A one-way valve combined hydrogen storage system durability test bench and test method

Abstract

The application relates to the technical field of hydrogen storage system testing, and discloses a one-way valve combined hydrogen storage system durability test bench and a testing method. A main control computer of the bench is used for configuring test task parameters, coordinating operation of each subsystem, and processing test data; a high-pressure hydrogen gas supply subsystem contains an adjustable pressure hydrogen gas source and a pressure closed-loop control module, can apply accurate controllable hydrogen gas pressure to an inlet end of a measured system according to test task parameters; a multichannel valve state acquisition subsystem acquires valve inlet and outlet pressure, valve body surface temperature and vibration spectrum data in real time through a pressure, temperature and vibration sensor array arranged at each valve, and transmits the data to the main control computer; a valve action driving subsystem contains a high-speed electromagnetic actuator array and a displacement feedback module, and can drive each valve to execute a preset opening degree sequence and opening and closing frequency; and a durability evaluation subsystem is embedded in the main control computer, calculates valve cumulative damage degree, and predicts a remaining service life.

Description

Technical Field

[0001] This invention relates to the field of hydrogen storage system testing technology, specifically to a durability test bench and testing method for a one-way valve combined hydrogen storage system. Background Technology

[0002] In the process of energy transition, hydrogen storage technology, as an important component of the hydrogen energy industry chain, has attracted much attention regarding its safety and stability. One-way valve assemblies, as key components controlling the direction of hydrogen flow within hydrogen storage systems, play an irreplaceable role in scenarios such as hydrogen tank charging / discharging cycles and pipeline pressure regulation by restricting reverse hydrogen flow and preventing abnormal pressure fluctuations within the system. As hydrogen storage systems develop towards higher pressure and greater integration, one-way valve assemblies need to operate for extended periods under frequent charging / discharging cycles, complex pressure changes, and temperature fluctuations; their durability directly affects the overall operational status of the hydrogen storage system.

[0003] Existing durability testing equipment for one-way valve assemblies often employs fixed pressure or simple stepped pressure regulation modes during the pressure application phase. This makes it difficult to simulate the dynamic changes in hydrogen pressure under actual operating conditions, such as the instantaneous high-pressure impact during hydrogen charging and the slow pressure drop during hydrogen release. In terms of sensor placement, the focus is often on pressure parameter acquisition, with less attention paid to parameters related to material fatigue, such as valve body surface temperature changes and vibration characteristics. This results in the inability to detect potential problems such as material performance degradation caused by temperature increases and structural loosening caused by vibration and impact.

[0004] Regarding valve actuation, traditional devices mostly rely on mechanical transmission for opening and closing control, resulting in slow response speeds. This makes it difficult to reproduce the complex sequence of high-frequency, multi-opening actions in actual use, leading to discrepancies between valve actuation in tests and actual operating conditions. Furthermore, durability assessments are often completed after the test by disassembling the valve, observing its appearance, and measuring dimensional changes. This approach cannot track damage accumulation during the test in real time and fails to reflect the damage evolution patterns at different stages.

[0005] These factors make it difficult for test results to fully reflect the durability performance of one-way valve assemblies under long-term complex operating conditions, thus failing to provide sufficient test evidence for the design optimization of hydrogen storage systems. As the application scenarios of hydrogen storage systems expand, the testing requirements for the durability of one-way valve assemblies are becoming increasingly diverse, and existing devices are no longer suitable for new testing scenarios. Summary of the Invention

[0006] The purpose of this invention is to provide a durability test bench for a one-way valve combined hydrogen storage system to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides a durability test bench for a one-way valve combined hydrogen storage system, the bench comprising:

[0008] The main control computer is used to configure test task parameters, coordinate the operation of various subsystems, and process test data.

[0009] The high-pressure hydrogen supply subsystem, connected to the main control computer, includes an adjustable hydrogen source and a pressure closed-loop control module, used to apply precise and controllable hydrogen pressure to the inlet of the tested one-way valve combination hydrogen storage system according to the test task parameters.

[0010] The multi-channel valve status acquisition subsystem includes pressure sensor arrays, temperature sensor arrays, and vibration sensor arrays arranged at each valve of the tested one-way valve combination hydrogen storage system. It is used to acquire valve inlet pressure value, outlet pressure value, valve body surface temperature value, and vibration spectrum data in real time, and transmit the acquired data to the main control computer in real time.

[0011] The valve action drive subsystem, connected to the main control computer, includes a high-speed electromagnetic actuator array and a displacement feedback module, used to drive each valve in the tested one-way valve combination hydrogen storage system to execute a preset opening sequence and opening and closing frequency according to the test task parameters.

[0012] The durability assessment subsystem, embedded in the main control computer, is used to receive real-time data transmitted by the multi-channel valve status acquisition subsystem, combine it with valve drive history records, calculate the cumulative damage degree of the valve, and predict the remaining life cycle.

[0013] Preferably, the high-pressure hydrogen supply subsystem includes:

[0014] A high-pressure hydrogen storage container is connected to a hydrogen pressurization device via a pressure reducing valve assembly.

[0015] The hydrogen booster device is equipped with a dynamic pressure regulating valve and a high-precision pressure transmitter at the output end.

[0016] The pressure closed-loop control module receives the target pressure command issued by the main control computer, reads the measured pipeline pressure value collected by the high-precision pressure transmitter in real time, and dynamically adjusts the opening of the dynamic pressure regulating valve through a proportional-integral-derivative algorithm to ensure that the measured pipeline pressure value stably tracks the target pressure command.

[0017] Preferably, the multi-channel valve status acquisition subsystem includes:

[0018] Distributed data acquisition units are deployed at each installation station of the valve being tested.

[0019] The pressure sensor array includes a first pressure sensor installed on the valve inlet flange and a second pressure sensor installed on the valve outlet flange, which respectively collect inlet pressure values ​​and outlet pressure values;

[0020] A temperature sensor array, including thin-film thermocouples attached to the outer wall of the valve body, collects the surface temperature value of the valve body;

[0021] A vibration sensor array, including a magnetically adsorbed accelerometer, is fixed to the pressure-bearing housing of the valve body to collect three-dimensional vibration acceleration data;

[0022] The signal conditioning module amplifies, filters, and performs analog-to-digital conversion on the raw signals output by the pressure sensor array, temperature sensor array, and vibration sensor array, generating standardized digital signals that are then uploaded to the main control computer.

