An integrated fuel cell system and vehicle

Abstract

The application discloses an integrated fuel cell system and a car, the integrated fuel cell system comprises an integrated frame, the electric pile, the fluid distribution manifold, the control subsystem and the hydrogen subsystem are located on the top of the integrated frame, the electric pile is fixedly arranged on the top surface of the integrated frame, and the fluid distribution manifold is fixedly connected with the interface side of the electric pile; the hydrogen subsystem is located on the side and the top of the fluid distribution manifold and is fixedly arranged on the top surface of the electric pile close to the fluid distribution manifold; the control subsystem is fixedly arranged on the top surface of the electric pile away from the fluid distribution manifold; the air subsystem and the heat management subsystem are respectively located on the bottom of the integrated frame. Based on the integrated frame, the module structure coupling and fixation are realized, no adapter support is needed, the module part mounting path is optimized, interference is effectively avoided, the assembly logic is simplified, the separate disassembly and maintenance of each part can be realized; meanwhile, the hydrogen gas is arranged on the side and the top and the hydrogen gas flow channel is short, the electric pile single low can be avoided.

Description

Technical Field

[0001] This invention relates to the field of power technology, specifically to an integrated fuel cell system and a vehicle. Background Technology

[0002] As an important tool for hydrogen energy applications, hydrogen fuel cell systems are gradually being widely used in long-distance heavy-duty road transportation, rail transportation, ships, aircraft, independent power sources, and combined heat and power systems due to their advantages such as high efficiency (theoretical efficiency can reach more than 80%), zero emissions and no pollution (the only product is water), good low-temperature adaptability (can be used normally at -30℃), and fast energy replenishment speed.

[0003] A typical hydrogen fuel cell system consists of a stack, hydrogen supply, air supply, thermal management, and control modules. The system comprises hundreds of primary sub-components, making its overall structure quite complex. Therefore, it is crucial to rationally integrate and arrange these numerous components to achieve the expected system functions and performance, enabling easy installation on different vehicle models while simultaneously addressing requirements such as miniaturization, lightweight design, and ease of assembly and maintenance. Currently, the mainstream solution in the industry uses one or more combined brackets to form the system's support structure. The stack is mounted on top of this structure, and hydrogen / air / thermal management sub-components are mounted below it via several adapter brackets. A DC-DC converter is connected above the stack via copper busbars or high-voltage cables, and fluid transport and sealing are achieved on the stack's air inlet side via several adapters. However, to achieve system miniaturization and fully utilize the space within the system envelope, there is considerable obstruction and overlap between the various components in the installation space.

[0004] Due to its own structural limitations, the number of adapter brackets that make up the load-bearing body is large, which is not conducive to the miniaturization and weight reduction of the system. It also has disadvantages such as inconvenient assembly, high logistics and management costs. Furthermore, the components have too much assembly logic in the installation space, which causes inconvenience in assembly and after-sales maintenance.

[0005] In view of this, there is an urgent need to propose improvement solutions for fuel cell systems in order to overcome the above-mentioned defects. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides an integrated fuel cell system and a vehicle. By optimizing the integrated configuration scheme of the integrated fuel cell system, the assembly logic can be simplified, making assembly and after-sales maintenance easier.

[0007] The integrated fuel cell system provided by this invention includes an integrated frame, a fuel cell stack, a fluid distribution manifold, a control subsystem, a hydrogen subsystem, an air subsystem, and a thermal management subsystem. The fuel cell stack, the fluid distribution manifold, the control subsystem, and the hydrogen subsystem are located on top of the integrated frame. The fuel cell stack is fixedly mounted on the top surface of the integrated frame, and the fluid distribution manifold is fixedly connected to the interface side of the fuel cell stack. The hydrogen subsystem is located beside and on top of the fluid distribution manifold, and is fixedly mounted on the top surface of the fuel cell stack near the fluid distribution manifold. The control subsystem is fixedly mounted on the top surface of the fuel cell stack away from the fluid distribution manifold. The air subsystem and the thermal management subsystem are located at the bottom of the integrated frame.

[0008] Optionally, it also includes a wiring harness and sensor subsystem, wherein the sensors and wiring harnesses of the wiring harness and sensor subsystem are respectively disposed on the integrated frame, the fuel cell stack, the fluid distribution manifold, the control subsystem, the hydrogen subsystem, the air subsystem, and the thermal management subsystem.

[0009] Optionally, the integrated frame is provided with a first mounting hole, and the bottom of the fuel cell stack is provided with a seventh threaded hole, and both are fixed in the corresponding first mounting holes on the integrated frame by threaded fasteners.

