A heating and temperature maintaining device and method for an air path of a hydrogen fuel cell

Abstract

This invention belongs to the field of automotive technology, specifically relating to a heating and insulation device and method for the air intake of a hydrogen fuel cell. By installing a solenoid valve in the air intake of the fuel cell stack, the supply of external cold air can be cut off when the vehicle is stopped, avoiding the effects of low temperatures. Simultaneously, a heating valve and heater are installed on the internal air pipeline, and closed-loop electronic control is achieved through a precision temperature sensor to ensure that the air temperature entering the fuel cell stack is always above 5°C. The temperature sensor monitors and feeds back data in real time, and the electronic control system dynamically adjusts the working state of the heating valve and the power output of the heater, forming a precise and energy-saving temperature control loop. This achieves precise control of the intake air temperature of the fuel cell stack, improving the stability and energy efficiency of fuel cell vehicles under complex climatic conditions, while also optimizing the intelligence level and energy utilization rate of the overall thermal management system.

Description

Technical Field

[0001] This invention belongs to the field of automotive technology, specifically relating to a heating and insulation device and method for the air circuit of a hydrogen fuel cell. Background Technology

[0002] With the rapid development of hydrogen fuel cell vehicle technology, its high efficiency and environmental friendliness have attracted much attention. However, in practical applications, especially when operating in low-temperature environments, the fuel cell stack has strict requirements for the intake air temperature, which usually needs to be higher than a certain threshold (such as 5°C) to ensure stable operation and efficient power generation of the fuel cell system. In existing fuel cell vehicles, during startup or operation in cold weather, the direct entry of cold air into the fuel cell stack can lead to reduced stack efficiency or even freezing, severely impacting vehicle performance and lifespan.

[0003] Problems with existing technologies: Traditional thermal management systems often lack precise temperature control mechanisms, failing to respond quickly to changes in ambient temperature and the actual needs of the fuel cell stack to maintain a constant effective temperature in the air pretreatment section. Furthermore, the failure to fully utilize waste heat generated by the fuel cell system for air heating not only wastes energy but also fails to adequately address the thermal management challenges at low ambient temperatures. Summary of the Invention

[0004] The purpose of this invention is to provide a heating and insulation device and method for the air circuit of a hydrogen fuel cell. It adopts an energy-saving heating and insulation method, and achieves heating and insulation of various components of the fuel cell vehicle through precise heating control and low-cost equipment, thereby improving the energy efficiency and performance of the fuel cell vehicle and solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a heating and insulation device for the air path of a hydrogen fuel cell, comprising an air intake path for the fuel cell stack, a solenoid valve, an internal air pipeline, a heating valve, a heater, and a temperature sensor. The air intake path for the fuel cell stack is equipped with a solenoid valve for cutting off the external air supply when the vehicle is stopped. The internal air pipeline is equipped with a heating valve and a heater connected thereto.

[0006] The heating valve controls the heating process of the internal air pipeline to ensure that the air temperature entering the fuel cell stack is higher than 5°C; the heating valve is electronically controlled by a temperature sensor to achieve precise adjustment of the internal air temperature; the temperature sensors are located at the air inlet of the fuel cell stack to monitor the air temperature in real time and automatically adjust the heater power output based on the data.

[0007] The solenoid valve, heating valve, and temperature sensor form a closed-loop control circuit through an electronic control system, which dynamically adjusts the valve opening and closing status of the air pipeline and the heater operating mode based on the ambient temperature and air temperature.

[0008] Preferably, the solenoid valve includes a temperature sensing module. When the external ambient temperature is detected to be lower than a preset threshold, the temperature sensing module sends a signal to the electronic control system, causing the solenoid valve to automatically close, preventing cold air from entering the internal air pipeline, and linking the working status of the heating valve and heater, so as to heat and keep the internal air warm only in low-temperature environments.

