Bcc solid hydrogen storage safety control system and vehicle with same

Abstract

This invention provides a BCC solid-state hydrogen storage safety control system, comprising: a hydrogen storage device having a hydrogen storage tube with a built-in BCC hydrogen storage alloy, a hydrogen charging valve for controlling the opening and closing of the hydrogen storage tube, and a coolant channel; a cooling system forming a closed-loop circulation loop with the coolant channel for supplying coolant to the hydrogen storage device; and a safety interlock control module for collecting safety-related parameters of the hydrogen storage device, cooling system, and environment. When the parameters meet the first-level, second-level, and third-level interlock conditions, the module correspondingly activates the first-level interlock to open the hydrogen charging valve, the second-level interlock to adjust the hydrogen flow rate and the operating parameters of the cooling system, and the third-level interlock to close the hydrogen charging valve. The BCC solid-state hydrogen storage safety control system of this invention features high integration, good safety, and high intelligence. Through an optimized heat exchange structure, rigorous multi-level interlock logic, and a comprehensive fault diagnosis model, the system achieves efficient thermal management, full-process safety protection, and intelligent fault handling during the hydrogen charging process.

Description

Technical Field

[0001] This invention relates to the field of solid-state hydrogen storage technology, specifically to a BCC solid-state hydrogen storage safety control system and a vehicle having the same. Background Technology

[0002] Solid-state hydrogen storage technology, especially solutions using BCC (body-centered cubic) hydrogen storage alloys, has shown broad application prospects in on-board hydrogen storage and distributed energy storage due to its advantages such as high hydrogen storage density, low operating pressure, and good safety. However, BCC alloys undergo a violent exothermic reaction during hydrogen absorption (i.e., hydrogen charging). If the heat of reaction cannot be removed in a timely and uniform manner, it may lead to localized overheating of the hydrogen storage material, damage to the crystal structure, reduced cycle life, and even safety accidents such as temperature and pressure runaway.

[0003] To address the aforementioned issues, existing technologies mostly employ simple coil cooling or single-loop heat exchange structures, which suffer from drawbacks such as uneven heat exchange and slow response speed. More critically, there is currently a lack of multi-level safety interlock control logic deeply coupled with the hydrogen charging process. For typical abnormal operating conditions such as cooling system failures, hydrogen leaks, valve jamming, overpressure, and overtemperature, effective graded diagnosis, early warning, and corresponding protection mechanisms have not yet been established, resulting in poor overall system stability and reliability. Summary of the Invention

[0004] In view of this, in order to overcome the technical defects of existing solid hydrogen storage systems, such as uneven cooling and heat exchange, lack of multi-level safety interlocks and fault classification protection, this invention proposes a BCC solid hydrogen storage safety control system, including: A hydrogen storage device, which has a hydrogen storage tube with built-in BCC hydrogen storage alloy, a hydrogen filling valve for controlling the opening and closing of the hydrogen storage tube, and a coolant passage. The cooling system, together with the coolant channel, forms a closed-loop circulation circuit for supplying coolant to the hydrogen storage device; The safety interlock control module is used to collect safety-related parameters of the hydrogen storage device, cooling system, and environment. When the parameters meet the first-level interlock conditions, second-level interlock conditions, and third-level interlock conditions, the corresponding first-level interlock is activated to open the hydrogen charging valve, the second-level interlock is activated to adjust the hydrogen flow rate and the operating parameters of the cooling system, and the third-level interlock is activated to close the hydrogen charging valve.

[0005] In some embodiments, the hydrogen storage device includes: The housing defines a receiving cavity, in which the hydrogen storage tube array is arranged, and the gap between the hydrogen storage tube and the housing forms the coolant channel.

[0006] In some embodiments, the safety interlock control module includes: The sensing unit is used to collect safety-related parameters such as the temperature and pressure of the hydrogen storage device, the temperature and flow rate of the coolant in the cooling system, and the concentration of hydrogen in the environment. The interlocking control unit, which uses a PLC or embedded controller, is used to receive the safety-related parameters and execute the corresponding interlocking actions.

[0007] In some embodiments, the safety interlock control module includes: The fault diagnosis unit is used to receive the safety-related parameters and determine the fault type based on the parameters.

[0008] In some embodiments, the diagnostic unit is further configured to: Based on the severity of the fault, faults are classified into three levels: minor faults, general faults, and emergency faults. Minor faults are only recorded and a prompt is issued. General faults trigger a secondary interlock to reduce the hydrogen charging flow. Emergency faults trigger a tertiary interlock to close the hydrogen charging valve.

