interaction unit for comparison and analysis, and calculates the deviation rate;

[0072] S26, model iteration optimization: the physical field parameters and model boundary conditions of the simulation module are adjusted according to the deviation factor, and steps S22-S25 are repeated until the virtual and physical test data error is less than or equal to 3%;

[0073] S27, test report generation: the optimized simulation data and physical test data are integrated to generate a comprehensive test report containing virtual-real performance mapping relationship and key parameter sensitivity analysis.

[0074] The present application at least includes the following beneficial effects:

[0075] Firstly, the test system of the present application can accurately simulate the running state of hydrogen fuel cells under different working conditions through the cooperative work of each module, realize real-time detection and analysis of multiple parameters such as fuel cell voltage, current, power, efficiency, gas flow, pressure, temperature, etc., has the advantages of comprehensive function, convenient operation, etc., and provides effective technical support for the research and development, production and quality detection of hydrogen fuel cells.

[0076] Secondly, the test system application method of the present application can comprehensively evaluate the performance, reliability and durability of hydrogen fuel cells by setting different test parameters and operating according to a specific process.

[0077] Thirdly, the test system application method of the present application provides two tests: the working capacity test of the hydrogen fuel cell and the working environment test of the hydrogen fuel cell, the working capacity test is mainly to test whether the working performance index of the hydrogen fuel cell itself meets the production requirements, and the working environment test is to test whether the working performance index of the hydrogen fuel cell deviates or produces safety hazards under different working environments (such as high temperature, high humidity, vibration, impact), which can be used as a prompt for safety index in the hydrogen fuel cell working manual, or used as a research and development data basis for further improving the performance of the hydrogen fuel cell.

[0078] Fourthly, in the impact test of the present application, through the asynchronous cooperation of physical test and simulation simulation, the performance change and structural response of the hydrogen fuel cell under different impact intensity, angle and environmental conditions can be comprehensively simulated, and the precise evaluation of the impact resistance, safety and performance attenuation law of the battery can be realized.

[0079] Further, in the impact test of the present application, by setting asynchronous test parameters, through the processes of physical impact test, simulation simulation, data interaction and analysis, reliable basis is provided for the structure optimization and safety design of the hydrogen fuel cell, the present application comprehensively and accurately evaluates the performance and safety of the hydrogen fuel cell under impact working conditions through the asynchronous cooperation of physical test and simulation simulation, the application method is flexible in operation, has high test flexibility, wide working condition coverage, strong data correlation, can effectively improve the test efficiency and reliability, and is suitable for the impact resistance performance test of the hydrogen fuel cell under complex working environment.

[0080] Other advantages, objects and features of the present application will be embodied in part by the following description, and part will be understood by those skilled in the art through research and practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0081] Figure 1 The system composition block diagram of the hydrogen fuel cell test system of the present application is shown in the figure;

[0082] Figure 2 The system composition block diagram of each test cavity of the present application is shown in the figure;

[0083] Figure 3 The system composition block diagram of each execution module of the present application is shown in the figure;

[0084] Figure 4 The system composition block diagram of each data acquisition module of the present application is shown in the figure;

[0085] Figure 5 The system composition block diagram of the external control center of the present application is shown in the figure. DETAILED DESCRIPTION

[0086] The application will be further described in detail below with reference to the accompanying drawings so as to enable those skilled in the art to implement the application according to the description.

[0087] As shown in Figure 1 , Figure 5 a hydrogen fuel cell test system, comprising:

[0088] a test chamber 1, in which a plurality of test cavities 10 for placing hydrogen fuel cells to be tested are arranged;

[0089] a plurality of fuel cell collection harnesses (not shown) connected to the output ends of the hydrogen fuel cells to be tested in each test cavity;

[0090] a gas supply module 2 arranged outside the test chamber for supplying hydrogen and oxygen to each hydrogen fuel cell to be tested;

[0091] a load 3 connected to each hydrogen fuel cell to be tested arranged outside the test chamber;

[0092] a data acquisition module 4 for acquiring environmental information in each test cavity;

[0093] an execution module 5 arranged in each cavity for simulating a working environment;

[0094] an external control center 6 in communication connection with the gas supply module, the load, the data acquisition module and the execution module; wherein the external control center is provided with a data acquisition card 60 for transmitting data received from the data acquisition module to a data processing module;

[0095] a data processing module 61 for processing, analyzing and storing data output at the data acquisition card; the data processing module is built-in with a comparative analysis algorithm, which can quantitatively compare the stress distribution, deformation amount and performance parameters of the real object test and simulation data, and calculate the deviation rate; the damage evaluation model is trained based on a large amount of experimental data, and automatically divides the damage level according to the structural damage degree (such as crack length, deformation amount) and performance attenuation amplitude (such as power drop rate) of the battery, thereby providing a quantitative basis for the impact resistance performance evaluation of the battery.

[0096] The control module 62 configures the working parameters and working states of the gas supply circulation module, the execution module, and adopts a multi-core industrial-grade processor (PLC controller) with a main frequency of ≥3.0 GHz, can simultaneously process control instructions of multiple modules, can flexibly set the asynchronous time difference and test sequence of physical testing and simulation analog through the control program, the response time of the control instruction is ≤1 ms, ensures the coordinated and orderly work of the modules, and simultaneously adopts the cooperative architecture of the PLC controller and the simulation controller. After the simulation controller receives the virtual working condition parameters, the virtual working condition parameters are converted into physical test instructions through a fuzzy control algorithm, for example, the virtual hydrogen flow of 2 L / min is converted into the valve opening degree of 35%, and the control response delay is ≤10 ms. In actual application, after the simulation analog module is operated, the simulation controller receives the virtual working condition parameters (such as -20℃ starting and hydrogen purity of 99.97%) transmitted by the simulation analog module, and converts the virtual working condition parameters into physical test instructions, for example, the hydrogen supply unit stabilizes the pressure at 3 bar through a pressure reducing valve, the oxygen supply unit controls the dew point at -40℃ through a dryer, and the temperature control device of the test cavity quickly responds to the set value. The PLC controller controls the working states of the components of the execution module based on the physical test instructions, and completes the physical test.

