A sensor system for real-time monitoring of the working state of a type IV hydrogen storage tank
By installing a multi-dimensional sensor network inside the Type IV hydrogen storage tank, comprehensive monitoring of the tank is achieved, solving the problem of untimely damage detection in existing technologies and improving the safety and reliability of the hydrogen storage tank.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- XI AN JIAOTONG UNIV
- Filing Date
- 2024-06-14
- Publication Date
- 2026-07-21
Smart Images
Figure CN118775754B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of hydrogen storage tank technology, and specifically to a sensing system for real-time monitoring of the working status of a Type IV hydrogen storage tank. Background Technology
[0002] In recent years, driven by various hydrogen storage technologies and the resulting development of hydrogen energy, people have paid increasing attention to the application of hydrogen storage tanks in production, daily life, and industrial fields such as automobiles, energy, and aerospace. However, hydrogen itself has reactive chemical properties; once exposed to oxygen-rich environments, it can burn rapidly or even explode, endangering systems and personal safety. Considering this, Type IV hydrogen storage tanks have high design requirements for safe operation, making real-time monitoring and feedback of their status essential during operation.
[0003] The existing monitoring technology for Type IV hydrogen storage tanks (publication number CN117570364A, titled: A Leakage Alarm Device for Vehicle-Mounted Hydrogen Supply System) involves placing strain gauges or sensors inside the tank or on the surface of the inner liner. However, this method suffers from limitations in monitoring capabilities, as it can only monitor pressure changes. Furthermore, it is difficult to detect early-stage damage to hydrogen storage tanks during service, such as impact damage, fatigue damage, and matrix cracking, which can easily lead to system failure. This results in untimely warnings and an inability to respond quickly to damage. Additionally, it is difficult to comprehensively monitor damage occurring between fiber winding layers without compromising strength. Summary of the Invention
[0004] To overcome the shortcomings of the existing technology, the present invention aims to provide a sensing system for real-time monitoring of the working status of a Type IV hydrogen storage tank. By comprehensively collecting information from multiple dimensions such as the inner liner, winding layer, and surface, it can detect potential safety risks earlier and more accurately, and broaden the scope of damage perception. This effectively solves the safety problems existing in the practical application of hydrogen storage tanks and provides more possibilities for their promotion and application.
[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:
[0006] A sensing system for real-time monitoring of the working status of a Type IV hydrogen storage tank includes a sensing module consisting of an in-tank sensing module, an inner liner sensing module, a winding layer sensing module, and a surface sensing module. The output of the sensing module is connected to the input of an information collection and classification module, the output of the information collection and classification module is connected to the input of a monitoring and analysis module, and the output of the monitoring and analysis module is connected to the input of a display and early warning module. The system relies on the in-tank sensing module, the inner liner sensing module, the winding layer sensing module, and the surface sensing module to determine multi-dimensional parameter information of various parts of the hydrogen storage tank, including stress, strain, temperature, humidity, hydrogen density, and impact. This information is then collected and summarized by the information collection and classification module, which integrates and classifies the information, further integrating it according to its location, before transmitting it to the monitoring and analysis module. The monitoring and analysis module analyzes the information from various parts of the hydrogen storage tank, including identifying damage, predicting potential damage, detecting abnormal parameters, and locating weak points. The display and early warning module receives and integrates the abnormal information transmitted by the monitoring and analysis module, determines possible handling solutions for the abnormalities, and provides warnings to the hydrogen storage tank maintenance personnel.
[0007] The specific setup of the sensing module includes: multiple monitoring sensors placed at the bottle opening, body, weld seams, and bottom of the hydrogen storage tank where damage is likely; multiple monitoring sensors placed at the surface of the inner liner where damage is likely; multiple monitoring sensors placed inside the winding layer; and multiple monitoring sensors placed on the surface of the hydrogen storage tank to form an overall sensing module system. Sensor types include temperature sensors, strain sensors, pressure sensors, surface topography sensors, and fiber piezoresistive sensors. Sensor groups are placed periodically or in an array. The information is then collected and transmitted to the information classification and collection module, and processed in the monitoring and analysis module to form an internal parameter sensing network, generating an operational status image that displays areas where risks may have occurred or have already occurred.