[0023] Preferably, the valve actuation drive subsystem includes:

[0024] The servo motor drive module receives the valve opening command curve issued by the main control computer;

[0025] The planetary reduction mechanism has its input end connected to the output shaft of the servo motor drive module.

[0026] The linear actuator, comprising a ball screw pair and a displacement feedback encoder, converts the rotational motion of the planetary reduction mechanism into linear displacement, thereby driving the valve core to move.

[0027] The displacement closed-loop control module reads the actual displacement value of the valve core measured by the displacement feedback encoder in real time, compares it with the valve opening command curve, and adjusts the torque output of the servo motor to make the actual displacement value of the valve core accurately match the command curve.

[0028] Preferably, the durability assessment subsystem performs the following operations:

[0029] Receive inlet pressure value, outlet pressure value, valve body surface temperature value and vibration spectrum data uploaded by the multi-channel valve status acquisition subsystem;

[0030] The valve action drive subsystem records the valve opening history sequence and the cumulative number of opening and closing times.

[0031] Based on the fatigue characteristics database of valve materials, the cumulative damage caused by stress cycles due to pressure pulsation amplitude is calculated.

[0032] Based on the valve core friction and wear model, the predicted value of the wear of the sealing surface caused by the number of opening and closing cycles is calculated.

[0033] By combining the cumulative damage from stress cycles with the predicted wear of the sealing surface, an overall valve performance degradation index is generated.

[0034] Preferably, the present invention further includes a test method for a one-way valve combined hydrogen storage system, applied to a durability test bench for implementing the above-described one-way valve combined hydrogen storage system, the method comprising:

[0035] The test task parameters are set through the main control computer, including the target pressure spectrum, valve opening change sequence, single cycle duration and total cycle number threshold.

[0036] Start the high-pressure hydrogen supply subsystem to make the pipeline pressure value track the target pressure spectrum wave;

[0037] The valve action drive subsystem is started synchronously, driving each valve to act periodically according to the opening degree change sequence;

[0038] The multi-channel valve status acquisition subsystem collects and uploads inlet pressure, outlet pressure, valve body surface temperature, and vibration spectrum data in real time.

[0039] The durability assessment subsystem calculates the valve performance degradation increment within each cycle based on the uploaded data;

[0040] When the overall performance degradation index of the valve is detected to exceed the preset failure threshold or reach the total number of cycles threshold, the test is terminated and the cumulative test data packet is output.

[0041] Preferably, the parameters for setting the test task include:

[0042] Import the standard pressure load spectrum as the base waveform for the target pressure spectrum wave;

[0043] By superimposing random pressure disturbance components, a composite pressure spectrum wave containing high-frequency pressure pulsations is generated;

[0044] Define the valve opening change sequence, including the time to hold the fully open position, the time to hold the fully closed position, and the linear opening / closing rate;

[0045] Configure the duration of a single cycle and the cooldown time between cycles;

[0046] Set a threshold for the total number of cycles and a warning threshold for the valve performance degradation index.

[0047] Preferably, the durability assessment subsystem calculates the valve performance degradation increment within each cycle based on the uploaded data, including:

[0048] Extract the inlet and outlet pressure values ​​within the current cycle and calculate the pressure difference over time.

[0049] Peak and valley values ​​are detected in the pressure difference curve over time to identify the effective stress cycle number and stress amplitude distribution.

[0050] Query the valve material SN curve database to calculate the equivalent damage caused by stress cycling within the current cycle.

[0051] Extract the temperature change curve of the valve body surface over time and calculate the correction factor for the material yield strength based on the temperature fluctuation range.

[0052] Based on the revised equivalent damage degree and sealing surface wear model, the cumulative value of the overall valve performance degradation index is updated.

[0053] Preferably, the cumulative value of the overall performance degradation index of the updated valve includes:

[0054] Read the current number of valve opening and closing recorded by the valve action drive subsystem;

[0055] The predicted value of the wear depth of the sealing surface is calculated by applying the empirical formula for the friction coefficient of the valve core based on the number of opening and closing cycles.

[0056] Convert the predicted wear depth of the sealing surface into a percentage decrease in sealing performance;

[0057] The combined stress cycle equivalent damage and the percentage decrease in sealing performance are used to generate the overall performance degradation rate.

[0058] The overall performance degradation rate is added to the historical cumulative value and stored as a new cumulative value of the overall valve performance degradation index.

[0059] Preferably, the output cumulative test data packet includes:

[0060] Export the time series of inlet pressure, outlet pressure, valve body surface temperature, and vibration spectrum data recorded during the complete test process;

[0061] Statistical report on the deviation between the output valve opening command curve and the actual valve core displacement curve;

[0062] Generate a trend chart of the overall performance degradation index of the valve with the number of cycles as the horizontal axis;

[0063] Extract snapshots of key operating parameters and fault mode classification codes when the failure threshold is reached;

[0064] All data is packaged to generate a durability test certification report that meets industry standards.

[0065] Compared with the prior art, the beneficial effects of the present invention are:

[0066] In this one-way valve combined hydrogen storage system durability test bench, the main control computer can configure test task parameters and coordinate the synchronous operation of the high-pressure hydrogen supply subsystem, the multi-channel valve status acquisition subsystem, the valve action drive subsystem, and the durability assessment subsystem, so that the various parts form a linkage and avoid the test disconnect caused by the independent operation of a single subsystem.

[0067] The adjustable hydrogen source of the high-pressure hydrogen supply subsystem works in conjunction with the pressure closed-loop control module to apply hydrogen pressure according to the test task parameters. The pressure value can be dynamically adjusted as the test progresses, closely matching the pressure fluctuations in the actual operation of the hydrogen storage system, making the applied pressure environment closer to the real-world usage scenario.