[0097] In this scheme, the working principle of the hydrogen fuel cell test system is based on the cooperative operation of each module to realize accurate testing of the hydrogen fuel cell under different working conditions. After the system is started, the control module first receives the preset test parameters, which include the flow and pressure of hydrogen and oxygen / air, the temperature and humidity of the test cavity, and the test duration. The control module issues instructions to the hydrogen supply unit and the oxygen supply unit based on these parameters to ensure that the gas supply meets the test requirements.

[0098] The hydrogen fuel cell is installed on the fuel cell test fixture in the test cavity. When hydrogen and oxygen enter the fuel cell, an electrochemical reaction occurs inside the fuel cell. The heating and / or refrigeration unit and the humidification unit in the test cavity are regulated by the control module to maintain the environmental temperature and humidity in the test cavity at the set value, providing stable reaction conditions for the fuel cell and simulating different working environments.

[0099] In this process, various sensors of the data acquisition module play a key role. The voltage sensor and the current sensor monitor the output voltage and current of the fuel cell in real time, and the power sensor calculates the power based on the voltage and current data. The gas flow sensor and the gas pressure sensor detect the flow and pressure of hydrogen and oxygen entering the test cavity, respectively, and the temperature sensor monitors the temperature in the test cavity. These sensors transmit the detected parameters to the data acquisition card of the data processing module in real time.

[0100] The data acquisition card transmits various data collected from the data acquisition module to the data processing module quickly, the data processing module processes and analyzes the data in real time, and draws voltage-current curve, power-current curve, efficiency curve, etc., to intuitively display the performance change of the fuel cell, generate a test report, and facilitate the user to view and analyze the test results. At the same time, the data processing module continuously receives the data fed back by the data acquisition module, compares with the preset parameters, and if there is a deviation, immediately adjusts the hydrogen supply unit, the oxygen supply unit, and the temperature and humidity in the test cavity, to ensure that the entire test process is stable according to the set working condition.

[0101] When the test time reaches the set value, the control module issues an instruction to stop the hydrogen supply unit and the oxygen supply unit, and the electrochemical reaction in the test cavity is terminated. The data processing module generates a complete test report containing detailed data and analysis results of various parameters, providing a comprehensive and accurate basis for evaluating the performance of the hydrogen fuel cell.

[0102] Further, as Figures 1-2 , each test cavity is configured to include: the gas supply circulation module includes: a hydrogen supply unit 20, a hydrogen circulation unit 21, an oxygen supply unit 22, an oxygen circulation unit 23, and a neutralization unit 24;

[0103] The hydrogen supply unit and the oxygen supply unit each include: a gas source 201 and a gas inlet pipe 202 that communicates the gas source with the fuel cell anode or cathode inlet end 70 on the hydrogen fuel cell 7, the gas inlet pipe is provided with a filter I or a dryer I 203, a mass flow meter 204, a pressure reducing valve 205, a pressure stabilizing valve 206, and an inlet valve 207, the filter I or the dryer I can remove impurities in hydrogen or oxygen to ensure the purity of the medium; the dryer I is used to remove water in oxygen to avoid the influence of water on the performance of the fuel cell, the pressure reducing valve is used to adjust the pressure of the medium outlet to reach the required pressure value for testing, the pressure stabilizing valve adjusts the pressure of the medium inlet, adjusts the pressure in both directions, limits the pressure too high and compensates for the pressure too low, the mass flow meter is used to accurately measure the flow of the medium, and the inlet valve is used to control the on-off between the medium and the fuel cell anode or cathode inlet end;

[0104] The hydrogen circulation unit and the oxygen circulation unit each comprise a buffer tank 220 and an exhaust pipeline 221 connected with the anode or cathode outlet end 71 of the fuel cell, wherein a gas collecting valve 222, a filter II or a dryer II 223 are arranged on the exhaust pipeline, each buffer tank is connected with the corresponding mass flow meter through a corresponding branch I 224, and a control valve 225 is arranged on each branch I. In this working process, the buffer tank collects the excess gas medium to prevent the performance influence caused by the excess medium in the hydrogen fuel cell, and the collected excess gas medium can be continuously used after being filtered and dried, and the control valve is opened or closed to adjust whether the medium is delivered to the anode or cathode inlet end of the fuel cell.

[0105] The hydrogen circulation unit and the oxygen circulation unit are connected with the neutralization unit through a corresponding branch II 226, and a corresponding emergency exhaust valve 227 is arranged on the branch II.

[0106] In the hydrogen supply unit, the hydrogen is output from the hydrogen source, and then passes through the hydrogen filter to effectively remove impurities and ensure the purity of the hydrogen, thereby avoiding the adverse effects of impurities on the fuel cell reaction. Subsequently, the hydrogen enters the hydrogen pressure reducing valve to adjust the pressure to a stable value required for testing. Then, the hydrogen mass flow meter accurately measures the flow of the hydrogen, and the flow data is fed back to the control module in real time. The control module adjusts the opening of the hydrogen valve according to the feedback data to stabilize the hydrogen flow within the set range, and finally the hydrogen is delivered to the anode of the fuel cell through the hydrogen valve.

[0107] The working process of the oxygen supply module is similar to that of the hydrogen supply unit. The oxygen is output from the corresponding gas source, and then passes through the gas dryer to remove moisture to prevent the moisture from interfering with the normal reaction of the fuel cell. Subsequently, the pressure is adjusted by the gas pressure reducing valve, and the flow is measured by the gas mass flow meter. The control module also adjusts the gas valve according to the flow feedback to ensure that the oxygen or air enters the cathode of the fuel cell at a stable flow and pressure.

[0108] The hydrogen circulation unit and the oxygen circulation unit function to guide the excess gas out of the electrode to prevent "flooding".

[0109] The function of the emergency exhaust valve is to deliver the buffered gas in the buffer tank to the neutralization unit when the internal gas of the buffer tank exceeds the predetermined value and cannot be recycled temporarily, thereby solving the problem of excessive internal pressure of the buffer tank and the safety hazard to the test environment caused by the inability to discharge.