[0008] The sensor array has different periodicity or array configurations for different sensing modules: for the inside of the can, sensors are placed in a linear array along the generatrix of the cylinder from the bottle mouth; for the inner liner, sensors are arranged in a circular periodic pattern along the weld seam and bottle body; for the inside of the winding layer, sensors are arranged alternately in the transition layer and the ordinary layer; for the surface layer, sensors are arranged in a circular periodic pattern.
[0009] Different sensors perform different monitoring functions to achieve comprehensive and all-round monitoring:
[0010] The temperature sensor provides feedback on the temperature signal, displaying the temperature changes at the bottle opening and body during hydrogen storage and discharge. After processing by the monitoring and analysis module, the temperature is compared with the normal theoretical temperature value to determine whether the working status of the tank is normal during the hydrogen storage and discharge process.
[0011] The pressure sensor provides feedback on the pressure inside the tank, displaying the pressure change process inside the tank during the operation of the hydrogen storage tank. After being processed by the monitoring and analysis module, the pressure value is compared with the pressure value under normal theoretical working conditions to determine whether there is a gas leak or shortage.
[0012] The surface topography sensor provides feedback on the surface condition, displaying the corrosion and impact damage status of the inner and outer surfaces. This feedback is combined with that of the stress sensor, and the monitoring and analysis module compares and analyzes the data to determine the subsequent working time.
[0013] The fiber piezoresistive sensor provides feedback on the internal state of the winding layer, displaying the stress changes between each winding layer and between layers. After processing by the monitoring and analysis module, the results are compared with the normal theoretical values to determine whether there is interlayer fracture or minor internal damage such as internal cracks.
[0014] The fiber piezoresistive sensor is prepared by an electrically assisted impregnation method. The fiber types are T300, T700, and T800, which are selected according to requirements.
[0015] During the winding process, the fiber piezoresistive sensor is embedded between the helical winding layer and the circumferential winding layer at a selected angle, and is embedded in the winding layer following the helical winding direction; the selected angle is embedded in either the winding angle direction or the generatrix direction.
[0016] The specific settings of the information collection and classification module are as follows: the information transmitted by the sensors of each part of the sensing module is classified according to location and intensity. Signals below the set intensity threshold are identified and eliminated, while signals above the set intensity are sent first.
[0017] The specific settings of the monitoring and analysis module are as follows: the information transmitted by the information collection and classification module is parsed and displayed as images according to different priorities. Dangerous damage information is highlighted in red and presented in the restored three-dimensional graphic. At the same time, warnings are given for other possible damage information.
[0018] Compared with the prior art, the beneficial effects of the present invention are as follows:
[0019] Because this invention uses an embedded monitoring method with a fiber piezoresistive sensor, it has minimal impact on the strength of the Type IV hydrogen storage tank, effectively solving the problem that the winding layer of the Type IV hydrogen storage tank cannot simultaneously achieve both strength and damage monitoring.
[0020] Because this invention adds a comprehensive monitoring method for the winding layer, inner liner surface and interior of the Type IV hydrogen storage tank to the existing monitoring methods, and adds more damage measurement parameters, it ensures the early prediction of damage and nipps the risk in the bud.
[0021] Because this invention adds an information collection and classification module, it reduces system load and information redundancy. Attached Figure Description
[0022] Figure 1 This is a system block diagram according to an embodiment of the present invention.
[0023] Figure 2 This is a schematic diagram of the in-tank sensing module according to an embodiment of the present invention.
[0024] Figure 3 This is a schematic diagram of the winding layer sensing module according to an embodiment of the present invention. Detailed Implementation
[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0026] like Figure 1 As shown, a sensing system for real-time monitoring of the working status of a Type IV hydrogen storage tank includes a sensing module consisting of an in-tank sensing module, an inner liner sensing module, a winding layer sensing module, and a surface sensing module. The output of the sensing module is connected to the input of an information collection and classification module; the output of the information collection and classification module is connected to the input of a monitoring and analysis module; and the output of the monitoring and analysis module is connected to the input of a display and early warning module. The system relies on the in-tank sensing module, inner liner sensing module, winding layer sensing module, and surface sensing module to determine multi-dimensional parameter information of various parts of the hydrogen storage tank, including stress, strain, temperature, humidity, hydrogen density, and impact, etc., which is then collected via a bus. The information collection and classification module integrates and categorizes a large amount of complex information, eliminating useless and redundant information, retaining key information, and integrating it according to location relationships before transmitting it to the monitoring and analysis module. The monitoring and analysis module analyzes information from various parts of the hydrogen storage tank, including identifying damage, predicting potential damage, detecting abnormal parameters, and locating weak points. The display and early warning module receives and integrates abnormal information transmitted by the monitoring and analysis module. It internally stores normal operating status data of each sensor group for real-time comparative analysis, determines possible handling solutions for abnormalities, and alerts hydrogen storage tank maintenance personnel to facilitate actual maintenance and repair.