[0068] The multi-channel valve status acquisition subsystem uses pressure sensor arrays, temperature sensor arrays, and vibration sensor arrays to simultaneously acquire the inlet pressure, outlet pressure, valve body surface temperature, and vibration spectrum data of the valve under test. These data reflect the valve's state under stress, heat, and vibration from different dimensions, avoiding information gaps caused by acquiring only a single parameter and providing a more comprehensive view of the valve's changes during the test.

[0069] The high-speed electromagnetic actuator array of the valve action drive subsystem, combined with the displacement feedback module, can drive the valve under test to execute a preset opening sequence and opening / closing frequency. The displacement feedback module can sense the actual action state of the valve in real time, ensuring that the drive process remains consistent with the preset sequence, and reproducing the complex action modes of the valve in actual use, including high-frequency opening and closing, and switching between different opening degrees.

[0070] The durability assessment subsystem is embedded in the main control computer. It receives real-time data transmitted from the multi-channel valve status acquisition subsystem and, combined with valve actuation history, calculates the cumulative damage degree of the valve and predicts its remaining lifespan. This assessment is conducted throughout the entire test process, capturing damage trends in real time, rather than performing static analysis only after the test. It can more comprehensively reflect the valve's state evolution during long-term testing.

[0071] The various subsystems work together to form a complete test chain, from pressure environment simulation, status data acquisition, action driving to durability assessment. This covers the various requirements for durability testing of one-way valve combined hydrogen storage systems, making the test process more closely resemble actual operating conditions, collecting more comprehensive information, and the assessment results better reflecting the durability performance of the valves in complex environments. Attached Figure Description

[0072] Figure 1 This is a schematic diagram of the working principle of the one-way valve combined hydrogen storage system durability test bench described in this invention.

[0073] Figure 2 Schematic diagram of the working principle of the high-pressure hydrogen supply subsystem;

[0074] Figure 3 This is a schematic diagram of the working principle of the valve action drive subsystem.

[0075] Figure 4 A flowchart for setting test task parameters. Detailed Implementation

[0076] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0077] Please see Figure 1 This invention provides a durability test bench and testing method for a one-way valve combined hydrogen storage system, the method comprising:

[0078] A durability test bench for a one-way valve combined hydrogen storage system includes a main control computer, a high-pressure hydrogen supply subsystem, a multi-channel valve status acquisition subsystem, a valve action drive subsystem, and a durability assessment subsystem.

[0079] The main control computer, as the core control unit of the entire test bench, is responsible for configuring test parameters, coordinating the operation of various subsystems, and processing test data. Operators input relevant test parameters, such as target pressure range, valve opening and closing frequency, and number of cycles, through the main control computer's human-machine interface. The main control computer parses these parameters and sends them to the relevant subsystems, while also receiving data from each subsystem in real time for integration and analysis.

[0080] The high-pressure hydrogen supply subsystem is connected to the main control computer and includes an adjustable-pressure hydrogen source and a pressure closed-loop control module. During the test, the adjustable-pressure hydrogen source applies a precise and controllable hydrogen pressure to the inlet of the tested one-way valve combination hydrogen storage system according to the test task parameters issued by the main control computer, through the adjustment of the pressure closed-loop control module, in order to simulate the pressure environment under different operating conditions.

[0081] The multi-channel valve status acquisition subsystem deploys pressure sensor arrays, temperature sensor arrays, and vibration sensor arrays at each valve in the tested one-way valve combination hydrogen storage system. The pressure sensor arrays acquire real-time valve inlet and outlet pressure values, the temperature sensor arrays acquire valve body surface temperature values, and the vibration sensor arrays acquire vibration spectrum data. This acquired data is transmitted to the main control computer in real time, providing raw information for subsequent data analysis and durability assessment.

[0082] The valve actuation drive subsystem is connected to the main control computer and consists of a high-speed electromagnetic actuator array and a displacement feedback module. Based on the test task parameters issued by the main control computer, the high-speed electromagnetic actuator array drives each valve in the tested one-way valve combination hydrogen storage system to execute a preset opening sequence and opening / closing frequency. The displacement feedback module monitors the valve's actuation in real time and feeds the information back to the main control computer to ensure that the valve actuation meets the preset requirements.

[0083] The durability assessment subsystem is embedded in the main control computer. After receiving real-time data transmitted by the multi-channel valve status acquisition subsystem, it combines the valve drive history record, uses algorithms to calculate the cumulative damage degree of the valve, and predicts the remaining life cycle of the valve based on this, providing a basis for judging the durability of the one-way valve combination hydrogen storage system.

[0084] Example 1: See Figure 2 The high-pressure hydrogen supply subsystem consists of a high-pressure hydrogen storage container, a hydrogen pressurization device, and a pressure closed-loop control module. The high-pressure hydrogen storage container serves as the initial hydrogen source, storing hydrogen at high pressure. Its outlet is connected via a pipeline to a pressure-reducing valve assembly, which comprises multiple pressure-reducing valves of different specifications connected in series or parallel. This assembly initially adjusts the hydrogen pressure output from the high-pressure storage container to a range suitable for the inlet requirements of the hydrogen pressurization device. The input of the hydrogen pressurization device is connected to the output of the pressure-reducing valve assembly. After receiving the initially depressurized hydrogen, it pressurizes it through its internal pressurization mechanism to meet the high-pressure conditions required for testing. The output end of the hydrogen booster is equipped with a dynamic pressure regulating valve and a high-precision pressure transmitter. The dynamic pressure regulating valve is electrically regulated, and its valve opening can be continuously adjusted by an electrical signal, thereby changing the flow cross-sectional area to control the hydrogen flow rate and pressure. The high-precision pressure transmitter is installed on the pipe wall of the output pipeline, and its detection probe is in direct contact with the hydrogen in the pipe. It can sense and output the pressure signal of the hydrogen in the pipeline in real time. This signal is an analog electrical signal, and its amplitude has a linear relationship with the actual pressure value.