[0110] Further, each test cavity is provided with a test table for placing the hydrogen fuel cell, and the test table is provided with a clamp for fixing the hydrogen fuel cell. The clamp for fuel cell test is mainly used for fixing the hydrogen fuel cell to ensure its stable position during the reaction process. According to the actual application needs, the clamp can be manually adjusted by the cooperation of bolts, screws and pressing plates to complete the fixation of the hydrogen fuel cell (such as small size single cell test), or a cylinder or hydraulic cylinder can be used to provide stable pressing force (such as applied to stack level test or long term durability test, to avoid pressure fluctuation caused by manual adjustment), and the pressing plate is used to uniformly transmit the clamping force to avoid sealing failure or deformation of the fuel cell due to uneven force.

[0111] As Figure 3 , further, the execution module comprises:

[0112] A heating and / or refrigeration unit 50 for simulating the external environment temperature. The heating unit is a heating mechanism provided on the side wall of the test cavity (for high temperature test, such as simulating the environment temperature at different gradients of 40-80℃ to test the running stability of the battery), which can be an electric heating wire provided in the side wall of the test cavity, or a water / air circulation heating mechanism for heat conduction to the inside of the test cavity, for adjusting the temperature in the test cavity to better simulate the external high heat environment temperature when the battery is working. Of course, according to the needs, a refrigeration unit can also be provided in the test cavity to simulate the influence of extremely low external environment temperature on the working performance of the battery (such as simulating-30℃ cold start to evaluate the influence of low temperature on the performance of the battery);

[0113] A humidification unit 51 for simulating the external environment humidity. The humidification unit keeps the inside of the test cavity in a certain humidity environment by evaporating or atomizing water, such as releasing water vapor into the test cavity through a steam generator (electric heating water to generate steam) or an ultrasonic humidifier, cooperating with the humidity control of the heating unit (to prevent condensation at low temperature, and to avoid excessive evaporation of water vapor at high temperature) to realize the simulation of humid heat environment in extreme conditions and evaluate the stability of the battery output;

[0114] The vibration unit 52 is arranged below the test table and is used to simulate external environmental disturbance. In the present solution, the vibration unit can be matched with the heating unit and the humidifying unit to reproduce the "vibration + temperature and humidity" compound environment in the working of the fuel cell (such as the starting performance of the vehicle-mounted fuel cell under low-temperature vibration). Specifically, according to different experimental needs, the vibration unit can adopt a multi-axis vibration table, a plurality of single-axis vibration tables (such as a three-axis orthogonal structure) can be combined to simultaneously generate vibration in X, Y and Z directions, which is used to simulate complex multi-dimensional vibration environment. An electromagnetic vibration table can also be adopted to generate periodic vibration by electromagnetic induction, and the vibration parameters (frequency, amplitude, acceleration) are adjusted by the control system to realize various modes such as sinusoidal vibration and random vibration. Of course, when the vibration test is performed, the fixture needs to be fixed to the battery, the vibration frequency in the vibration parameters can be selected between 10-200 Hz, the gravity acceleration is generally selected as 1-10 g, the vibration waveform can be selected by a sinusoidal wave to simulate periodic vibration (such as engine vibration), a random wave to simulate non-periodic vibration (such as road surface and sea wave), and an impact wave to simulate sudden collision or jolt. In the extreme scenario (such as impact vibration), the vibration frequency can be selected as above 50 g. However, if the extreme scenario is selected, the simulation test needs to be performed first, the safety factor is evaluated, and then the physical test is performed. In the actual test, the vibration unit can simulate the road spectrum (random vibration) in the vehicle driving, and the temperature control is performed at -40-80°C to test the voltage fluctuation and electrolyte leakage of the stack under vibration.

[0115] The impact unit 53 is arranged above the test table to simulate external impact force. It is mainly used to simulate the influence of the battery on the structure, performance and safety of the battery under the impact of external force.

[0116] The impact unit includes a power mechanism, an adjusting mechanism for adjusting the position and / or angle of the power mechanism, a plate impact head and / or a spike impact head connected to the output end of each power mechanism. In actual application, the power mechanism is used to generate an impact force, and the adjusting mechanism is used to adjust the impact angle to 0-90°. In actual application, the control module can monitor the impact force and impact depth in real time through the pressure sensor and displacement sensor, and the built-in closed-loop control algorithm is used to control the impact force control accuracy within ±5 N and the action time control accuracy ≤0.1 s.

[0117] Further, as shown in Figure 4 The data acquisition module includes:

[0118] Voltage sensor 400, current sensor 401, and power sensor 402 are connected with the fuel cell collection harness to detect the voltage, current, and power of the hydrogen fuel cell in real time, wherein the sampling frequency of the voltage sensor, current sensor, and power sensor is 1 kHz, which is used to capture the voltage, current, and power changes of the battery in normal working state, at the moment of vibration and impact, and after impact;

[0119] Gas flow sensor 403 and gas pressure sensor 404 are arranged on the gas inlet pipeline to detect the flow and pressure of hydrogen and oxygen in real time;

[0120] Temperature and humidity sensor 405 is arranged in the test chamber to detect the temperature and humidity of the test environment in real time;

[0121] Infrared camera and / or industrial camera 406 is arranged in the test chamber, and in actual application, the camera can be used as an auxiliary detection device for battery structure deformation, such as a high-definition camera with a resolution of 12 million pixels and a frame rate of 100 fps, to clearly record the deformation and crack generation process of the battery surface;

[0122] Hydrogen sensor 407 is arranged in the test chamber, which monitors the hydrogen concentration in the test chamber in real time by installing the hydrogen sensor to ensure the safety of the test chamber operation by setting an alarm threshold (such as 0.1% volume concentration triggering warning);

[0123] Stress sensor 408, pressure sensor 409, and displacement sensor 410 are arranged at multiple positions on the surface of the fuel cell to be tested to detect the structural deformation of the battery. The stress sensor is used to detect the structural deformation of the battery in real time, and its measurement range can be set to 0-1000 MPa with an accuracy of ±1 MPa to detect the stress distribution inside the battery. The pressure sensor and displacement sensor are used to monitor the impact force and impact depth in real time. In this scheme, high-precision sensors are used to accurately detect various parameters of the hydrogen fuel cell, ensuring the accuracy of the test results, and enabling the control module to accurately control the gas flow, pressure, and reaction module temperature and humidity, providing a stable test environment for the fuel cell;

[0124] Noise sensor 411 is arranged in the test chamber to detect the operating noise of the hydrogen fuel cell, which is used to detect the operating noise of the hydrogen fuel cell in ordinary environment, high heat, high humidity, and other working conditions in real time, so as to optimize the design parameters of the hydrogen fuel cell, such as gas flow and sound absorption of equipment structure, in the later stage.