[0027] The specific setup of the sensing module includes: multiple monitoring sensors placed at the bottle opening, body, weld seams, and bottom of the hydrogen storage tank where damage is likely; multiple monitoring sensors placed at the surface of the inner liner where damage is likely; multiple monitoring sensors placed inside the winding layer; and multiple monitoring sensors placed on the surface of the hydrogen storage tank to form an overall sensing module system. Sensor types include temperature sensors, strain sensors, pressure sensors, surface topography sensors, and fiber piezoresistive sensors. Considering that hydrogen storage tanks are typically large and their components are not closely interconnected, the sensor groups are placed periodically or in an array to facilitate comprehensive and error-free sensing of the tank's interior. The information is then collected and transmitted to the information classification and collection module, and processed in the monitoring and analysis module to form a parameter sensing network within the tank, generating a working status image that displays areas where risks may have occurred or have already occurred.
[0028] The sensor array uses different periodicity or array methods for different sensing modules: For the inside of the can, where space is limited and internal parameters are relatively consistent, a small number of sensors are placed in a linear array along the generatrix of the cylinder from the bottle mouth; for the inner liner, due to the presence of many critical parts and the possibility of damage, a large number of sensors are arranged in a circular period along the weld seam and the bottle body; for the inside of the winding layer, to reduce the impact of sensors on strength, a small number of sensors are arranged alternately in the critical transition layer and the ordinary layer; for the surface layer, a large number of sensors are arranged in a circular period.
[0029] Different sensors perform different monitoring functions to achieve comprehensive and all-round monitoring:
[0030] The temperature sensor provides feedback on the temperature signal, showing the temperature changes at the bottle opening and body during hydrogen storage and discharge. After processing by the monitoring and analysis module, the temperature is compared with the normal theoretical temperature value to determine whether the working status of the tank is normal during the hydrogen storage and discharge process and whether there is any risk of damage.
[0031] The pressure sensor provides feedback on the pressure inside the tank, displaying the pressure change process inside the tank during the operation of the hydrogen storage tank. After being processed by the monitoring and analysis module, the pressure value is compared with the pressure value under normal theoretical working conditions to determine whether there is a gas leak or shortage, so as to detect risks in a timely manner.
[0032] The surface topography sensor provides feedback on the surface condition, displaying the corrosion, impact, and other damage conditions on the inner and outer surfaces. This feedback is combined with that from the stress sensor, and the monitoring and analysis module compares and analyzes the data to determine the subsequent working time, thus avoiding the risk of leakage and damage.
[0033] The fiber piezoresistive sensor provides feedback on the internal state of the winding layer, displaying the stress changes between each winding layer and between layers. After processing by the monitoring and analysis module, the results are compared with the normal theoretical values to determine whether there are any minor internal damages such as interlayer fractures and internal cracks, so that timely repairs can be carried out.
[0034] The specific settings of the information collection and classification module are as follows: the information transmitted by the sensors of each part of the sensing module is classified according to location and intensity. Signals below the set intensity threshold are identified and eliminated, while signals above the set intensity are sent first. This ensures that the monitoring and analysis module responds to damage in a timely and rapid manner, while also alleviating the pressure of information volume and reducing the burden.
[0035] The monitoring and analysis module is specifically configured to parse and display information from the information collection and classification module according to different priorities. Dangerous information such as damage is highlighted in red and presented in the restored 3D graphics to help operators quickly locate the damage and carry out repairs. At the same time, it provides warnings for other possible damage information to ensure safe operation to the greatest extent possible.