[0010] Optionally, the fuel cell stack has the following on the side opposite to the fluid distribution manifold: a first hydrogen inlet, a first hydrogen outlet, a first air inlet, a first air outlet, a first cooling water inlet, and a first cooling water outlet; and an eighth threaded hole for mounting the fluid distribution manifold is also provided on the same side. The fluid distribution manifold has the following: a second hydrogen outlet, a second hydrogen inlet, a second air outlet, a second air inlet, a second cooling water outlet, and a second cooling water inlet; wherein the second hydrogen outlet on the fluid distribution manifold is connected to the first hydrogen inlet on the fuel cell stack. The second hydrogen inlet on the fluid distribution manifold is connected to the first hydrogen outlet on the fuel cell stack; the second air outlet on the fluid distribution manifold is connected to the first air inlet on the fuel cell stack; the second air inlet on the fluid distribution manifold is connected to the first air outlet on the fuel cell stack; the second cooling water outlet on the fluid distribution manifold is connected to the first cooling water inlet on the fuel cell stack; the second cooling water inlet on the fluid distribution manifold is connected to the first cooling water outlet on the fuel cell stack; the fluid distribution manifold is provided with a through hole and is connected to the eighth threaded hole of the fuel cell stack by a bolt.

[0011] Optionally, the top surface of the fuel cell stack is provided with a copper busbar and a ninth threaded hole; the control subsystem includes a DCF, an integrated controller, and a T-BOX; the control subsystem is provided with a through hole, which is connected to the ninth threaded hole of the fuel cell stack by bolts; the control subsystem is provided with a second mounting hole for connection with the integrated controller and the T-BOX; the DCF is provided with a high-voltage copper busbar interface, which is connected to the copper busbar on the fuel cell stack; the integrated controller is provided with a first DC interface, which is connected to a second DC interface via a cable, and is connected to the hydrogen circulation pump in the hydrogen subsystem via a first internal port; the integrated controller is also provided with a second internal port for connection with the sensors and valves of the wiring harness and sensor subsystem.

[0012] Optionally, the top surface of the fuel cell stack is further provided with a tenth threaded hole; the fluid distribution manifold is provided with a first set of interfaces, a second set of interfaces, and a third set of interfaces; the hydrogen subsystem includes a hydrogen circulation pump, a hydrogen supply assembly, a hydrogen heat exchanger, a hydrogen discharge valve, and a safety valve; wherein, the hydrogen circulation pump is provided with a third mounting hole, which is connected to the tenth threaded hole on the fuel cell stack by bolts; the hydrogen supply assembly is provided with a sixth set of interfaces, which is connected to the first set of interfaces on the fluid distribution manifold; the hydrogen discharge valve is provided with a seventh set of interfaces, which is connected to the second set of interfaces on the fuel cell stack; the safety valve is provided with an eighth set of interfaces, which is connected to the third set of interfaces on the fluid distribution manifold, and the mounting port on the hydrogen heat exchanger is connected to the hydrogen supply assembly by bolts.

[0013] Optionally, the integrated frame is provided with a first threaded hole, a second threaded hole, and a third threaded hole; the fluid distribution manifold is provided with a fourth set of interfaces and a fifth set of interfaces; the air subsystem includes an air compressor, an air compressor controller, an intercooler, a combination valve, and a back pressure valve, wherein the air compressor is provided with a fourth mounting hole, which is connected to the first threaded hole on the integrated frame by bolts; the air compressor controller is provided with a fifth mounting hole, which is connected to the second threaded hole on the integrated frame by bolts; the intercooler is provided with a sixth mounting hole, which is connected to the third threaded hole on the integrated frame by bolts; the combination valve is provided with a ninth set of interfaces, which is connected to the fourth set of interfaces on the fluid distribution manifold; and the back pressure valve is provided with a tenth set of interfaces, which is connected to the fifth set of interfaces on the fluid distribution manifold.

[0014] Optionally, the integrated frame is provided with a fourth threaded hole and a fifth threaded hole; the air compressor controller is provided with a seventh mounting hole; the thermal management subsystem includes a water pump, a thermostat, and a deionizer; wherein, the water pump is provided with a ninth mounting hole, which is connected to the fifth threaded hole on the integrated frame by bolts; the thermostat is provided with an eleventh mounting hole, which is connected to the seventh mounting hole on the air subsystem by bolts; and the deionizer is provided with a tenth mounting hole, which is connected to the fourth threaded hole on the integrated frame by bolts.

[0015] Optionally, the integrated frame is provided with a sixth threaded hole for connection with the vehicle body.

[0016] The present invention also provides an automobile, including a vehicle body and an integrated fuel cell system disposed on the vehicle body, the integrated fuel cell system employing the integrated fuel cell system described above.

[0017] Compared with existing technologies, this invention proposes a novel approach to the implementation of an integrated fuel cell system. Specifically, based on this integrated framework, the structural coupling of each module is fixed without adapter brackets, thereby optimizing the installation path of each module component, effectively avoiding interference, and simplifying the assembly logic, enabling individual disassembly and maintenance of each component. At the same time, the side-mounted and top-mounted hydrogen path of this implementation scheme and the shortened hydrogen flow path can avoid water vapor condensation and low-temperature freezing, improve the low-temperature ice-breaking capability of the circulation pump and the cold start performance of the system, and avoid low fuel cell stack temperature caused by water flooding on the fuel cell stack inlet side. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the layout architecture of the integrated fuel cell system described in the embodiments of this application;

[0019] Figure 2 for Figure 1 An exploded view of the integrated fuel cell system shown in the image.