[0125] The scheme can detect the voltage, current, power, efficiency, gas flow, pressure, temperature and other parameters of the hydrogen fuel cell at the same time through the setting of multiple sensors, comprehensively reflect the performance of the fuel cell, and design various test working conditions by controlling the temperature and humidity in the test cavity, the flow and pressure of hydrogen and oxygen to meet different test requirements.

[0126] Further, as shown in Figure 5 the external control center also includes a virtual simulation module 63 for simulating the working environment of the hydrogen fuel cell;

[0127] The simulation module is connected with the data processing module and the control module, and is used for constructing a digital model of the hydrogen fuel cell, performing virtual working condition simulation and virtual-real data interaction.

[0128] The simulation module includes a three-dimensional modeling unit 630, a physical field simulation unit 631, a working condition simulation unit 632, a data interaction unit 633, a material attribute database 634, and an impact simulation unit 635.

[0129] The three-dimensional modeling unit is used for constructing a fuel cell geometric model and an internal structure model consistent with the actual object.

[0130] The physical field simulation unit is used for simulating the physical processes of electrochemical reaction, heat transfer and mass transfer inside the battery. -6 A / cm 2 ;

[0131] The working condition simulation unit is used for setting virtual environment parameters to generate diversified virtual test working conditions.

[0132] The data interaction unit is used for realizing real-time transmission and associated storage of simulation data and actual test data.

[0133] The material attribute database is used for storing material mechanical property parameters of each component of the battery, and the material mechanical property parameters include parameters such as elastic modulus, Poisson's ratio and yield strength of various materials such as carbon fibers, metals and proton exchange membranes, and support parameter calling and modification according to different battery models;

[0134] The impact simulation unit adopts an explicit finite element analysis software to simulate the dynamic response of the battery during the impact process, and the calculation accuracy reaches 10-3 mm of the deformation amount

[0135] The control module cooperates with the simulation controller, the simulation controller is used for receiving virtual parameter instructions of the simulation simulation module, and the virtual parameter instructions are converted into physical test parameters executable by the PLC controller, and the control module adopts the PLC controller to realize automatic control of the test process, so as to reduce manual operation and improve test efficiency.

[0136] An application method of a hydrogen fuel cell test system, including a working capacity test of a hydrogen fuel cell and a working environment test of the hydrogen fuel cell, the working capacity test process including:

[0137] System initialization: check whether each module is working normally, such as whether the valve of the hydrogen supply module can normally open and close, whether the sensor of the detection module is sensitive, etc., initialize the control module, the data acquisition module and the data processing module, and ensure that each module is in a normal working state;

[0138] Install the fuel cell: install the hydrogen fuel cell to be tested in the corresponding test cavity, fix the hydrogen fuel cell through the clamp, and ensure tight connection to avoid poor contact affecting the test result, connect the fuel cell with the external load, in actual application, the load can be connected to perform working condition test under voltage cycle (0.6V-0.9V) to evaluate long-term running stability, and the start-stop cycle test under actual working condition can also be simulated to record the performance degradation rate;

[0139] Set the test parameters: set the flow and pressure of hydrogen and oxygen, the rated temperature and humidity of the test cavity, and the test time through the control module, and set multiple test working conditions according to different test requirements, such as different gas flow, pressure, temperature and humidity combinations, to comprehensively evaluate the performance of the fuel cell under different conditions;

[0140] Start the test: the control module controls the hydrogen supply module and the oxygen supply module to supply hydrogen and oxygen to the test cavity, and the hydrogen fuel cell starts to generate electrochemical reaction to generate electric energy;

[0141] Data detection and collection: The data collection module detects various parameters in the hydrogen fuel cell reaction process in real time, such as voltage, current, power, gas flow, pressure, temperature, etc., and transmits the data to the external control center through the data acquisition card;

[0142] Data processing and analysis: The data processing software of the external control center processes and analyzes the collected data, such as calculating the efficiency of the fuel cell, drawing the voltage-current curve, power-current curve, efficiency curve, etc., generating a test report, which includes the performance parameters of the fuel cell and the trend of the parameters, etc., providing detailed test results for the user;

[0143] End of test: After the test time reaches the set value, the control module controls each supply module to stop gas supply, the hydrogen fuel cell stops reaction, the tested hydrogen fuel cell is removed, the system is closed, and the whole test process is completed.

[0144] Further, the working environment test includes: using physical objects and simulation to synchronously test the temperature and / or humidity in the working environment of the hydrogen fuel cell according to the standard test, and the process includes:

[0145] S01, system initialization and model construction: obtaining the physical parameters of each module under the current working state, and constructing a digital model of the hydrogen fuel cell through a three-dimensional modeling unit of the simulation module;

[0146] S02, virtual working condition setting: setting at least three groups of different virtual test parameters I in the simulation module through a working condition simulation unit, the virtual test parameters I including material properties, structure parameters, virtual environment temperature and / or humidity, and gas flow pressure;

[0147] S03, physical test parameter matching: the simulation controller automatically matches the gas flow pressure of the hydrogen supply unit and the oxygen supply unit and the operating parameters of the test chamber based on the virtual test parameters I, and the execution module controls the temperature and humidity inside the test chamber based on the operating parameters;

[0148] S04, synchronous test: the simulation module directly performs virtual testing based on the virtual test parameters I to obtain simulation data I, while the PLC controller starts the physical test process based on the physical test parameters output by the simulation controller, the data collection module synchronously collects to obtain physical test data I, and the physical test data I is stored through the data interaction unit. In actual operation, the simulation model and the physical test are started synchronously, the simulation module outputs current density distribution every 0.1s, the physical data collection module synchronously records the voltage of the single cell, and the data interaction unit realizes bidirectional data marking (such as time stamp error ≤1ms);

[0149] S05, data interaction and analysis: the data processing module calls the physical test data I and the simulation data I from the data interaction unit for comparative analysis and calculation of deviation rate. Meanwhile, the data processing module can also generate three-dimensional comparison maps, such as virtual and real temperature field cloud map superposition analysis, identify the correlation rule of "virtual high temperature area-real low voltage point" through machine learning, and output the impact factor ranking (such as flow channel structure> humidity> pressure);

[0150] S06, model iteration optimization: adjust the physical field parameters and model boundary conditions of the simulation module according to the deviation rate, and repeat steps S02-S05 until the virtual and real test data error is ≤5%;

[0151] S07, test report generation: integrate all test data and analysis results to generate a comprehensive test report containing virtual-real performance mapping relationship and key parameter sensitivity analysis.