[0009] In some embodiments, the safety-related parameters satisfying the first-level interlocking condition means satisfying all of the following conditions: The cooling system starts normally, and the coolant output temperature is 5 ℃~10 ℃; The coolant circulation flow rate is ≥2.0 m³ / h; The initial temperature of the coolant passage is ≤40 ℃; Hydrogen storage pipe pressure ≤ 5 MPa; The ambient hydrogen concentration is <20% LEL.

[0010] In some embodiments, the safety-related parameters satisfying the secondary interlocking conditions include one of the following: Coolant flow rate is 80% or more than 120% of the set value; The wall temperature of the hydrogen storage tube is ≥60 ℃ or the rate of temperature rise exceeds the set threshold. Hydrogen pressure fluctuations exceed ±0.5 MPa; When any of the above conditions are met, the interlock control unit automatically reduces the hydrogen charging flow rate and adjusts the chiller load and water pump frequency of the cooling system; when all of the above conditions are eliminated, the load reduction state is automatically released.

[0011] In some embodiments, the safety-related parameters satisfying the three-level interlocking conditions include satisfying one of the following conditions: Hydrogen pressure ≥ 5.2 MPa; Coolant flow rate ≤ 50% of set value or ≥ 150% of set value; Hydrogen storage tube wall temperature ≥80℃; Ambient hydrogen concentration ≥40% LEL; The duration of a single hydrogen refueling exceeds the preset safety time limit; The cooling system has stopped or the coolant circulation has been interrupted.

[0012] In some embodiments, the interlocking control unit also issues an audible and visual alarm signal when the safety-related parameters do not meet the first-level interlocking conditions or meet the third-level interlocking conditions.

[0013] Based on the same inventive concept, according to another aspect of the present invention, the present invention also provides a hydrogen fuel cell vehicle, including the BCC solid-state hydrogen storage safety control system described in the above embodiments.

[0014] The present invention has one of the following beneficial technical effects: it provides a highly integrated, safe, and intelligent BCC solid-state hydrogen storage safety control system. The system achieves efficient thermal management, full-process safety protection, and intelligent fault handling during the hydrogen charging process through optimized heat exchange structure, rigorous multi-level interlocking logic, and comprehensive fault diagnosis model. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a structural block diagram of the BCC solid-state hydrogen storage safety control system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the assembly and closed-loop structure of the hydrogen storage device and cooling system according to an embodiment of the present invention. Figure 3 A perspective view of a hydrogen storage device according to an embodiment of the present invention; Figure 4 This is a flowchart illustrating the control logic for three-level safety interlocking and fault diagnosis according to an embodiment of the present invention.

[0017] Figure Labels BCC solid-state hydrogen storage safety control system 100; hydrogen storage device 10; shell 11; hydrogen storage pipe 12; cooling system 20; safety interlock control module 30; sensing unit 31; interlock control unit 32; fault diagnosis unit 33; low-pressure solid-state hydrogen dispenser 200. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to specific examples and the accompanying drawings.

[0019] It should be noted that all uses of "first" and "second" in the embodiments of the present invention are for the purpose of distinguishing two entities or parameters with the same name but different names. It is clear that "first" and "second" are only for the convenience of expression and should not be construed as limiting the embodiments of the present invention. Subsequent embodiments will not explain this in detail.

[0020] According to one aspect of the present invention, an embodiment of the present invention provides a BCC solid-state hydrogen storage safety control system 100, including a hydrogen storage device 10, a cooling system 20 and a safety interlock control module 30.

[0021] Specifically, the hydrogen storage device 10 has a hydrogen storage pipe 12 with built-in BCC hydrogen storage alloy, a hydrogen charging valve for controlling the opening and closing of the hydrogen storage pipe 12, and a coolant channel; the cooling system 20 forms a closed circulation loop with the coolant channel to supply coolant to the hydrogen storage device 10; the safety interlock control module 30 is used to collect safety-related parameters of the hydrogen storage device 10, the cooling system 20, and the environment, and respectively activates the first-level interlock to open the hydrogen charging valve, the second-level interlock to adjust the hydrogen flow rate and the parameters of the cooling system 20, and the third-level interlock to close the hydrogen charging valve when the parameters meet the first-level interlock conditions, the second-level interlock to adjust the hydrogen flow rate and the parameters of the cooling system 20, and the third-level interlock to close the hydrogen charging valve.