[0020] Figure 3 This is an isometric view of the integrated framework described in the embodiments of this application;

[0021] Figure 4 This is another isometric view of the integrated framework described in the embodiments of this application;

[0022] Figure 5 This is a bottom view of the fuel cell stack described in the embodiments of this application;

[0023] Figure 6 This is a bottom view of the fuel cell stack installed on the integrated frame according to an embodiment of this application;

[0024] Figure 7 This is an isometric view of the fuel cell stack described in the embodiments of this application;

[0025] Figure 8 This is a rear view of the fluid distribution manifold described in the embodiment of this application;

[0026] Figure 9 This is an isometric view of the fluid distribution manifold as described in the embodiments of this application, mounted on the fuel cell stack and integrated frame;

[0027] Figure 10 This is a top view of the fluid distribution manifold described in the embodiment of this application;

[0028] Figure 11 This is a right-side view of the fluid distribution manifold described in an embodiment of this application;

[0029] Figure 12 This is a front view of the fluid distribution manifold described in the embodiment of this application;

[0030] Figure 13 This is a top view of the control subsystem described in the embodiments of this application;

[0031] Figure 14 This is an isometric view of the control subsystem described in the embodiments of this application installed in the fluid distribution manifold, fuel cell stack, and integrated frame;

[0032] Figure 15 This is an isometric view of the control subsystem described in the embodiments of this application;

[0033] Figure 16 This is an isometric view of the hydrogen subsystem described in the embodiments of this application;

[0034] Figure 17 This is a top view of the hydrogen subsystem described in the embodiments of this application;

[0035] Figure 18 This is an isometric view of the hydrogen subsystem described in this application, installed to the control subsystem, fluid distribution manifold, fuel cell stack, and integrated frame.

[0036] Figure 19 This is an isometric view of the air subsystem described in the embodiments of this application;

[0037] Figure 20 This is a bottom view of the air subsystem installed to the hydrogen subsystem, control subsystem, fluid distribution manifold, fuel cell stack, and integrated frame according to an embodiment of this application.

[0038] Figure 21 This is an isometric view of the air subsystem installed to the hydrogen subsystem, control subsystem, fluid distribution manifold, fuel cell stack, and integrated frame as described in the embodiments of this application.

[0039] Figure 22 This is an isometric view of the thermal management subsystem described in the embodiments of this application;

[0040] Figure 23 This is an isometric view of the thermal management subsystem described in this application, installed to the air subsystem, hydrogen subsystem, control subsystem, fluid distribution manifold, fuel cell stack, and integrated frame.

[0041] In the picture:

[0042] Integrated fuel cell system 100;

[0043] Integrated frame 10, sixth threaded hole 11, first mounting hole 12, first threaded hole 161, second threaded hole 162, third threaded hole 163, fourth threaded hole 171, fifth threaded hole 172;

[0044] 20. Seventh threaded hole 21. First hydrogen inlet 231. First hydrogen outlet 232. First air inlet 233. First air outlet 234. First cooling water inlet 235. First cooling water outlet 236. Eighth threaded hole 237. Copper busbar 241. Ninth threaded hole 242. Tenth threaded hole 251.

[0045] Fluid distribution manifold 30, second hydrogen outlet 321, second hydrogen inlet 322, second air outlet 323, second air inlet 324, second cooling water outlet 325, second cooling water inlet 326, through hole 327, first set of interfaces 351, second set of interfaces 352, third set of interfaces 353, fourth set of interfaces 361, and fifth set of interfaces 362;

[0046] Control subsystem 40, DCF 401, integrated controller 402, T-BOX 403, through hole 421, high voltage copper busbar interface 422, second mounting hole 441, external port 442, first DC interface 443, second DC interface 444, first internal port 45, second internal port 48;

[0047] Hydrogen subsystem 50, hydrogen circulation pump 501, hydrogen supply assembly 502, hydrogen heat exchanger 503, hydrogen discharge valve 504, safety valve 505, third mounting hole 52, sixth group interface 531, seventh group interface 532, eighth group interface 533, mounting port 55.

[0048] Air subsystem 60, air compressor 601, air compressor controller 602, intercooler 603, combination valve 604, back pressure valve 605, fourth mounting hole 611, fifth mounting hole 612, sixth mounting hole 613, ninth group interface 631, tenth group interface 632, seventh mounting hole 67;

[0049] Thermal management subsystem 70, water pump 701, thermostat 702, deionizer 703, ninth mounting hole 71, tenth mounting hole 72, eleventh mounting hole 76;

[0050] Wiring harness and sensor subsystem 80. Detailed Implementation

[0051] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0052] Please see Figure 1 and Figure 2 ,in, Figure 1 This is a schematic diagram of the layout architecture of the integrated fuel cell system described in this embodiment. Figure 2 for Figure 1 The exploded view of the integrated fuel cell system shown is an assembly diagram.

[0053] The integrated fuel cell system 100 includes an integrated frame 10, a stack 20, a fluid distribution manifold 30, a control subsystem 40, a hydrogen subsystem 50, an air subsystem 60, and a thermal management subsystem 70.

[0054] This implementation plan adopts an integrated frame 10 as the main carrier and skeleton of the entire system to solve the problem that the large number of adapter brackets in the system is not conducive to the miniaturization, lightweighting, and assembly convenience of the system, and the high cost of parts logistics management.