[0152] In this scheme, when the system is working, first, a digital model of the hydrogen fuel cell consistent with the real object is constructed by the simulation module, the three-dimensional modeling unit imports the fuel cell design drawing to generate a geometric model, and the physical field simulation unit assigns the model material properties (such as proton exchange membrane conductivity 0.1 S / cm) and reaction parameters. The simulation controller receives the virtual working condition parameters (such as -20°C start, hydrogen purity 99.97%) output by the simulation module, and converts the virtual working condition parameters into real test instructions: the hydrogen supply unit stabilizes the pressure at 3 bar through the pressure reducing valve, the oxygen supply unit controls the dew point to -40°C through the dryer, and the temperature control device of the test cavity quickly responds to the set value. In the real test, the sensors (sampling frequency 1 kHz) of the data acquisition module collect parameters such as membrane electrode temperature and output voltage in real time; the simulation module outputs simulation results such as virtual current density distribution and water flooding area ratio simultaneously. The data processing module performs time and space alignment through data fusion, for example, correlates and analyzes the 5s transient power fluctuation of the real test with the flow field distribution change of the simulation, and identifies the flow channel design defects. When the deviation between virtual and real data exceeds the threshold value (default 5%), the control module automatically triggers model calibration: according to the data measured by the real object, the related parameters in the simulation are corrected (such as based on the activation overpotential measured by the real object, the exchange current density parameter in the simulation is corrected until the deviation converges), until the deviation converges. This closed-loop process can achieve engineering application precision within 10 iterations.

[0153] Further, the working environment test further includes: a non-standard test I for impact in the working environment of the hydrogen fuel cell using real object and simulation for asynchronous test, and the working process of the non-standard test I includes:

[0154] S11, system initialization: check whether each module is working normally, initialize and set the control module, data interaction unit and data analysis module, establish the associated parameters of physical test and simulation simulation, such as checking whether the power mechanism and adjusting mechanism of the impact unit are running normally, whether the sensor of the data acquisition module is sensitive, whether the software of the simulation simulation module is normally started, whether the network connection of the data interaction module is smooth, initializing the parameters of the control module, setting the data storage path, test number and the like; configuring the data processing module, selecting appropriate comparative analysis algorithm and damage evaluation model;

[0155] S12, model construction and parameter setting: constructing a hydrogen fuel cell digital model through a three-dimensional modeling unit of a simulation simulation module (in the three-dimensional modeling unit of the simulation simulation module, a three-dimensional model containing all components is constructed by importing design drawings of the hydrogen fuel cell, and the model is meshed, and the mesh size is 1-5 mm.), importing material attribute parameters (such as the elastic modulus of the stainless steel material used by the bipolar plate is 200 GPa, and the Poisson's ratio is 0.3) from a material attribute database; setting virtual test parameters II through a working condition simulation unit, the virtual test parameters II including: impact parameters of the impact unit, virtual environment temperature and / or humidity, gas flow pressure, and asynchronous time difference and test sequence of physical test and simulation simulation, the impact parameters including impact force, angle, and action time, such as setting impact force to 500-4000 N, impact angle to 15°-75°, and action time to 0.2-1 s; setting asynchronous parameters, such as asynchronous time difference to 25 s, and test sequence to simulation first and then physical test;

[0156] S13, simulation simulation: starting the simulation simulation module, simulating the battery response and external structure change under the corresponding impact parameters based on the hydrogen fuel cell digital model to obtain simulation data II, the simulation data II being stored through the data interaction unit, and evaluating the safety factor of the hydrogen fuel cell under the corresponding impact parameters through the data analysis module, if the safety factor is within a predetermined threshold range, then entering S14, otherwise returning to S12 to reset the impact parameters, the simulation unit simulating the battery response under the set impact parameters based on the three-dimensional model, calculating the stress distribution cloud picture at different times, the deformation amount-time curve and the simulation values of voltage and current, the simulation step being 0.01 s, the simulation data II being transmitted to the data interaction module in real time, through this simulation test, the acting force in the impact will not exceed the predetermined impact resistance of the test cavity, ensuring safety;

[0157] S14, physical impact test: according to the set asynchronous parameters, after simulation, the control module controls the impact unit to apply impact to the physical hydrogen fuel cell according to the set impact parameters, the data acquisition module synchronously detects the performance parameters and structural state during and after the impact, and stores the data through the data interaction unit; the performance detection sensor of the data acquisition module records the voltage, current and power change curves before, during and after the impact in real time; a high-definition camera shoots the surface image of the battery, and a stress sensor records the internal stress change to obtain physical test data II, and the physical test data II is stored through the data interaction unit;

[0158] S15, data interaction and analysis: the data processing module calls the physical test data II and simulation data II from the data interaction unit for comparative analysis, calculates the deviation rate to evaluate the performance decay and structural damage of the battery after impact, and the data interaction module adds time stamps to the simulation data and physical test data and stores them in association according to the test number. After calling the data, the data analysis module compares the stress peak value of the physical test with the simulation result, calculates the deviation rate, and if the deviation rate exceeds 1%, it is marked as a key analysis item; compare the deformation of different structures under the same impact force or the deformation of the same structure under different impact forces, draw the comparative curve of the deformation under different conditions; combined with the performance parameter decay situation, such as 20% power drop and 5mm crack length detected by the structure, determine the battery as moderate damage through the damage evaluation model; the specific damage degree can be selected according to different types of batteries;

[0159] S16, model iteration optimization: according to the analysis result, adjust the impact parameters or model parameters, repeat steps S12-S15 until the error between virtual and physical test data is ≤1%; according to the data analysis result, if the simulation and physical data deviation is large, adjust the material property parameters in the simulation module, such as adjusting the elastic modulus of the membrane electrode from 3GPa to 2.8GPa; if more extreme impact conditions need to be tested, increase the impact force to 4500N, repeat steps S12-S15 for a new round of asynchronous test;

[0160] S17, test report generation: integrate all test data and analysis results to generate a test report containing battery impact resistance performance evaluation and structural weak point analysis, the test report contains test parameter setting, physical test and simulation data comparison table, stress distribution comparison chart, deformation comparison curve, damage level evaluation result, etc., points out the structural weak point of the battery, such as stress concentration at the edge of the bipolar plate, and puts forward optimization suggestions, such as increasing the edge radius.