[0085] The pressure closed-loop control module is connected to the main control computer, the dynamic pressure regulating valve, and the high-precision pressure transmitter via data transmission lines. When the test begins, the pressure closed-loop control module receives the target pressure command from the main control computer. This command includes the target pressure values ​​at different time points during the test, forming a pressure curve that changes over time. Simultaneously, the high-precision pressure transmitter transmits the collected pipeline pressure measurements to the pressure closed-loop control module in real time. The signal processing unit inside the pressure closed-loop control module compares the target pressure command with the measured pressure values ​​to obtain the deviation. Based on this deviation, the pressure closed-loop control module uses a proportional-integral-differential algorithm to calculate the regulating signal to be applied to the dynamic pressure regulating valve. This regulating signal is output to the actuator of the dynamic pressure regulating valve in the form of current or voltage, driving the valve disc to move and change the valve opening. When the measured pressure is lower than the target pressure command, the proportional-integral-derivative (PID) algorithm calculates an adjustment signal to increase the valve opening, allowing more hydrogen to flow into the pipeline and increasing the pipeline pressure. When the measured pressure is higher than the target pressure command, an adjustment signal to decrease the valve opening is output, reducing the amount of hydrogen flowing in and lowering the pipeline pressure. Through this continuous detection, comparison, and adjustment process, the measured pipeline pressure can closely follow changes in the target pressure command and remain within the set accuracy range.

[0086] The multi-channel valve status acquisition subsystem comprises a distributed data acquisition unit, a pressure sensor array, a temperature sensor array, a vibration sensor array, and a signal conditioning module. The distributed data acquisition unit adopts a modular design, with each module corresponding to an installation position of the valve under test. The module integrates data receiving and preliminary processing circuitry, enabling it to receive signals from various sensors nearby, reducing attenuation and interference during signal transmission.

[0087] The pressure sensor array consists of a first pressure sensor and a second pressure sensor, both employing piezoelectric pressure sensors, which offer high measurement accuracy and response speed. The first pressure sensor is installed via a flange connection at a pre-reserved interface on the side of the valve inlet flange, with its sensing surface in direct contact with the hydrogen gas at the valve inlet, for real-time acquisition of the hydrogen pressure value at the valve inlet. The second pressure sensor is fixed to the side of the valve outlet flange in the same manner, acquiring the hydrogen pressure value at the valve outlet. The output signals of both pressure sensors are weak charge signals proportional to the pressure.

[0088] The temperature sensor array uses thin-film thermocouples, which are only a few micrometers thick and have good flexibility and thermal conductivity. The thin-film thermocouples are attached to multiple key locations on the outer wall of the valve body using a high-temperature adhesive, such as the connection between the valve body and the flange, and the outer wall corresponding to the valve core movement area. They can quickly sense temperature changes on the valve body surface and output corresponding thermoelectric potential signals, which are correlated with the temperature values.

[0089] The vibration sensor array uses magnetically adsorbed accelerometers, each with a strong magnetic base at the bottom, allowing them to firmly adhere to the pressure-bearing surface of the valve body without requiring additional drilling or welding, facilitating installation and disassembly. Each magnetically adsorbed accelerometer can simultaneously collect vibration acceleration data in three mutually perpendicular directions (X-axis, Y-axis, and Z-axis), corresponding to the valve body's vibration in the horizontal, vertical, and transverse directions, respectively. The output signal is a voltage signal proportional to the vibration acceleration.

[0090] The signal conditioning module is connected to the pressure sensor array, temperature sensor array, vibration sensor array, and distributed data acquisition unit via shielded cables. For the weak charge signal output from the pressure sensor array, the signal conditioning module first converts it into a voltage signal using a built-in charge amplifier and amplifies it to improve the signal-to-noise ratio. For the thermoelectric potential signal output from the temperature sensor array, due to its small amplitude and susceptibility to interference, the signal conditioning module amplifies it using a precision instrumentation amplifier and employs a low-temperature drift circuit design to reduce the impact of ambient temperature on the amplification factor. For the voltage signal output from the vibration sensor array, the signal conditioning module uses a bandpass filter to filter out high-frequency noise and low-frequency drift components, retaining the signal within the effective frequency range relevant to valve vibration. The amplified and filtered signals are still analog signals. The analog-to-digital converter (ADC) inside the signal conditioning module converts these analog signals into digital signals, using a high-bit-count ADC to ensure conversion accuracy. The standardized digital signals are then transmitted to the distributed data acquisition unit via a data bus, and finally aggregated by the distributed data acquisition unit and transmitted to the main control computer.

[0091] Example 2: See Figure 3 The valve actuation drive subsystem consists of a servo motor drive module, a planetary reduction mechanism, a linear actuator, and a displacement closed-loop control module. The servo motor drive module includes a servo driver and a servo motor. The servo driver connects to the main control computer via a data cable and receives the valve opening command curve from the main control computer. This command curve is transmitted in the form of a digital signal, containing multiple time nodes and the target opening value corresponding to each node, forming a continuous opening change trajectory. According to the timing requirements of the command curve, the servo driver outputs corresponding voltage and current signals to the servo motor, controlling the servo motor's speed and direction. The output shaft of the servo motor is connected to the input end of the planetary reduction mechanism via a coupling. The planetary reduction mechanism consists of a sun gear, planet gears, an internal gear ring, and a planet carrier. After the high-speed rotational motion output by the servo motor is transmitted through the planetary reduction mechanism, the speed decreases and the torque increases to adapt to the force and speed characteristics required for valve spool actuation.

[0092] The output end of the planetary reducer is connected to a linear actuator, which includes a ball screw pair and a displacement feedback encoder. The ball screw pair consists of a screw and a nut. One end of the screw is fixed to the output shaft of the planetary reducer via a key and rotates synchronously with the output shaft. The outer side of the nut is rigidly connected to the valve core via a connecting seat. When the screw rotates, the nut moves linearly along the screw axis, thereby pushing the valve core to move along the internal axis of the valve body, thus adjusting the valve opening. The displacement feedback encoder is installed at the end of the ball screw pair and rotates coaxially with the screw. It contains a grating disk and a photoelectric detection component. When the screw rotates, the grating disk rotates synchronously. The photoelectric detection component generates pulse signals by detecting changes in the bright and dark stripes on the grating disk. The number of pulse signals is proportional to the rotation angle of the screw, thus reflecting the linear displacement of the nut, i.e., the actual displacement value of the valve core.