[0022] like Figure 1 and Figure 2 As shown, the BCC solid-state hydrogen storage safety control system 100 according to an embodiment of the present invention controls the relevant parameters of the cooling system 20 supplying coolant to the hydrogen storage device 10, and controls the opening and closing of the hydrogen valve and the flow rate of hydrogen on the hydrogen storage device 10 when the low-pressure solid hydrogen dispenser 200 adds hydrogen to the hydrogen storage device 10. Specifically, it mainly includes the following three levels of control: I. Hydrogen Charging Preparation and Level 1 Interlock Verification: The system first initializes and performs a self-check of all internal modules. After confirming that all modules are ready, the operator issues a start command to turn on the chiller and circulating pump. The safety interlock control module 30 collects parameters such as water temperature, flow rate, pressure, and hydrogen concentration in real time. When all parameters meet the level 1 interlock conditions, the hydrogen charging valve is allowed to open.

[0023] II. Hydrogen charging operation and secondary interlock monitoring: During the hydrogen charging process, the system continuously monitors various key parameters. Once an abnormal trend occurs, the secondary interlock is automatically triggered to dynamically adjust the hydrogen charging flow rate and cooling power to maintain stable system operation.

[0024] III. Abnormal Operating Conditions and Three-Level Interlock Response: When the system triggers a three-level interlock condition, such as an alarm for overpressure, overtemperature, or high gas concentration, the controller immediately cuts off the hydrogen source, closes the relevant valves, and automatically records the event information.

[0025] For details, please refer to [link / reference]. Figure 4The control flowchart of the BCC solid-state hydrogen storage safety control system 100 in one embodiment described herein.

[0026] Therefore, the present invention provides a highly integrated, safe, and intelligent BCC solid-state hydrogen storage safety control system 100. This system achieves efficient thermal management, full-process safety protection, and intelligent fault handling during the hydrogen charging process through an optimized heat exchange structure, rigorous multi-level interlocking logic, and a comprehensive fault diagnosis model.

[0027] According to one embodiment of the present invention, such as Figure 3 As shown, the hydrogen storage device 10 includes a housing 11, which defines a receiving cavity. The hydrogen storage tubes 12 are arranged in an array within the receiving cavity, and the gap between the hydrogen storage tubes 12 and the housing 11 forms the coolant channel.

[0028] Specifically, such as Figure 3 As shown, the hydrogen storage device 10 is centered around the integrated arrangement of hydrogen storage tubes 12. The main module is a shell 11, inside which multiple hydrogen storage tubes 12 with built-in BCC hydrogen storage alloy are arranged in an array. A closed cooling water jacket channel, i.e., a coolant channel, is formed between the hydrogen storage tubes 12 and the inner wall of the shell 11. Furthermore, both ends of the hydrogen storage tubes 12 are connected to the main hydrogen pipe to achieve centralized hydrogen filling and releasing. Cooling water inlet and outlet are provided on the shell 11, forming a closed loop with the external cooling system 20. The structure of the arrayed hydrogen storage tubes 12 inside the shell 11, combined with the low-temperature closed-loop cooling water circulation, ensures the rapid and uniform removal of the heat of hydrogen filling reaction of the BCC material, avoids local overheating, and extends the material life.

[0029] In one embodiment of the present invention, the safety interlock control module 30 includes a sensing unit 31 and an interlock control unit 32.

[0030] Specifically, the sensing unit 31 is used to collect safety-related parameters of the hydrogen storage device 10, the cooling system 20, and the environment; the interlocking control unit 32 adopts a PLC or embedded controller to receive the safety-related parameters and execute corresponding interlocking actions.

[0031] Optionally, the interlocking control unit 32 can be a PLC (such as the Siemens S7-1200 series) or an embedded controller. The interlocking control unit 32 integrates analog and digital signal acquisition and output, interlocking logic operations, fault diagnosis algorithms, and communication functions (supporting protocols such as CAN bus and Modbus). This interlocking control unit 32 can achieve independent control of a single module or be expanded to support parallel and collaborative control of multiple modules, exhibiting high reliability.

[0032] In one embodiment of the present invention, the safety interlock control module 30 further includes a fault diagnosis unit 33, which is used to receive the safety-related parameters and determine the fault type based on the parameters. Specifically, the diagnosis unit 33 receives relevant parameters of the cooling system 20 and the hydrogen storage module through multi-dimensional sensor data acquisition and model algorithms, realizes real-time fault identification, classification and recording of fault information, and supports local display and remote query.