[0161] Working principle: When the system is working, first, the control module is initialized to set up the associated parameters of the real battery test and simulation, such as battery model, test standard, etc. The three-dimensional modeling unit of the simulation module constructs an accurate three-dimensional model according to the real battery parameters, and calls the corresponding material parameters from the material attribute database to complete the model initialization.

[0162] The control module sets the impact parameters (such as impact force 3000N, angle 45°, action time 0.5s) and asynchronous test parameters (such as first simulation, and within the safety index in the rated load range of the test chamber, set a predetermined time (such as 10s-60s) to perform real battery test) according to the user's settings, and sends instructions to each module.

[0163] The impact simulation unit of the simulation module simulates the stress distribution, deformation and performance change process of the battery under the set impact parameters based on the three-dimensional model, and the simulation data II is stored in real time through the data interaction module.

[0164] At the set asynchronous time point, the control module starts the impact unit, which applies impact to the real battery according to the set impact force, angle and action time under the control of the control module; at the same time, the corresponding performance detection sensors (such as voltage sensor, current sensor, power sensor, noise sensor, etc.) and structure detection mechanisms (such as infrared camera and / or industrial camera, stress sensor, pressure sensor, displacement sensor, etc.) of the data acquisition module work synchronously, collect the performance parameters such as voltage, current and power and the state data such as structure deformation and crack during and after the impact, and transmit them to the data interaction module for storage.

[0165] The data interaction module timestamps and stores the real test data and simulation data for the data analysis module to call. After the data analysis module extracts the data from the data interaction module, it uses comparative analysis algorithm to compare the stress value and deformation obtained by real test with the simulation results, calculates the deviation rate; through the damage evaluation model, combined with performance degradation data and structure damage data, the damage level of the battery is evaluated.

[0166] According to the data analysis results, the control module can automatically or manually adjust the impact parameters or model parameters, and perform multiple rounds of asynchronous test iteration to obtain satisfactory test results. The whole process realizes the asynchronous cooperation of real test and simulation, which not only guarantees the authenticity of the test, but also expands the coverage range of the test working condition.

[0167] The scheme can flexibly arrange the execution rhythm of physical testing and simulation according to actual needs, avoid the conflict between the two in time, and improve the utilization rate of the test equipment; further, the test method combines the authenticity of physical testing and the flexibility of simulation, can cover various impact working conditions from normal to extreme, such as high impact force and special angle impact, provides comprehensive data support for battery anti-impact performance evaluation, at the same time, through the correlation storage and analysis of physical test data II and simulation data II, the difference between the two can be clearly compared, which provides basis for correcting the simulation model and improving the simulation accuracy, and also verifies the accuracy of physical testing, further, compared with pure physical testing, the test method reduces a large number of repeated physical test times, reduces the test cost and period; compared with separate simulation, the reliability of the test result is improved, which provides an efficient and accurate test method for structure optimization and safety design of hydrogen fuel cells.

[0168] Further, the working environment test further comprises a non-standard test II for testing external vibration in the working environment of the hydrogen fuel cell, and a working process of the non-standard test II comprises:

[0169] S21, system initialization and model building: obtaining physical parameters of each module in the current working state, and building a digital model of the hydrogen fuel cell through a three-dimensional modeling unit of the simulation simulation module;

[0170] S22, virtual working condition setting: setting virtual test parameters III in the simulation simulation module, including material properties, structure parameters, virtual environment temperature and / or humidity, gas flow pressure, vibration parameters, and generating at least three groups of differentiated virtual test working condition parameters, which can cover a reduction of 60% of the physical test amount according to needs, so that the research and development period or the test period is shortened by 40%;

[0171] S23, physical test parameter matching: the simulation controller automatically matches the gas flow pressure of the hydrogen supply unit and the oxygen supply unit and the operating parameters of the test cavity based on the virtual test parameters III, and the execution module adjusts the temperature and humidity inside the test cavity based on the operating parameters, and sets the working parameters of the vibration unit;

[0172] S24, synchronous testing: the simulation simulation module directly performs virtual testing based on the virtual test parameters III to obtain simulation data III, while the PLC controller starts the physical test process based on the physical test parameters output by the simulation controller, the data acquisition module synchronously collects to obtain physical test data III, and the physical test data III is stored through the data interaction unit;

[0173] S25, data interaction and analysis: the data processing module calls the physical test data III and the simulation data III from the data interaction unit, performs comparative analysis, and calculates the deviation rate;

[0174] S26, model iteration optimization: according to the deviation factor, the physical field parameters of the simulation simulation module and the model boundary conditions are adjusted, and steps S02-S05 are repeated until the virtual and real test data error is less than or equal to 3%, through real data closed loop calibration, the control simulation result and the measured value deviation is less than or equal to 3%;

[0175] S27, test report generation: integrate the simulation data and the real test data after optimization, generate a comprehensive test report containing virtual-real performance mapping relationship, key parameter sensitivity analysis, in the present application, the simulation model and the real test are started simultaneously, the simulation simulation module outputs current density distribution every 0.1s, the real data acquisition module synchronously records the single battery voltage, the data interaction unit realizes bidirectional data marking (such as time stamp error is less than or equal to 1ms), in order to detect the influence on the battery performance under the vibration condition, and the working principle of the battery performance detection under the vibration condition is consistent with the previous standard test, so it is not described.

[0176] Similarly, in actual application, a plurality of corresponding pressure sensors and the like can also be arranged on the inner side wall of the test cavity, so as to set different water pressures and different water depths when carrying out water immersion test (that is, after the battery is completely submerged in water, the battery performance test), through this test, the influence of different immersion time on the battery performance after the battery is partially or completely submerged in water is tested, and the test process is consistent with the vibration test, which is not described here.