[0093] The displacement closed-loop control module is connected to both the displacement feedback encoder and the servo driver via signal lines. It receives the pulse signals output from the displacement feedback encoder in real time and converts them into the actual displacement value of the valve core. Simultaneously, the displacement closed-loop control module obtains the target displacement value corresponding to the valve opening command curve from the main control computer and compares the actual displacement value with the target displacement value in real time to obtain the deviation. When the deviation exceeds a set range, the displacement closed-loop control module outputs an adjustment signal to the servo driver. The servo driver changes the magnitude and direction of the current output to the servo motor according to the adjustment signal, thereby adjusting the output torque and direction of the servo motor. This changes the rotation speed or direction of the lead screw, which in turn changes the moving speed or direction of the nut until the actual displacement value of the valve core matches the target displacement value.

[0094] The durability assessment subsystem, an embedded software module of the main control computer, receives real-time data from the multi-channel valve status acquisition subsystem via an internal data interface. This data includes valve inlet pressure, outlet pressure, valve body surface temperature, and vibration spectrum data. This data, timestamped and forming a continuous data stream, is stored in the main control computer's memory. Simultaneously, the durability assessment subsystem accesses historical data recorded by the valve action drive subsystem, including the valve opening degree, the timing of opening and closing actions, and the cumulative number of times these actions occur at each time point. This historical data is correlated and matched with the status acquisition data using timestamps.

[0095] The durability assessment subsystem incorporates a valve material fatigue characteristic database. This database stores fatigue damage parameters of valves made of different materials under various pressure and temperature conditions, obtained through material mechanics experiments. The assessment subsystem calculates the internal pressure difference of the valve based on the inlet and outlet pressure values. Combining this with the pressure difference over time curve, it identifies the amplitude and frequency of pressure pulsations. Then, based on the parameters in the material fatigue characteristic database, it calculates the stress cycle damage caused by each pressure pulsation and accumulates these values ​​to obtain the cumulative stress cycle damage.

[0096] The durability assessment subsystem also includes a valve core friction and wear model. This model simulates the friction process between the valve core and the sealing surface based on parameters such as the number of valve opening and closing cycles, the range of opening degree changes, and fluid medium characteristics. The assessment subsystem calculates the wear amount of the sealing surface using the friction and wear model, based on the number of opening and closing cycles recorded by the valve actuation drive subsystem and the amount of opening degree change during each cycle, thus obtaining a predicted value for the sealing surface wear. Finally, the durability assessment subsystem weights and fuses the cumulative stress cycle damage degree with the predicted value of the sealing surface wear to generate a comprehensive index, namely the overall valve performance degradation index. This index changes with time and the number of cycles, reflecting the decline in valve performance.

[0097] Example 3: See Figure 4 A testing method for a one-way valve combined hydrogen storage system is presented, applied to the aforementioned one-way valve combined hydrogen storage system durability test bench. This method uses a main control computer as the operating core, and firstly, the test task parameters are set. Operators complete the parameter configuration through the interactive interface of the main control computer; the entire process covers parameter definitions across multiple dimensions.

[0098] Regarding pressure parameter settings, a standard pressure load spectrum is first imported. This spectrum is drawn based on the actual application scenario of a one-way valve combined hydrogen storage system, including pressure values ​​and durations at different stages, such as the pressure rise process during system startup, the constant pressure value during stable operation, and the pressure drop curve during shutdown. This serves as the base waveform for the target pressure spectrum. Random pressure disturbance components are then superimposed on this spectrum. These disturbance components simulate sudden pressure fluctuations that may occur in actual operating conditions, such as airflow impacts within the pipeline and minor pressure fluctuations caused by changes in the external environment, ultimately generating a composite pressure spectrum. During the formation of the composite pressure spectrum, the amplitude range of the random disturbances is set according to the test requirements, typically fluctuating within a certain percentage of the base pressure value. The frequency distribution of the disturbances covers the frequency bands that may affect valve performance, thus more closely resembling the real operating environment.

[0099] The valve actuation parameters are also set via the main control computer, primarily defining the valve opening sequence. This sequence clarifies the valve's actuation state within one cycle, including: fully open position holding time (the duration the valve remains in this state after being fully open); fully closed position holding time (the duration the valve remains closed after being fully closed); linear opening rate (the rate at which the opening increases linearly with time during the transition from fully closed to fully open); and linear closing rate (the rate at which the opening decreases linearly with time during the transition from fully open to fully closed). The setting of these parameters must consider the design characteristics of the valve under test, such as maximum permissible opening and closing speeds and sealing requirements, to ensure that the actuation process complies with the valve's mechanical performance limitations.

[0100] The configuration of the cycle parameters includes the duration of a single cycle and the cooling time between cycles. The duration of a single cycle is the time required to complete one full sequence of opening changes, and is the sum of the fully open holding time, the fully closed holding time, and the opening / closing transition time. The cooling time between cycles is the pause time between two consecutive cycles. During this period, the high-pressure hydrogen supply subsystem stops applying pressure to the system under test, the valve remains fully closed, and the valve body temperature is allowed to cool naturally, avoiding the temperature accumulation effect caused by continuous cycles.

[0101] The threshold parameters involve setting the total cycle count threshold and the valve performance degradation index warning threshold. The total cycle count threshold is determined based on the testing objective, and may correspond to the expected number of cycles in the valve's design life, or be set according to a specific testing standard. The warning threshold is a predefined performance degradation index value. When the index calculated by the durability assessment subsystem reaches this value, the main control computer will issue a prompt message to remind the operator to pay attention to the valve status.

[0102] After the parameters are set, the main control computer sends start commands to each subsystem. Upon receiving the command, the high-pressure hydrogen supply subsystem releases hydrogen from the high-pressure hydrogen storage container through the pressure reducing valve assembly. After being pressurized by the hydrogen pressurization device, the pressure value in the output pipeline is strictly controlled according to the set target pressure spectrum under the regulation of the pressure closed-loop control module. During the pressure regulation process, the dynamic pressure regulating valve continuously adjusts its opening based on real-time pressure feedback to ensure that the deviation between the actual pressure and the target pressure is controlled within the allowable range.