[0055] The fuel cell stack 20, fluid distribution manifold 30, control subsystem 40, and hydrogen subsystem 50 are located on top of the integrated frame 10. The fuel cell stack 20 is fixedly mounted on the top surface of the integrated frame 10. The fluid distribution manifold 30 is fixedly connected to the interface side of the fuel cell stack 20. Here, the "interface side" refers to the side where the hydrogen, air, and coolant inlets and outlets of the fuel cell stack 20 are located, allowing communication of the fluid medium between the fuel cell stack 20 and the fuel cell stack 20 through the fluid distribution manifold 30. The hydrogen subsystem 50 is located beside and on top of the fluid distribution manifold 30, and is fixedly mounted on the top surface of the fuel cell stack 20 near the fluid distribution manifold 30. The control subsystem 40 is fixedly mounted on the top surface of the fuel cell stack 20 away from the fluid distribution manifold 30.

[0056] The air subsystem 60 and the thermal management subsystem 70 are located at the bottom of the integrated frame 10. After assembly, there are no other connecting brackets between them, and all mounting holes can be exposed, leaving no obstruction for the installation tool space.

[0057] Overall, based on this integrated framework 10, the structural coupling of each module is fixed without the need for adapter brackets. This optimizes the installation path of each module component, effectively avoids interference, and simplifies the assembly logic, enabling individual disassembly and maintenance of each component. At the same time, the side-mounted and top-mounted hydrogen path of this implementation scheme and the shortened hydrogen flow path can avoid water vapor condensation and low-temperature freezing, improve the low-temperature ice-breaking capability of the circulating pump and the cold start performance of the system, and avoid low voltage of the fuel cell stack caused by water flooding on the fuel cell stack inlet side.

[0058] In addition, the integrated fuel cell system provided in this embodiment also includes a wiring harness and sensor subsystem 80, such as... Figure 2 As shown, the sensors of the wiring harness and sensor subsystem 80 are installed on the corresponding modules, and the wiring harness of the wiring harness and sensor subsystem 80 is connected to the components of the corresponding modules through connectors. It should be understood that the wiring harness and sensor subsystem 80 is distributed among the modules of the entire system to achieve the corresponding functional requirements. The relevant functional principles are not the core inventive point of this application, and those skilled in the art can implement them based on existing technology, so they will not be described in detail here.

[0059] In practical implementation, the integrated frame 10 can be made of high-pressure die-cast aluminum, formed using an integrated process, which offers good manufacturability and meets the trend of lightweight product design. Please refer to [link / reference]. Figure 3 and Figure 4 ,in, Figure 3 This is an isometric view of the integrated framework described in the embodiments of this application. Figure 4 This is another isometric view of the integrated framework described in the embodiments of this application.

[0060] As the only main load-bearing structure in the entire system, the integrated frame 10 is provided with a first mounting hole 12 for connecting to the fuel cell stack 20, a first threaded hole 161, a second threaded hole 162 and a third threaded hole 163 for connecting to the air subsystem 60, a fourth threaded hole 171 and a fifth threaded hole 172 for connecting to the thermal management subsystem 70, and a sixth threaded hole 11 for forming a four-point suspension connection with the vehicle (not shown in the figure). As shown in the figure, the multiple sixth threaded holes 11 are respectively opened on the front and rear end faces and are located at the left and right ends of the same side end face, so as to be fixedly connected to the vehicle body for assembly.

[0061] It is understood that the aforementioned vias and threaded holes correspond to the configurations of the respective assembly modules, and the specific number can be determined according to the actual product design requirements, rather than being limited to the configuration number shown in the figure.

[0062] In addition, the integrated frame 10 is provided with several threaded holes (not shown in the figure) for fixing the wire harness and the wire harness in the sensor subsystem 80, which will not be described in detail here.

[0063] For the assembly of fuel cell stack 20, please refer to [link / reference]. Figure 5 and Figure 6 ,in, Figure 5 A bottom view of the fuel cell stack 20 is shown. Figure 6 A bottom view of the fuel cell stack 20 mounted on the integrated frame 10 is shown.

[0064] like Figure 5As shown, a seventh threaded hole 21 is provided at the bottom of the fuel cell stack 20, which is fixed to the corresponding first mounting hole 12 on the integrated frame 10 by threaded fasteners. Specifically, the fuel cell stack 20 is fixed to the integrated frame 10 by the threaded engagement of bolts and nuts. A schematic diagram after assembly is shown below. Figure 6 As shown, the fuel cell stack 20 is directly connected to the integrated frame 10 without any other adapter brackets in between, and all mounting holes are exposed, leaving no obstruction to the operating space of the installation tools.

[0065] Please see Figure 7 The figure is an isometric view of the fuel cell stack 20 described in an embodiment of this application. The fuel cell stack 20 is provided with mounting interfaces for a fluid distribution manifold 30, a control subsystem 40, and a hydrogen subsystem 50.

[0066] like Figure 7 As shown, the fuel cell stack 20 has six fluid inlet and outlet ports on the side opposite to the fluid distribution manifold 30, namely a first hydrogen inlet 231, a first hydrogen outlet 232, a first air inlet 233, a first air outlet 234, a first cooling water inlet 235, and a first cooling water outlet 236. Several eighth threaded holes 237 for installing the fluid distribution manifold 30 are also provided on the same side.