[0177] Through the method of the present application, various extreme use environments and working modes encountered by the battery during design or factory delivery of the battery are simulated and measured, and a series of performance simulation and measurement data are provided, which provides more accurate reference data for later structure and performance optimization.

[0178] The above scheme is only a description of a preferred example, but is not limited thereto. In the implementation of the present application, appropriate replacement and / or modification can be made according to the user's needs.

[0179] Although the embodiments of the present application have been disclosed as above, it is not limited to the application listed in the specification and the embodiments. It can be fully applied to various fields suitable for the present application. Additional modifications can be easily realized by those skilled in the art. Therefore, the present application is not limited to specific details and the figures shown and described herein without departing from the general concept defined by the claims and the equivalent scope.

Claims

1. A hydrogen fuel cell testing system, characterized in that, include: The testing chamber contains multiple test chambers for placing the hydrogen fuel cells to be tested. Multiple fuel cell acquisition harnesses are connected to the output terminals of the hydrogen fuel cells under test in each test chamber. A gas supply module installed outside the test room to supply hydrogen and oxygen to each hydrogen fuel cell under test; The load is set outside the test room and connected to each hydrogen fuel cell under test. A data acquisition module used to collect environmental information within each test chamber; Execution modules are installed in each chamber to simulate the working environment; An external control center that communicates with the gas supply module, load, data acquisition module, and execution module; The external control center is equipped with a data acquisition card, a data processing module that processes, analyzes and stores the data output by the data acquisition card, and a control module that configures the working parameters and working status of the gas supply circulation module and the execution module.

2. The hydrogen fuel cell testing system as described in claim 1, characterized in that, Each test chamber is configured to include: the gas supply and circulation module includes: a hydrogen supply unit, a hydrogen circulation unit, an oxygen supply unit, an oxygen circulation unit, and a neutralization unit; The hydrogen supply unit and oxygen supply unit both include: a gas source and an intake pipe that connects the gas source to the inlet of the anode or cathode of the fuel cell. The intake pipe is equipped with a filter I or dryer I, a mass flow meter, a pressure reducing valve, a pressure regulating valve and an intake valve. The hydrogen circulation unit and oxygen circulation unit both include: a buffer tank and an exhaust pipe connecting the buffer tank to the anode or cathode outlet of the fuel cell. The exhaust pipe is equipped with a gas collecting valve, a filter II or a dryer II. Each buffer tank is connected to the inlet side of the corresponding mass flow meter through a corresponding branch I. Each branch I is equipped with a control valve. The hydrogen circulation unit and the oxygen circulation unit are connected to the neutralization unit through corresponding branch II. Each branch II is equipped with a corresponding emergency exhaust valve and a corresponding control valve II.

3. The hydrogen fuel cell testing system as described in claim 2, characterized in that, Each test chamber is equipped with a test platform for placing hydrogen fuel cells, and the test platform is equipped with clamps for fixing the hydrogen fuel cells.

4. The hydrogen fuel cell testing system as described in claim 3, characterized in that, The execution module includes: Heating and / or cooling units used to simulate external ambient temperature; Humidification unit used to simulate the humidity of the external environment; A vibration unit installed below the test bench to simulate external environmental disturbances; Impact unit positioned above the test bench to simulate external impact forces; The impact unit includes a power mechanism, an adjustment mechanism for adjusting the position and / or angle of the power mechanism, and a plate-type impact head and / or a spike-type impact head connected to the output end of each power mechanism.

5. The hydrogen fuel cell testing system as described in claim 4, characterized in that, The data acquisition module includes: Voltage sensors, current sensors, and power sensors are connected to the fuel cell acquisition harness to monitor the voltage, current, and power of the hydrogen fuel cell in real time. Gas flow sensor and gas pressure sensor installed on the intake pipe to detect the flow rate and pressure of hydrogen and oxygen in real time; A temperature and humidity sensor installed inside the test chamber to monitor the ambient temperature and humidity in real time during the test; Infrared cameras and / or industrial cameras installed inside the test chamber; Stress sensors, pressure sensors, and displacement sensors are installed at multiple locations on the surface of the fuel cell under test to detect structural deformation of the cell. A noise sensor is installed inside the test chamber to detect the operating noise of the hydrogen fuel cell.

6. The hydrogen fuel cell testing system as described in claim 1, characterized in that, The external control center also includes a virtual simulation module for the working environment of the hydrogen fuel cell; The simulation module is connected to the data processing module and the control module, and is used to construct a digital model of the hydrogen fuel cell, perform virtual operating condition simulation and virtual-real data interaction. The simulation module includes a 3D modeling unit, a physics field simulation unit, a working condition simulation unit, a data interaction unit, a material property database, and an impact simulation unit. The three-dimensional modeling unit is used to construct a geometric model and internal structure model of the fuel cell that are consistent with the actual object. The physical field simulation unit is used to simulate the physical processes of electrochemical reactions, heat transfer, and mass transfer inside the battery. The operating condition simulation unit is used to set virtual environment parameters and generate diverse virtual test conditions. The data interaction unit is used to realize the real-time transmission and associated storage of simulation data and physical test data; The material property database is used to store the material mechanical property parameters of each component of the battery; The control module employs a PLC controller and a simulation controller working together. The simulation controller receives virtual parameter instructions from the simulation module and converts them into physical test parameters that can be executed by the PLC controller.

7. A method for applying the hydrogen fuel cell testing system as described in any one of claims 1-6, characterized in that, This includes performance testing of hydrogen fuel cells and testing of their operating environment. The performance testing process includes: System initialization: Check whether each module is working properly, and initialize the control module, data acquisition module, and data processing module; Installing the fuel cell: Install the hydrogen fuel cell to be tested in the corresponding test chamber, fix the hydrogen fuel cell with clamps and ensure a tight connection, and connect the fuel cell to the external load; Set test parameters: Set the flow rate and pressure of hydrogen and oxygen, the temperature and humidity of the test chamber, and the test time through the control module; Start-up test: The control module controls the hydrogen supply module and oxygen supply module to supply hydrogen and oxygen to the test chamber, and the hydrogen fuel cell begins to undergo an electrochemical reaction; Data detection and acquisition: The data acquisition module monitors various parameters and operating noise during the hydrogen fuel cell reaction process in real time, and transmits the data to the external control center through the data acquisition card; Data processing and analysis: The data processing software in the external control center processes and analyzes the collected test data and generates test reports; End of test: After the test time reaches the set value, the control module controls each supply module to stop supplying gas, removes the hydrogen fuel cell after the test, and shuts down the system.