[0036] In this embodiment, the inner liner is an elliptical end cap with a body length of 600mm, an inner diameter of 165mm, a wall thickness of 3mm, and openings of 60mm at both ends.
[0037] like Figure 2 As shown, the tank opening is the most critical and dangerous part of the hydrogen filling and releasing process. In this embodiment, a temperature sensor 1 and a pressure sensor 2 are placed to monitor the nearby temperature and pressure to ensure the safety and stability of the tank opening and to eliminate the risk of leakage. At weak points in the inner liner of the tank, such as the connection between the cylinder head and the tank body, two surface topography sensors 3 are placed in an array at 180° intervals around the circumference to monitor the surface corrosion. A pressure sensor 2 is placed in the center of the tank to monitor the overall internal pressure. The combination of these sensor groups forms an internal sensing module to fully perceive the working status inside the tank.
[0038] like Figure 3 As shown, maintaining a constant stress in the winding layer is the most important aspect. However, the connections between the winding layers are quite close and the relationships are complex. In this embodiment, strain sensors 4 need to be placed between the winding layers and between the winding mode switching layers to monitor the stress state of the winding layers. At the same time, the fiber winding layer is prone to fatigue damage, interlayer fracture, debonding and other phenomena during long-term operation. A small number of fiber piezoresistive sensors 5 can effectively monitor the changes between the carbon fibers in the winding layer during operation, and have little impact on the overall strength, thus achieving early warning of fatigue damage, interlayer fracture and debonding.
[0039] In this embodiment, the winding layers are arranged using alternating circumferential and helical winding methods, employing an industrial four-axis winding machine. The fiber used for winding is T700SC. The first layer of helical winding is performed at a winding angle of 10° to 15°, with the tension decreasing layer by layer from 140-180N to 70-100N to ensure the internal stress of the matrix. The circumferential winding angle is 80-88°, with the tension varying according to the helical winding layer. The total thickness of the helical fiber is 4.2mm, and the thickness of the circumferential fiber is 6.2mm. That is, there are 23 layers of helical winding and 34 layers of circumferential winding. The overall winding process uses a wet winding method with four strands of yarn. The epoxy resin used is a high-strength epoxy resin, with the binder accounting for 12% and the fiber accounting for 70% of the total weight. To prevent end-point accumulation during fiber winding, the winding angle is extended to 30° every two layers by 1-2°.
[0040] In this embodiment, the fiber piezoresistive sensor is prepared using an electrically assisted impregnation method. A T700 or T800 fiber is selected to remove surface impurities and contaminants, and then impregnated in a CNT solution for 15 minutes in an electric field of 300-500V to enhance the resistive characteristics and ensure the bonding effect. Subsequently, it is impregnated in PVA for 30 minutes in an electric field of 30-70V to enhance the mechanical properties and internal bonding force. Finally, it is immersed in resin to form a fiber piezoresistive sensor. During the winding process, it is embedded between the helical winding layer and the circumferential winding layer in the 0° generatrix direction, and embedded in the winding layer in the direction of helical winding, serving as the 5th yarn to assist in winding, thus tightly bonding the sensor inside the winding layer.
[0041] The fiber piezoresistive sensor prepared in this embodiment has an actual tensile strength of up to 2300 MPa, which is close to the strength of the fiber used for winding, thus ensuring both the strength requirements of the winding layer and the sensing requirements.
[0042] The Type IV hydrogen storage tank manufactured in this embodiment has a working pressure of up to 35 MPa and a burst pressure of up to 70 MPa, which can effectively meet most usage requirements. The Type IV hydrogen storage tank manufactured in this embodiment has a winding layer monitoring coverage of up to 100%, and the winding layer strength does not decrease significantly, meeting the needs of daily monitoring and use.
[0043] In this embodiment, a total of 20 fiber piezoresistive sensors 5 are embedded, which are staggered between the circumferential winding layer and the helical winding layer. They can detect fractures, interlayer damage, and fatigue damage that occur inside the winding layer, with a detection accuracy of up to 97%.