[0067] The top surface of the fuel cell stack 20 is provided with a copper busbar 241 for connecting to the control subsystem 40, and a ninth threaded hole 242 for connecting to the control subsystem 40; the top surface is also provided with a tenth threaded hole 251 for connecting to the hydrogen subsystem 50. Hydrogen and air enter the fuel cell stack 20 through the first hydrogen inlet 231 and the first air inlet 233, respectively, and undergo an electrochemical reaction inside the fuel cell stack 20. The generated electrical energy is output through the copper busbar 241, and the waste gas flows out through the first hydrogen outlet 232 and the first air outlet 234. At the same time, the coolant in the thermal management subsystem 70 enters and exits the fuel cell stack 20 through the first cooling water inlet 235 and the first cooling water outlet 236, thereby removing the waste heat generated by the fuel cell stack.

[0068] For the assembly of the fluid distribution manifold 30, please refer to [the relevant documentation]. Figure 7 and Figure 8 ,in, Figure 8 This is a rear view of the branch manifold described in an embodiment of this application.

[0069] The fluid distribution manifold 30 is provided with six fluid inlet and outlet ports, namely a second hydrogen outlet 321, a second hydrogen inlet 322, a second air outlet 323, a second air inlet 324, a second cooling water outlet 325, and a second cooling water inlet 326. Specifically, the second hydrogen outlet 321 on the fluid distribution manifold 30 is connected to the first hydrogen inlet 231 on the fuel cell stack 20; the second hydrogen inlet 322 on the fluid distribution manifold 30 is connected to the first hydrogen outlet 232 on the fuel cell stack 20; the second air outlet 323 on the fluid distribution manifold 30 is connected to the first air inlet 233 on the fuel cell stack 20; the second air inlet 324 on the fluid distribution manifold 30 is connected to the first air outlet 234 on the fuel cell stack 20; the second cooling water outlet 325 on the fluid distribution manifold 30 is connected to the first cooling water inlet 235 on the fuel cell stack 20; and the second cooling water inlet 326 on the fluid distribution manifold 30 is connected to the first cooling water outlet 236 on the fuel cell stack 20. In the above-mentioned connection relationship, the connection of the corresponding fluid media is achieved by sealing with a sealing ring.

[0070] Meanwhile, several through holes 327 are provided around the fluid distribution manifold 30 and around the six medium inlets and outlets, which are connected to the eighth threaded hole 237 of the fuel cell stack 20 by bolts. The schematic diagram after assembly is shown below. Figure 9 As shown. Similarly, the fuel cell stack 20 is directly connected to the fluid distribution manifold 30 without any other connecting brackets in between, and all mounting holes are exposed, leaving no obstruction for the installation tool space.

[0071] Please also see Figure 10 , Figure 11 and Figure 12 ,in, Figure 10 This is a top view of the fluid distribution manifold described in the embodiment of this application. Figure 11 This is a right-side view of the fluid distribution manifold described in an embodiment of this application. Figure 12 This is a front view of the fluid distribution manifold described in the embodiment of this application.

[0072] The fluid distribution manifold 30 is provided with a first set of interfaces 351, a second set of interfaces 352 and a third set of interfaces 353 connected to the hydrogen subsystem 50, and a fourth set of interfaces 361 and a fifth set of interfaces 362 connected to the air subsystem 60, so as to realize the fixation and function of the hydrogen subsystem and the air subsystem respectively.

[0073] In addition, the fluid distribution manifold 30 is also equipped with several pipe fittings, sensor interfaces, and wiring harness fixing holes for connection to the hydrogen subsystem 50, air subsystem 60, thermal management subsystem 70, and wiring harness and sensor subsystem 80, which will not be described in detail here. Overall, the fluid distribution manifold 30 is a single integrated component, replacing multiple scattered adapters and connecting pipes, greatly simplifying the system structure, reducing potential leakage points, and improving system reliability; at the same time, this module also has functions such as water vapor separation, fluid mixing and pressure stabilization, and fluid shut-off.

[0074] For the assembly of control subsystem 40, please refer to [link / reference]. Figure 13 This figure is a top view of the control subsystem described in an embodiment of this application.

[0075] like Figure 13 As shown, the control subsystem 40 includes a DCF (DC / DC Converter for Fuel Cell) 401, an integrated controller 402, and a T-BOX (Telematics BOX, intelligent vehicle terminal) 403. The control subsystem 40 has multiple through holes 421, which are directly connected to the ninth threaded hole 242 of the fuel cell stack 20 via bolts. The control subsystem 40 also has a second mounting hole 441 inside, enabling the connection between the integrated controller 402 and the T-BOX 403. There are no other adapter brackets in between, and all mounting holes are exposed, leaving no obstruction for installation tools. A schematic diagram of the entire control subsystem 40 after installation is shown below. Figure 14 As shown.