[0033] Furthermore, the diagnostic unit is also used to classify faults into three levels according to their severity: minor faults, general faults, and emergency faults; where minor faults are only recorded and a prompt is issued, general faults trigger a secondary interlock to reduce the hydrogen charging flow, and emergency faults trigger a tertiary interlock to close the hydrogen charging valve.

[0034] Specifically, the fault diagnosis of the cooling system 20 includes fault types such as low flow / interruption (diagnosing pump failure, blockage), decreased heat exchange efficiency (diagnosing scaling, chiller degradation), and abnormal temperature (diagnosing flow channel short circuit); and the fault diagnosis of the hydrogen storage device 10 includes faults such as abnormal hydrogen charging rate and pressure-temperature mismatch (diagnosing leakage, valve jamming, material degradation); and comprehensive fault classification and linkage: faults are classified into three levels: minor faults (only recording a prompt), general faults (triggering a level 2 load reduction), and emergency faults (triggering a level 3 shutdown), and fault codes and parameters are stored for traceability. A detailed workflow diagram can be found in [link to relevant documentation]. Figure 4 .

[0035] According to one embodiment of the present invention, the safety-related parameters satisfy the first-level interlocking condition by satisfying all of the following conditions: The cooling system 20 starts normally, and the coolant output temperature is 5 ℃~10 ℃; The coolant circulation flow rate is ≥2.0 m³ / h; The initial temperature of the coolant passage is ≤40 ℃; Hydrogen storage tube 12 pressure ≤ 5 MPa; The ambient hydrogen concentration is <20% LEL.

[0036] In one embodiment of the present invention, the safety-related parameters satisfying the secondary interlocking conditions include one of the following situations: Coolant flow rate is 80% or more than 120% of the set value; The wall temperature of the hydrogen storage tube is ≥60 ℃ or the rate of temperature rise exceeds the set threshold. Hydrogen pressure fluctuations exceed ±0.5 MPa; When any of the above conditions are met, the interlock control unit automatically reduces the hydrogen charging flow rate and adjusts the chiller load and water pump frequency of the cooling system; when all of the above conditions are eliminated, the load reduction state is automatically released.

[0037] According to another embodiment of the present invention, the safety-related parameters satisfying the three-level interlocking conditions include satisfying one of the following conditions: Hydrogen pressure ≥ 5.2 MPa; Coolant flow rate ≤ 50% of set value or ≥ 150% of set value; The wall temperature of hydrogen storage tube 12 is ≥80℃; Ambient hydrogen concentration ≥40% LEL; The duration of a single hydrogen refueling exceeds the preset safety time limit, such as exceeding 120 minutes; The cooling system 20 is shut down or the coolant circulation is interrupted.

[0038] According to another embodiment of the present invention, the interlocking control unit 32 also issues an audible and visual alarm signal when the safety-related parameters do not meet the first-level interlocking conditions or meet the third-level interlocking conditions. Figure 4 The conditions for issuing audible and visual alarm signals are illustrated in detail.

[0039] Therefore, the BCC solid-state hydrogen storage safety control system 100 according to embodiments of the present invention has at least the following advantages compared with the prior art: Significantly improved safety performance: Multiple hard interlock conditions, including overpressure, flow rate dual thresholds, gas alarm, and operation timeout, have been added, constructing a comprehensive protection system from early warning and load reduction to emergency shutdown; Highly efficient and uniform heat exchange: The array-type hydrogen storage tube 12, combined with a low-temperature closed-loop cooling water circulation, ensures the rapid and uniform removal of the heat of hydrogen charging reaction of BCC material, avoids local overheating, and extends the material life. Intelligent fault management: The comprehensive fault diagnosis model can identify, locate and classify various faults in real time, which greatly improves the maintainability and operational reliability of the system.

[0040] Modular and highly adaptable: The system structure is standardized and the control is universal, making it easy to adapt to solid-state hydrogen storage systems of different scales, such as the hydrogen storage and filling system of vanadium-based solid-state hydrogen fuel cell sightseeing vehicles.

[0041] The hydrogen fuel cell vehicle according to a second aspect of the present invention includes the BCC solid hydrogen storage safety control system 100 described in the above embodiments.

[0042] Since other structures of hydrogen fuel cell vehicles and other stationary equipment according to embodiments of the present invention are prior art in the art, they will not be described in detail here.

[0043] It should be understood that, as used herein, the singular form “a” is intended to include the plural form as well, unless the context clearly supports an exception. It should also be understood that, as used herein, “and / or” refers to any and all possible combinations of one or more of the associated listed items.