[0103] Synchronously with the startup of the high-pressure hydrogen supply subsystem, the valve actuation drive subsystem begins operation. The servo motor drive module, based on the valve opening command curve, drives the valve core through a planetary reduction gear and a linear actuator, causing each valve to perform periodic movements according to a set opening sequence. During operation, the displacement feedback module monitors the valve core position in real time and feeds the data back to the displacement closed-loop control module. By continuously adjusting the servo motor output, it ensures that the valve core displacement accurately follows the command curve.

[0104] During the test, the multi-channel valve status acquisition subsystem remained operational. The distributed data acquisition unit coordinated the operation of each sensor array. The first and second pressure sensors of the pressure sensor array acquired the pressure values ​​at the valve inlet and outlet, respectively. The thin-film thermocouples of the temperature sensor array recorded temperature changes at different locations on the valve body surface. The magnetically attached accelerometers of the vibration sensor array captured vibration data of the valve body in three directions. These raw signals were processed by the signal conditioning module, converted into standardized digital signals, and uploaded to the main control computer in real time for storage.

[0105] The durability assessment subsystem continuously receives uploaded status data and combines it with historical information such as the number of opening and closing cycles and changes in opening degree recorded by the valve action drive subsystem to calculate the incremental degradation of valve performance within each cycle. During the calculation, the impact of stress cycling and frictional wear on valve performance is assessed by analyzing changes in pressure difference, temperature fluctuations, and vibration spectrum characteristics.

[0106] When the test reaches a certain stage, if the durability assessment subsystem detects that the overall performance degradation index of the valve exceeds the preset failure threshold, or the cumulative number of cycles reaches the total number of cycles threshold, the main control computer will issue a termination command, and each subsystem will stop working. At this time, the system automatically organizes all the data generated during the test to form a cumulative test data package, completing the entire test process.

[0107] The generation of composite pressure spectrum waves involves the superposition calculation of random pressure disturbance components, and its expression is as follows:

[0108]

[0109] in, for The composite pressure value at any given moment; for The baseline pressure value at any given time is taken from the standard pressure load spectrum; for The amplitude of the disturbance at any given moment changes randomly over time; for The perturbation frequency at any given time is randomly selected within a set frequency band; for The initial phase angle at time t is a random value between 0 and 2π.

[0110] Example 4: When calculating the valve performance degradation increment within each cycle, the durability assessment subsystem first extracts the inlet and outlet pressure values ​​for the current cycle from the data uploaded by the multi-channel valve status acquisition subsystem. These pressure values ​​are recorded at fixed time intervals, forming two curves that change over time. By subtracting the outlet pressure value from the inlet pressure value at the same time point, the pressure difference is obtained, and thus a pressure difference curve over time is generated. This curve reflects the change in the valve's resistance to fluid pressure during the cycle, and the fluctuations in the curve are related to factors such as valve opening and closing actions and internal structural vibrations.

[0111] Peak-valley detection is performed on the pressure difference versus time curve, requiring the identification of all peak and trough points. A peak point is the maximum value within a local range of the curve, and a trough point is the minimum value within that local range. Each pair of adjacent peaks and troughs constitutes one stress cycle, with the stress amplitude of the cycle being half the difference between the peak and trough values. By counting the number of such peak-valley pairs in the curve, the effective stress cycle count can be obtained; the number of cycles corresponding to different stress amplitudes is then categorized to form a stress amplitude distribution.

[0112] The SN curve database for valve materials is queried. This database stores fatigue performance data of the materials used in the tested valve, including the number of cycles the material can withstand under different stress amplitudes. Based on the identified stress amplitude distribution, the corresponding number of cycles for each stress amplitude is matched from the database. Then, combined with the effective stress cycle count within the current cycle, the damage proportion under each stress amplitude is calculated. These damage proportions are added together to obtain the equivalent damage caused by stress cycles within the current cycle.

[0113] The temperature curve of the valve body surface over time is extracted. This curve is generated by averaging temperature values ​​from multiple measuring points collected by a temperature sensor array. The temperature fluctuation range is calculated by identifying the highest and lowest temperature values ​​in the curve. The yield strength of different materials varies with temperature; it typically decreases as temperature increases and may increase as temperature decreases. Based on the material's temperature characteristics data, a correction coefficient is calculated based on the temperature fluctuation range to adjust the previously obtained equivalent damage level, making the damage assessment results more consistent with the material properties under actual temperature conditions.

[0114] When updating the cumulative value of the overall valve performance degradation index based on the corrected equivalent damage degree and sealing surface wear model, it is necessary to read the current valve opening and closing count recorded by the valve action drive subsystem. This count represents the total number of fully open and fully closed action cycles completed by the valve from the start of the test to the end of the current cycle.

[0115] The sealing surface wear model is established based on the friction process between the valve core and the sealing surface, taking into account factors such as the number of opening and closing cycles, contact pressure, and friction coefficient. Based on the current number of opening and closing cycles, the model utilizes a built-in empirical relationship for the valve core friction coefficient, which reflects the change in the friction coefficient as the number of opening and closing cycles increases. Combined with parameters such as contact pressure, the model calculates the predicted wear depth of the sealing surface.

[0116] The predicted wear depth of the sealing surface is compared with the initial allowable wear depth to obtain a percentage, which is the percentage decrease in sealing performance. This percentage indicates the degree of reduction in sealing capacity due to wear; the higher the value, the more severe the degradation of sealing performance.

[0117] The equivalent damage from stress cycles is superimposed with the percentage decrease in sealing performance. This superposition requires calculation based on the weighted impact of each factor on the overall valve performance to generate a comprehensive performance degradation rate. This degradation rate reflects the degree of performance degradation caused by the combined effects of stress cycles and seal wear within the current cycle.

[0118] Finally, the overall performance degradation rate is added to the historical cumulative value to obtain a new cumulative value for the overall valve performance degradation index. This cumulative value gradually increases from zero at the start of the test and continues to increase with the number of cycles, intuitively reflecting the overall degradation process of valve performance.

[0119] The following table shows the stress amplitude distribution and corresponding damage ratio within a certain cycle:

[0120]

[0121] In the table, the stress amplitude range represents different intervals, the effective stress cycle count is the number of stress cycles falling within that interval in the current cycle, the material corresponding cycle count is the total number of cycles the material can withstand at that stress amplitude, and the damage ratio is the ratio of the effective stress cycle count to the material corresponding cycle count. By adding the damage ratios of each interval, the equivalent damage degree of stress cycles within that cycle can be obtained.