[0076] like Figure 15 As shown, the DCF 401 is equipped with a high-voltage copper busbar interface 422, which connects to the copper busbar 241 in the fuel cell stack 20 to transmit the electrical energy generated by the fuel cell stack reaction. The DCF 401 performs voltage boosting and power distribution internally, and then outputs the power to the entire vehicle (not shown in the figure) through an external port 442. The integrated controller 402 is equipped with a first DC interface 443, which connects to a second DC interface 444 via a cable to transmit DC power. After inversion within the integrated controller 402, the DC power is connected to the hydrogen circulation pump in the hydrogen subsystem 50 via a first internal port 45. Furthermore, the integrated controller 402 is also equipped with a second internal port 48, which connects to various sensors, valves, etc., through wiring harnesses and cables in the sensor subsystem 80 to achieve signal acquisition, processing, and control functions. Here, the integrated controller 402 uses a single main control chip, thereby improving chip utilization and reducing controller cost; it combines the traditional hydrogen circulation pump controller, FCU (Fuel-cell Control Unit), and valve controller into one, saving the packaging housing of multiple controllers and the wiring harness connections between them, which helps to miniaturize and lighten the control system.

[0077] For the assembly of hydrogen subsystem 50, please refer to [link / reference]. Figure 16 and Figure 17 ,in, Figure 16 This is an isometric view of the hydrogen subsystem described in the embodiments of this application. Figure 17 This is a top view of the hydrogen subsystem described in the embodiments of this application.

[0078] like Figure 16 As shown, the hydrogen subsystem 50 includes a hydrogen circulation pump 501, a hydrogen supply assembly 502, a hydrogen heat exchanger 503, a hydrogen discharge valve 504, a safety valve 505, and rubber tubing for other fluid channels. The hydrogen circulation pump 501 has five third mounting holes 52, which are bolted to the tenth threaded holes 251 on the fuel cell stack 20. The hydrogen supply assembly 502 has a sixth set of interfaces 531, which are connected to the first set of interfaces 351 on the fluid distribution manifold 30. The hydrogen discharge valve 504 has a seventh set of interfaces 532, which are connected to the second set of interfaces 352 on the fuel cell stack 20. The safety valve 505 has an eighth set of interfaces 533, which are connected to the third set of interfaces 353 on the fluid distribution manifold 30. Figure 17 As shown, the four mounting ports 55 on the hydrogen heat exchanger 503 can be directly connected to the hydrogen supply assembly 502 using four bolts. A schematic diagram of the assembled hydrogen subsystem 50 is shown below. Figure 18 As shown, there are no other adapter brackets between them, and all mounting holes are exposed, leaving no obstruction for the installation tools.

[0079] In addition, such as Figure 18 As shown, the hydrogen circulation pump 501 in the entire hydrogen subsystem is arranged on top of the fuel cell stack 20, which effectively reduces the risk of the circulation pump freezing at low temperatures and failing to start; the remaining parts are deeply integrated with the fluid distribution manifold 30, which shortens the hydrogen path and avoids excessive water vapor condensation during transportation, thus preventing low temperatures in the fuel cell stack.

[0080] For the assembly of air subsystem 60, please refer to [link / reference needed]. Figure 19 and Figure 20 ,in, Figure 19 This is an isometric view of the air subsystem described in an embodiment of this application. Figure 20 This is a bottom view of the air subsystem installed to the hydrogen subsystem, control subsystem, fluid distribution manifold, fuel cell stack, and integrated frame, as described in the embodiments of this application.

[0081] like Figure 19As shown, the air subsystem 60 includes an air compressor 601, an air compressor controller 602, an intercooler 603, a combination valve 604, a back pressure valve 605, and rubber tubing for other fluid passages. The air compressor 601 has four fourth mounting holes 611, which are bolted to the first threaded holes 161 on the integrated frame 10. The air compressor controller 602 has three fifth mounting holes 612, which are bolted to the second threaded holes 162 on the integrated frame 10. The intercooler 603 has three sixth mounting holes 613, which are bolted to the third threaded holes 163 on the integrated frame 10. The combination valve 604 has a ninth set of interfaces 631, which are connected to the fourth set of interfaces 361 on the fluid distribution manifold 30. The back pressure valve 605 has a tenth set of interfaces 632, which are connected to the fifth set of interfaces 362 on the fluid distribution manifold 30. A schematic diagram of the assembled air subsystem 60 is shown below. Figure 20 and Figure 21 As shown, there are no other adapter brackets between them, and all mounting holes are exposed, leaving no obstruction for the installation tools.

[0082] In addition, combined Figure 20 As shown, the air compressor controller 602 is provided with four seventh mounting holes 67 for fixing the thermostat in the thermal management subsystem 70.

[0083] For the assembly of the thermal management subsystem 70, please refer to [link / reference]. Figure 22 This figure is an isometric view of the thermal management subsystem described in an embodiment of this application.

[0084] like Figure 22 As shown, the thermal management subsystem 70 includes a water pump 701, a thermostat 702, and a deionizer 703, as well as rubber tubing for other fluid channels. The water pump 701 has four ninth mounting holes 71, which are bolted to the fifth threaded holes 172 on the integrated frame 10. The thermostat 702 has four eleventh mounting holes 76, which are bolted to the seventh mounting holes 67 on the air subsystem 60. The deionizer 703 has two tenth mounting holes 72, which are bolted to the fourth threaded holes 171 on the integrated frame 10. A schematic diagram of the assembled thermal management subsystem 70 is shown below. Figure 23 As shown, there are no other adapter brackets between them, and all mounting holes are exposed, leaving no obstruction for the installation tools.