Claims
1. A sensing system for real-time monitoring of the operating status of a Type IV hydrogen storage tank, characterized in that: The system includes a sensing module consisting of an internal sensing module, an inner liner sensing module, a winding layer sensing module, and a surface sensing module. The outputs of these sensing modules are connected to the input of an information collection and classification module. The outputs of the information collection and classification module are also connected to the input of a monitoring and analysis module. Finally, the outputs of the monitoring and analysis module are connected to the input of a display and early warning module. The system uses the internal sensing module, inner liner sensing module, winding layer sensing module, and surface sensing module to determine multi-dimensional parameter information for various parts of the hydrogen storage tank, including stress, strain, temperature, humidity, hydrogen density, and impact. This information is then collected and classified by the information collection and classification module, and further integrated according to location relationships before being transmitted to the monitoring and analysis module. The monitoring and analysis module analyzes the information from various parts of the hydrogen storage tank, including identifying damage, predicting potential damage, detecting abnormal parameters, and locating weak points. The display and early warning module receives and integrates the abnormal information transmitted by the monitoring and analysis module, determines possible handling solutions for the abnormalities, and alerts the hydrogen storage tank maintenance personnel. The specific setup of the sensing module includes: multiple monitoring sensors placed at the bottle opening, body, weld seams, and bottom of the hydrogen storage tank where damage is likely; multiple monitoring sensors placed at the surface of the inner liner where damage is likely; multiple monitoring sensors placed inside the winding layer; and multiple monitoring sensors placed on the surface of the hydrogen storage tank to form an overall sensing module system. The sensor types include temperature sensors, strain sensors, pressure sensors, surface topography sensors, and fiber piezoresistive sensors. The sensor groups are placed in a periodic or array manner. The information is then collected and transmitted to the information collection and classification module, and processed in the monitoring and analysis module to form an internal parameter sensing network, generate an operating status image, and display areas where risks may occur or have already occurred. The temperature sensor provides feedback on the temperature signal, displaying the temperature changes at the bottle opening and body during hydrogen storage and discharge. After processing by the monitoring and analysis module, the temperature is compared with the normal theoretical temperature value to determine whether the working status of the tank is normal during the hydrogen storage and discharge process. The pressure sensor provides feedback on the pressure inside the tank, displaying the pressure change process inside the tank during the operation of the hydrogen storage tank. After being processed by the monitoring and analysis module, the pressure value is compared with the pressure value under normal theoretical working conditions to determine whether there is a gas leak or shortage. The surface topography sensor provides feedback on the surface condition, displaying the corrosion and impact damage status of the inner and outer surfaces. This feedback is combined with that of the stress sensor, and the monitoring and analysis module compares and analyzes the data to determine the subsequent working time. The fiber piezoresistive sensor provides feedback on the internal state of the winding layer, showing the stress changes between each winding layer and between layers. After being processed by the monitoring and analysis module, it is compared with the normal theoretical value to determine whether there is interlayer fracture or minor internal damage such as internal cracks. During the winding process, the fiber piezoresistive sensor is embedded between the helical winding layer and the circumferential winding layer at a selected angle, and is embedded in the winding layer following the helical winding direction; the selected angle is embedded in either the winding angle direction or the generatrix direction.
2. The sensing system according to claim 1, characterized in that: The sensor array has different periodicity or array configurations for different sensing modules: for the inside of the can, sensors are placed in a linear array along the generatrix of the cylinder from the bottle mouth; for the inner liner, sensors are arranged in a circular periodic pattern along the weld seam and bottle body; for the inside of the winding layer, sensors are arranged alternately in the transition layer and the ordinary layer; for the surface layer, sensors are arranged in a circular periodic pattern.
3. The sensing system according to claim 1, characterized in that, The fiber piezoresistive sensor was prepared by an electrically assisted impregnation method, and the fiber types were T300, T700, and T800.
4. The sensing system according to claim 1, characterized in that, The specific settings of the information collection and classification module are as follows: the information transmitted by the sensors of each part of the sensing module is classified according to location and intensity. Signals below the set intensity threshold are identified and eliminated, while signals above the set intensity are sent first.
5. The sensing system according to claim 1, characterized in that, The specific settings of the monitoring and analysis module are as follows: the information transmitted by the information collection and classification module is parsed and displayed as images according to different priorities. Dangerous damage information is highlighted in red and presented in the restored three-dimensional graphic. At the same time, warnings are given for other possible damage information.