[0122] Example 5: When outputting the cumulative test data package, it is necessary to first export the time series of inlet pressure value, outlet pressure value, valve body surface temperature value and vibration spectrum data recorded during the complete test process.

[0123] The inlet pressure time series is plotted on the horizontal axis, with each time point corresponding to a pressure data point collected by the first pressure sensor. It comprehensively records the continuous changes in hydrogen pressure at the valve inlet throughout the entire process from test initiation to termination, including detailed data on pressure rise, stabilization, fluctuation, and decline. The outlet pressure time series, collected by the second pressure sensor, is also plotted on the horizontal axis, reflecting the changes in valve outlet pressure as the test progresses. Its trend is related to the inlet pressure value, but exhibits different characteristics due to the valve's throttling effect. The valve body surface temperature time series integrates temperature data from various measuring points collected by thin-film thermocouples, averaging them to form a continuous curve, recording the temperature fluctuations of the valve body from its initial temperature to the heating, cooling, and stabilization stages during the test. The vibration spectrum data time series includes the spectral information of the three-dimensional vibration acceleration data within each time segment after Fourier transform, reflecting the vibration energy distribution at different frequencies and how these distributions change over time. All these time series data are recorded with precise timestamps at the millisecond level to ensure data time correspondence.

[0124] To generate a statistical report on the deviation between the valve opening command curve and the actual valve core displacement curve, the main control computer must first retrieve the opening command curve data stored in the valve action drive subsystem and the actual displacement curve data recorded by the displacement feedback module. The opening command curve is a preset ideal action trajectory, containing the target opening value at each time point; the actual displacement curve is a record of the actual movement of the valve core. Both are plotted with time on the horizontal axis and opening value on the vertical axis. The values ​​of the two curves at the same time point are compared to calculate the deviation value at each time point, which is the actual displacement value minus the commanded opening value. The statistical report must include the maximum, minimum, average, and standard deviation of the deviation values. The maximum value reflects the maximum deviation, the minimum value reflects the minimum deviation, the average value reflects the overall deviation trend, and the standard deviation reflects the dispersion of the deviation. The report must also indicate the time points where the deviation values ​​reach extreme values, and the corresponding valve action stage, such as the opening process, closing process, or holding stage.

[0125] To generate a trend chart of the overall valve performance degradation index with the number of cycles as the horizontal axis, the cumulative value of the overall performance degradation index calculated by the durability assessment subsystem at the end of each cycle needs to be extracted. The horizontal axis is plotted from 1 to the total number of cycles; the vertical axis is plotted from 0 to the failure threshold. The index value corresponding to each cycle number is marked as a point on the coordinate system, and these points are connected by a smooth curve to form the trend chart. The chart should indicate the horizontal lines corresponding to the warning threshold and the failure threshold, as well as the cycle number corresponding to the intersection of the index curve and these two lines, clearly showing the change pattern of the performance degradation index with the increase of the number of cycles, including the rate of degradation and the presence of abrupt change points.

[0126] The system extracts snapshots of key operating parameters and fault mode classification codes at the moment the failure threshold is reached. The key operating parameter snapshots are various state parameters at the instant the failure threshold is reached, including inlet pressure, outlet pressure, valve body surface temperature, peak three-dimensional vibration acceleration, and actual valve core displacement. These parameters are recorded as instantaneous values, reflecting the operating conditions at the moment of failure. The fault mode classification codes encode failure modes according to preset classification standards. These standards are based on common valve failure types, such as seal failure, valve core jamming, and valve body leakage. Each failure type corresponds to a unique code, which is a combination of letters and numbers for easy data storage and retrieval.

[0127] To generate an industry-standard durability test and certification report, all data must be packaged and integrated, including the aforementioned time-series data, deviation statistics, trend charts, key parameter snapshots, and failure mode codes. The report should begin with basic test information, such as the tested valve model, specifications, manufacturer, test date, ambient temperature, and humidity. The test process description should briefly explain the test parameter settings, such as the target pressure spectrum type, cycle threshold, and opening / closing frequency. The data presentation section should display the time-series data and trend charts in a combination of graphs and tables. The appendix includes complete raw data tables and detailed deviation statistics. The final section of the report is a test results summary, summarizing the changes in the performance degradation index, key parameters at the time of failure, and failure mode codes. The entire report should be formatted using a standardized format, with fonts, chart numbering, headers, and footers conforming to general industry test report specifications.

[0128] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0129] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A one-way valve combined hydrogen storage system durability test bench, characterized in that, The application relates to a hydrogen storage system test platform, which comprises the following parts: a host computer for configuring test task parameters, coordinating operation of subsystems and processing test data; a high-pressure hydrogen supply subsystem connected with the host computer, comprising an adjustable pressure hydrogen source and a pressure closed-loop control module, which is used for applying accurate and controllable hydrogen pressure to an inlet end of a measured one-way valve combined hydrogen storage system according to the test task parameters; a multi-channel valve state acquisition subsystem comprising a pressure sensor array, a temperature sensor array and a vibration sensor array arranged at each valve of the measured one-way valve combined hydrogen storage system, which is used for collecting valve inlet pressure values, outlet pressure values, valve body surface temperature values and vibration spectrum data in real time and transmitting the collected data to the host computer in real time; a valve action driving subsystem connected with the host computer, comprising a high-speed electromagnetic actuator array and a displacement feedback module, which is used for driving each valve in the measured one-way valve combined hydrogen storage system to execute a preset opening degree sequence and opening and closing frequency according to the test task parameters; a durability evaluation subsystem embedded in the host computer, which is used for receiving real-time data transmitted by the multi-channel valve state acquisition subsystem, combining valve driving history records, calculating valve cumulative damage degree and predicting residual service life; the durability evaluation subsystem performs the following operations: receiving inlet pressure values, outlet pressure values, valve body surface temperature values and vibration spectrum data uploaded by the multi-channel valve state acquisition subsystem; calling valve opening degree history sequences and opening and closing times cumulative values recorded by the valve action driving subsystem; calculating stress cycle cumulative damage degree caused by pressure pulsation amplitude based on a valve material fatigue characteristic database; calculating sealing surface wear amount prediction values caused by opening and closing times based on a valve core friction and wear model; fusing the stress cycle cumulative damage degree and the sealing surface wear amount prediction values to generate a valve overall performance degradation index.