[0085] In this implementation scheme, the wiring harness and sensor subsystem 80 consists of high and low voltage wiring harnesses and sensors. The sensors are installed into the cavity embedded in the integrated module via external threads, and the wiring harnesses are connected to each component via connectors, secured with cable ties and clips. The specific securing method can be implemented using existing technology, so it will not be described in detail here.

[0086] In summary, the integrated fuel cell system provided by this implementation plan, apart from the integrated frame as the main load-bearing structure, has all other components fixed together by structural coupling through their respective encapsulated shells, without other adapter brackets. This contributes to the miniaturization, weight reduction, and ease of assembly of the system, and reduces the cost of parts and materials management. Space is reserved for fixing and installing tools for each component, and they can be disassembled and assembled individually at the system level without any sequential assembly logic, thereby improving the convenience of system assembly and maintenance.

[0087] The integrated fuel cell system provided in this embodiment has the following beneficial technical effects:

[0088] First, it contributes to the miniaturization and weight reduction of the system, including the use of an integrated fluid distribution manifold; an integrated frame without adapter brackets; and a multi-functional controller that combines FCU / hydrogen circulation pump controller / low-pressure valve control and drive functions.

[0089] Second, it helps improve system reliability, including the use of an integrated fluid distribution manifold to reduce potential leak points; the top and side placement of the hydrogen path reduces the risk of low-temperature icing of the circulating pump and the risk of low fuel cell stack condensation caused by water vapor condensation in the hydrogen path.

[0090] Third, it helps reduce system costs, including by adopting an integrated fluid distribution manifold and an integrated framework, reducing mold costs and component material management costs; and by adopting a single-chip integrated controller, improving chip utilization and reducing mold costs for multiple controller housings, interconnection wiring harness material costs, and component material management costs.

[0091] Fourth, it helps improve system compatibility. Through modular integration of the hydrogen / air / cooling subsystem, it can be compatible with more different types of components.

[0092] Fifth, it helps improve the ease of system assembly and maintenance, including integrated design and processing of parts, which reduces the number of parts that need to be assembled; it reserves space for assembly tools for each part, and the assembly path has no interference or sequential logical relationship, enabling individual disassembly and maintenance of individual parts.

[0093] It should be noted that the number of interfaces used to fix the modules of the integrated fuel cell system is not limited to the exemplary illustration shown in the figure. It should be understood that in the specific implementation, it can be determined according to the overall design requirements of the actual product, as long as reliable fixing between the adapter modules can be achieved.

[0094] In addition to the aforementioned integrated fuel cell system, this embodiment also provides a vehicle comprising a vehicle body and an integrated fuel cell system as described above, mounted on the vehicle body. The vehicle can be a pure electric vehicle or a hybrid electric vehicle.

[0095] It should be understood that the specific implementation of other functions of the vehicle is not the core inventive point of this application, and those skilled in the art can implement them based on existing technology, so it will not be elaborated here.

[0096] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An integrated fuel cell system, characterized by comprising: The integrated frame (10), the stack (20), the fluid distribution manifold (30), the control subsystem (40), the hydrogen subsystem (50), the air subsystem (60) and the thermal management subsystem (70); The stack (20), the fluid distribution manifold (30), the control subsystem (40) and the hydrogen subsystem (50) are located on the top of the integrated frame (10), the stack (20) is fixedly arranged on the top surface of the integrated frame (10), and the fluid distribution manifold (30) is fixedly connected with the interface side of the stack (20); the hydrogen subsystem (50) is located on the side and top of the fluid distribution manifold (30) and is fixedly arranged on the top surface of the stack (20) close to the fluid distribution manifold (30); the control subsystem (40) is fixedly arranged on the top surface of the stack (20) away from the fluid distribution manifold (30); the air subsystem (60) and the thermal management subsystem (70) are respectively located on the bottom of the integrated frame (10); The side opposite to the stack (20) and the fluid distribution manifold (30) is provided with a first hydrogen inlet (231), a first hydrogen outlet (232), a first air inlet (233), a first air outlet (234), a first cooling water inlet (235) and a first cooling water outlet (236), and the same side is also provided with an eighth threaded hole (237) for mounting the fluid distribution manifold (30); The fluid distribution manifold (30) is provided with a second hydrogen outlet (321), a second hydrogen inlet (322), a second air outlet (323), a second air inlet (324), a second cooling water outlet (325) and a second cooling water inlet (326); wherein the second hydrogen outlet (321) on the fluid distribution manifold (30) is in communication with the first hydrogen inlet (231) on the stack (20); the second hydrogen inlet (322) on the fluid distribution manifold (30) is in communication with the first hydrogen outlet (232) on the stack (20); the second air outlet (323) on the fluid distribution manifold (30) is in communication with the first air inlet (233) on the stack (20); the second air inlet (324) on the fluid distribution manifold (30) is in communication with the first air outlet (234) on the stack (20); the second cooling water outlet (325) on the fluid distribution manifold (30) is in communication with the first cooling water inlet (235) on the stack (20); the second cooling water inlet (326) on the fluid distribution manifold (30) is in communication with the first cooling water outlet (236) on the stack (20); the fluid distribution manifold (30) is provided with a through hole (327) and is connected with the eighth threaded hole (237) of the stack (20) through a bolt.