8. The application method of the hydrogen fuel cell testing system as described in claim 7, characterized in that, The working environment testing includes: standard testing of temperature and / or humidity in the hydrogen fuel cell working environment using both physical samples and simulations, the process of which includes: S01. System initialization and model construction: Obtain the physical parameters of each module under the current working state, and construct the digital model of the hydrogen fuel cell through the three-dimensional modeling unit of the simulation module; S02, Virtual Working Condition Setting: In the simulation module, at least 3 sets of differentiated virtual test parameters I are set through the working condition simulation unit. Virtual test parameters I include material properties, structural parameters, virtual ambient temperature and / or humidity, and gas flow rate and pressure. S03, Physical test parameter matching: The simulation controller automatically matches the gas flow rate and pressure of the hydrogen supply unit and oxygen supply unit of the physical test, as well as the operating parameters of the test chamber, based on the virtual test parameter I. The execution module regulates the temperature and humidity inside the test chamber based on the operating parameters. S04. Synchronous Testing: The simulation module performs virtual testing directly based on virtual test parameters I to obtain simulation data I. At the same time, the PLC controller starts the physical testing process based on the physical test parameters output by the simulation controller. The data acquisition module synchronously acquires the physical test data I and stores the physical test data I through the data interaction unit. S05, Data Interaction and Analysis: The data processing module calls physical test data I and simulation data I from the data interaction unit, performs comparative analysis, and calculates the deviation rate; S06. Model Iteration Optimization: Adjust the physical field parameters of the simulation module and the boundary conditions of the model according to the deviation rate, and repeat steps S02-S05 until the error between the virtual and physical test data is ≤5%. S07. Test Report Generation: Integrate all test data and analysis results to generate a comprehensive test report that includes virtual-real performance mapping and sensitivity analysis of key parameters.

9. The application method of the hydrogen fuel cell testing system as described in claim 8, characterized in that, The working environment testing also includes: Non-standard Test I, which involves asynchronous testing of impacts in the hydrogen fuel cell working environment using physical objects and simulations. The workflow of Non-standard Test I includes: S11. System initialization: Check whether each module is working properly, initialize the control module, data interaction unit and data analysis module, and establish the correlation parameters between physical testing and simulation. S12. Model Construction and Parameter Setting: A digital model of the hydrogen fuel cell is constructed through the 3D modeling unit of the simulation module, and material property parameters are imported from the material property database; virtual test parameters II are set through the working condition simulation unit. The virtual test parameters II include: impact parameters of the impact unit, virtual ambient temperature and / or humidity, gas flow rate and pressure, and asynchronous time difference and test sequence between physical testing and simulation. The impact parameters include impact force magnitude, angle, and action time. S13. Simulation: The simulation module performs virtual testing directly based on virtual test parameters II to simulate the battery response and external structural changes of the hydrogen fuel cell digital model under the corresponding impact parameters, and obtains simulation data II. The simulation data II is stored through the data interaction unit and the safety factor of the hydrogen fuel cell under the corresponding impact parameters is evaluated by the data analysis module. If the safety factor is within the predetermined threshold range, proceed to S14; otherwise, return to S12 to reset the impact parameters. S14. Physical Impact Test: Based on the set asynchronous parameters, after simulation, the control module controls the impact unit to apply an impact to the physical hydrogen fuel cell according to the set impact parameters. The data acquisition module synchronously detects the impact process and the performance parameters and structural state after the impact to obtain physical test data II, and stores the physical test data II through the data interaction unit. S15. Data Interaction and Analysis: The data processing module calls physical test data II and simulation data II from the data interaction unit, performs comparative analysis, and calculates the deviation rate to evaluate the battery's performance degradation and structural damage after impact. S16. Model Iteration Optimization: Based on the analysis results, adjust the impact parameters or model parameters, and repeat steps S12-S15 until the error between virtual and physical test data is ≤1%. S17. Test Report Generation: Integrate all test data and analysis results to generate a test report that includes battery impact resistance performance evaluation and structural weak point analysis.

10. The application method of the hydrogen fuel cell testing system as described in claim 8, characterized in that, The working environment test also includes: a non-standard test II for testing external vibrations in the working environment of the hydrogen fuel cell. The workflow of the non-standard test II includes: S21. System initialization and model construction: Obtain the physical parameters of each module under the current working state, and construct the digital model of the hydrogen fuel cell through the three-dimensional modeling unit of the simulation module; S22. Virtual working condition setting: Set at least 3 sets of differentiated virtual test parameters Ⅲ in the simulation module, including material properties, structural parameters, virtual ambient temperature and / or humidity, gas flow and pressure, and vibration parameters; S23. Physical test parameter matching: The simulation controller automatically matches the gas flow rate and pressure of the hydrogen supply unit and oxygen supply unit of the physical test, as well as the operating parameters of the test chamber, based on the virtual test parameter Ⅲ. The execution module regulates the temperature and humidity inside the test chamber based on the operating parameters, and sets the working parameters of the vibration unit at the same time. S24. Synchronous Testing: The simulation module performs virtual testing directly based on virtual test parameters III to obtain simulation data III. At the same time, the PLC controller starts the physical testing process based on the physical test parameters output by the simulation controller. The data acquisition module synchronously acquires the physical test data III and stores the physical test data III through the data interaction unit. S25. Data Interaction and Analysis: The data processing module calls physical test data III and simulation data III from the data interaction unit, performs comparative analysis, and calculates the deviation rate. S26. Model Iteration Optimization: Adjust the physical field parameters of the simulation module and the boundary conditions of the model according to the deviation factor, and repeat steps S22-S25 until the error between the virtual and physical test data is ≤3%. S27. Test Report Generation: Integrate the optimized simulation data and physical test data to generate a comprehensive test report that includes the virtual-real performance mapping relationship and sensitivity analysis of key parameters.

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