2. The one-way valve combined hydrogen storage system durability test bench according to claim 1, wherein, The high-pressure hydrogen supply subsystem comprises: a high-pressure hydrogen storage container connected to a hydrogen pressure increasing device through a pressure reducing valve group; a hydrogen pressure increasing device, the output end of which is provided with a dynamic pressure regulating valve and a high-precision pressure transmitter; a pressure closed-loop control module, which receives a target pressure instruction issued by the host computer, reads a pipeline pressure measured value collected by the high-precision pressure transmitter in real time, dynamically adjusts the opening degree of the dynamic pressure regulating valve through a proportional integral differential algorithm, and makes the pipeline pressure measured value stably track the target pressure instruction.

3. The durability test bench for the one-way valve combined hydrogen storage system according to claim 1, wherein The multi-channel valve state acquisition subsystem comprises: a distributed data acquisition unit arranged at each measured valve installation station; a pressure sensor array, which comprises a first pressure sensor arranged on a valve inlet flange and a second pressure sensor arranged on a valve outlet flange, and is used for collecting inlet pressure values and outlet pressure values respectively; a temperature sensor array, which comprises a thin film thermocouple attached to a valve body outer wall and is used for collecting valve body surface temperature values; a vibration sensor array, which comprises a magnetic adsorption accelerometer fixed on a valve body pressure-bearing shell and is used for collecting three-dimensional vibration acceleration data. Signal conditioning module, which amplifies, filters and digitizes the raw signals output by the pressure sensor array, temperature sensor array and vibration sensor array, and generates standardized digital signals uploaded to the host computer.

4. The one-way valve combined hydrogen storage system durability test bench according to claim 1, wherein, The valve action driving subsystem comprises: A servo motor driving module receives the valve opening instruction curve issued by the host computer; A planetary reduction mechanism, the input end of which is connected to the output shaft of the servo motor driving module; A linear actuator, which includes a ball screw pair and a displacement feedback encoder, converts the rotary motion of the planetary reduction mechanism into linear displacement and pushes the valve spool to move; A displacement closed-loop control module, which reads the actual displacement value of the valve spool measured by the displacement feedback encoder in real time, compares it with the valve opening instruction curve, and adjusts the torque output of the servo motor to make the actual displacement value of the valve spool accurately match the instruction curve.

5. A test method of a one-way valve combined hydrogen storage system, applied to a durability test bench of the one-way valve combined hydrogen storage system according to any one of claims 1 to 4, characterized in that, The method comprises: Setting test task parameters through the host computer, including target pressure spectrum wave, valve opening change sequence, single cycle duration and total cycle number threshold; Starting the high-pressure hydrogen gas supply subsystem to make the pipeline pressure value track the target pressure spectrum wave; Starting the valve action driving subsystem synchronously to drive each valve to act periodically according to the opening change sequence; A multi-channel valve state acquisition subsystem acquires and uploads the inlet pressure value, outlet pressure value, valve body surface temperature value and vibration frequency spectrum data in real time; The durability evaluation subsystem calculates the valve performance degradation increment in each cycle period according to the uploaded data; When the overall valve performance degradation index is detected to exceed the preset failure threshold or the total cycle number threshold is reached, the test is terminated and the cumulative test data package is output.

6. The method of claim 5, wherein the one-way valve combination hydrogen storage system is tested by, The setting of test task parameters comprises: Importing a standard pressure load spectrum as the basic waveform of the target pressure spectrum wave; Superimposing a random pressure disturbance component to generate a composite pressure spectrum wave containing high-frequency pressure pulsation; Defining the valve opening change sequence, including the full open position holding time, the full closed position holding time and the linear opening / closing rate; Configuring the single cycle duration and the cycle interval cooling time; Setting the total cycle number threshold and the valve performance degradation index warning threshold.

7. The method of claim 5, wherein the one-way valve combination hydrogen storage system is tested by, The durability evaluation subsystem calculates the valve performance degradation increment in each cycle period according to the uploaded data, which comprises: Extracting the inlet pressure value and outlet pressure value in the current cycle period to calculate the pressure difference value-time curve; Detecting the peak and valley values of the pressure difference value-time curve to identify the effective stress cycle number and stress amplitude distribution; Querying the valve material S-N curve database to calculate the equivalent damage degree caused by stress cycle in the current cycle period; Extracting the valve body surface temperature value-time curve to calculate the correction coefficient of the temperature fluctuation range on the material yield strength; Based on the corrected equivalent damage degree and the seal face wear model, updating the cumulative value of the overall valve performance degradation index.

8. The method of claim 7, wherein the one-way valve combination hydrogen storage system is tested by, The updating of the cumulative value of the overall valve performance degradation index comprises: Reading the current valve opening and closing number recorded by the valve action driving subsystem; According to the opening and closing number, calling the empirical formula of the valve spool friction coefficient to calculate the predicted value of the seal face wear depth; Converting the predicted value of the seal face wear depth into the percentage of the decline in sealing performance; Superimpose stress cycle equivalent damage degree and sealing performance decline percentage to generate comprehensive performance degradation rate; Add the comprehensive performance degradation rate to the historical cumulative value to store as a new valve overall performance degradation index cumulative value.

9. The method of claim 5, wherein the one-way valve combined hydrogen storage system is tested by, The output cumulative test data package includes: Export the time series of inlet pressure value, outlet pressure value, valve body surface temperature value and vibration spectrum data recorded during the complete test process; Output the deviation statistical report of valve opening instruction curve and actual displacement curve of valve core; Generate the valve overall performance degradation index trend graph with cycle number as the horizontal coordinate; Extract the key operating parameter snapshot when the failure threshold is reached and the fault mode classification code; Package all data to generate a durability test certification report in accordance with industrial standards.

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