[0044] The embodiment numbers disclosed in the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0045] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples. Within the framework of the invention, technical features of the above embodiments or different embodiments can be combined, and many other variations of different aspects of the invention exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A BCC solid state hydrogen storage safety control system, characterized in that, include: A hydrogen storage device, which has a hydrogen storage tube with built-in BCC hydrogen storage alloy, a hydrogen filling valve for controlling the opening and closing of the hydrogen storage tube, and a coolant passage. The cooling system, together with the coolant channel, forms a closed-loop circulation circuit for supplying coolant to the hydrogen storage device; The safety interlock control module is used to collect safety-related parameters of the hydrogen storage device, cooling system, and environment. When the parameters meet the first-level interlock conditions, second-level interlock conditions, and third-level interlock conditions, the corresponding first-level interlock is activated to open the hydrogen charging valve, the second-level interlock is activated to adjust the hydrogen flow rate and the operating parameters of the cooling system, and the third-level interlock is activated to close the hydrogen charging valve.

2. The BCC solid-state hydrogen storage safety control system according to claim 1, characterized in that, The hydrogen storage device includes: The housing defines a receiving cavity, in which the hydrogen storage tube array is arranged, and the gap between the hydrogen storage tube and the housing forms the coolant channel.

3. The BCC solid-state hydrogen storage safety control system according to claim 1, characterized in that, The safety interlock control module includes: The sensing unit is used to collect safety-related parameters such as the temperature and pressure of the hydrogen storage device, the temperature and flow rate of the coolant in the cooling system, and the concentration of hydrogen in the environment. The interlocking control unit, which uses a PLC or embedded controller, is used to receive the safety-related parameters and execute the corresponding interlocking actions.

4. The BCC solid-state hydrogen storage safety control system according to claim 1, characterized in that, The safety interlock control module also includes: The fault diagnosis unit is used to receive the safety-related parameters and determine the fault type based on the parameters.

5. The BCC solid-state hydrogen storage safety control system according to claim 4, characterized in that, The diagnostic unit is also used for: Based on the severity of the fault, faults are classified into three levels: minor faults, general faults, and emergency faults. Minor faults are only recorded and a prompt is issued. General faults trigger a secondary interlock to reduce the hydrogen charging flow. Emergency faults trigger a tertiary interlock to close the hydrogen charging valve.

6. The BCC solid-state hydrogen storage safety control system according to claim 1, characterized in that, The safety-related parameters satisfy the Level 1 interlocking condition by satisfying all of the following conditions: The cooling system starts normally, and the coolant output temperature is 5 ℃~10 ℃; The coolant circulation flow rate is ≥2.0 m³ / h; The initial temperature of the coolant passage is ≤40 ℃; Hydrogen storage pipe pressure ≤ 5 MPa; The ambient hydrogen concentration is <20% LEL.

7. The BCC solid-state hydrogen storage safety control system according to claim 1, characterized in that, The safety-related parameters satisfying the secondary interlocking conditions include one of the following situations: Coolant flow rate is 80% or more than 120% of the set value; The wall temperature of the hydrogen storage tube is ≥60 ℃ or the rate of temperature rise exceeds the set threshold. Hydrogen pressure fluctuations exceed ±0.5 MPa; When any of the above conditions are met, the interlock control unit automatically reduces the hydrogen charging flow rate and adjusts the chiller load and water pump frequency of the cooling system; when all of the above conditions are eliminated, the load reduction state is automatically released.

8. The BCC solid-state hydrogen storage safety control system according to claim 7, characterized in that, The safety-related parameters that meet the three-level interlocking conditions include meeting one of the following conditions: Hydrogen pressure ≥ 5.2 MPa; Coolant flow rate ≤ 50% of set value or ≥ 150% of set value; Hydrogen storage tube wall temperature ≥80℃; Ambient hydrogen concentration ≥40% LEL; The duration of a single hydrogen refueling exceeds the preset safety time limit; The cooling system has stopped or the coolant circulation has been interrupted.

9. The BCC solid-state hydrogen storage safety control system according to claim 8, characterized in that, The interlocking control unit also issues an audible and visual alarm signal when the safety-related parameters do not meet the first-level interlocking conditions or meet the third-level interlocking conditions.

10. A hydrogen fuel cell vehicle comprising the BCC solid-state hydrogen storage safety control system according to any one of claims 1-9.

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