2. The integrated fuel cell system of claim 1, wherein Also included is a wiring harness and sensor subsystem (80) having sensors and wiring harnesses disposed on the integrated frame (10), the stack (20), the fluid distribution manifold (30), the control subsystem (40), the hydrogen subsystem (50), the air subsystem (60), and the thermal management subsystem (70), respectively.

3. The integrated fuel cell system of claim 2, wherein The integrated frame (10) is provided with first mounting holes (12), and the bottom of the stack (20) is provided with seventh threaded holes (21), which are respectively fixed on the integrated frame (10) through threaded fasteners in the corresponding first mounting holes (12).

4. The integrated fuel cell system of claim 2, wherein The top surface of the stack (20) is provided with a copper bar (241) and a ninth threaded hole (242); The control subsystem (40) includes a DCF (401), an integrated controller (402), and a T-BOX (403). The control subsystem (40) is provided with a through hole (421) connected to the ninth threaded hole (242) of the stack (20) through a bolt. The control subsystem (40) is internally provided with a second mounting hole (441) for connection with the integrated controller (402) and the T-BOX (403). The DCF (401) is provided with a high-voltage copper bar interface (422) connected to the copper bar (241) on the stack (20). The integrated controller (402) is provided with a first DC interface (443) connected to a second DC interface (444) through a cable and connected to a hydrogen circulating pump in the hydrogen subsystem (50) through a first internal connection port (45). The integrated controller (402) is also provided with a second internal connection port (48) for connection with sensors and valves of the wiring harness and sensor subsystem (80).

5. The integrated fuel cell system of claim 4, wherein The top surface of the stack (20) is also provided with a tenth threaded hole (251). The fluid distribution manifold (30) is provided with a first group of interfaces (351), a second group of interfaces (352), and a third group of interfaces (353). The hydrogen subsystem (50) includes a hydrogen circulating pump (501), a hydrogen supply assembly (502), a hydrogen heat exchanger (503), a hydrogen discharge valve (504), and a safety valve (505). The hydrogen circulating pump (501) is provided with a third mounting hole (52) connected to the tenth threaded hole (251) on the stack (20) through a bolt. The hydrogen supply assembly (502) is provided with a sixth group of interfaces (531) connected to the first group of interfaces (351) on the fluid distribution manifold (30). The hydrogen discharge valve (504) is provided with a seventh group of interfaces (532) connected to the second group of interfaces (352) on the stack (20). The safety valve (505) is provided with an eighth group of interfaces (533) connected to the third group of interfaces (353) on the fluid distribution manifold (30), and the mounting port (55) on the hydrogen heat exchanger (503) is connected to the hydrogen supply assembly (502) through a bolt.

6. The integrated fuel cell system of claim 1, wherein The integrated frame (10) is provided with a first threaded hole (161), a second threaded hole (162) and a third threaded hole (163); the fluid distribution manifold (30) is provided with a fourth group of interfaces (361) and a fifth group of interfaces (362); The air subsystem (60) comprises an air compressor (601), an air compressor controller (602), an intercooler (603), a combination valve (604) and a back pressure valve (605), wherein the air compressor (601) is provided with a fourth mounting hole (611) and is connected to the first threaded hole (161) of the integrated frame (10) by bolts; the air compressor controller (602) is provided with a fifth mounting hole (612) and is connected to the second threaded hole (162) of the integrated frame (10) by bolts; the intercooler (603) is provided with a sixth mounting hole (613) and is connected to the third threaded hole (163) of the integrated frame (10) by bolts; the combination valve (604) is provided with a ninth group of interfaces (631) and is connected to the fourth group of interfaces (361) of the fluid distribution manifold (30); and the back pressure valve (605) is provided with a tenth group of interfaces (632) and is connected to the fifth group of interfaces (362) of the fluid distribution manifold (30).

7. The integrated fuel cell system of claim 6, wherein The integrated frame (10) is provided with a fourth threaded hole (171) and a fifth threaded hole (172); and the air compressor controller (602) is provided with a seventh mounting hole (67). The thermal management subsystem (70) comprises a water pump (701), a thermostat (702) and a deionizer (703); wherein the water pump (701) is provided with a ninth mounting hole (71) and is connected to the fifth threaded hole (172) of the integrated frame (10) by bolts; the thermostat (702) is provided with an eleventh mounting hole (76) and is connected to the seventh mounting hole (67) of the air subsystem (60) by bolts; and the deionizer (703) is provided with a tenth mounting hole (72) and is connected to the fourth threaded hole (171) of the integrated frame (10) by bolts.

8. The integrated fuel cell system of claim 1, wherein The integrated frame (10) is provided with a sixth threaded hole (11) to be connected to a vehicle body.

9. An automobile comprising a vehicle body and an integrated fuel cell system provided on the vehicle body, characterized by, The integrated fuel cell system adopts the integrated fuel cell system according to any one of claims 1 to 8.

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