[0009] Preferably, the heater includes a microprocessor control module and a signal receiving module, which are connected to a temperature sensor to acquire air temperature data at the inlet and outlet of the fuel cell stack.

[0010] The microprocessor control module is used to analyze temperature data and output control commands. An actuator is connected to the microprocessor control module, and the actuator adjusts the working state of the heater according to the commands.

[0011] Preferably, the heater includes an energy recovery device, which includes a waste heat recovery unit connected to the fuel cell stack via a heat transfer medium and transfers the collected waste heat to a heat exchanger.

[0012] The waste heat recovery unit drives the flow of heat transfer medium through a circulating pump. The heat exchanger is integrated into the internal air pipeline, adjacent to the heating valve, so that when cold air flows through, it can be preheated by waste heat through heat exchange.

[0013] The energy recovery device also includes a monitoring system for monitoring the working status and heat exchange efficiency of the waste heat recovery unit, adjusting the working frequency of the circulating pump and the cooperative working mode with the heater, and ensuring that the air temperature meets the requirement of being higher than 5°C.

[0014] Preferably, the temperature sensors adopt a multi-point distributed layout: multiple temperature sensor nodes are set at the air inlet, air outlet and internal air pipeline of the fuel cell stack air intake path. Each node has signal conversion and transmission functions, and collects and measures the air temperature at its location in real time; each temperature sensor is connected to the electronic control system.

[0015] Preferably, it further includes: a controller module, the controller module including a microprocessor, a memory and multiple input / output interfaces; the controller module is electrically connected to a temperature sensor, a solenoid valve, a heating valve and a heater through the input / output interfaces;

[0016] The temperature sensor transmits real-time air temperature data to the input port of the controller module. The microprocessor calculates the heating power requirement and valve opening / closing status, and sends command signals to the solenoid valve and heating valve through the output port.

[0017] Preferably, it also includes: an overheat protection mechanism for the heater, which is integrated inside the heater and includes a temperature detection element, a signal processor, and an actuator;

[0018] The temperature detection element monitors the actual temperature inside the air duct in real time. Once the temperature exceeds the preset safety threshold, it sends an overheat signal to the controller module. After receiving the signal, the controller module adjusts the power supply or operating status of the heater.

[0019] Preferably, it also includes a temperature compensation control module, which is connected to the solenoid valve and the heating valve via a data bus.

[0020] Preferably, it also includes: a remote monitoring module, which includes an in-vehicle communication module, a cloud server and a user terminal. The in-vehicle communication module is integrated inside the electronic control system and has a bidirectional communication connection with the controller module. It uploads vehicle status information, temperature data at various points in the air circuit and the status of the heating and insulation system to the cloud server through wireless communication.

[0021] On the other hand, the present invention proposes a heating and insulation method for a heating and insulation device for the air path of a hydrogen fuel cell, comprising:

[0022] When starting a hydrogen fuel cell vehicle, air enters the internal air pipeline through the air intake of the fuel cell stack. When the vehicle stops running, the solenoid valve automatically cuts off or connects the external air supply based on the external ambient temperature detected by the temperature sensing module.

[0023] The heating valve works in conjunction with the heater. Through a temperature sensor connected to the internal air pipeline, the temperature of the air entering the fuel cell stack is monitored in real time and precisely adjusted to be above 5°C. The temperature sensor transmits the data to the electronic control system to form a closed-loop control, so as to dynamically adjust the valve opening and closing status and the heater power output.

[0024] The microprocessor control module acquires air temperature data at the inlet and outlet of the fuel cell stack through the signal receiving module, and analyzes and calculates the optimal control command based on this data. The actuator adjusts the working state of the heater according to the command.

[0025] The energy recovery device uses a waste heat recovery unit to collect waste heat generated by the fuel cell stack. A circulating pump drives a heat transfer medium to a heat exchanger to preheat the cold air entering the air duct. At the same time, a monitoring system ensures that the air temperature is always kept above 5°C.

[0026] Technical effects and advantages of the present invention: The heating and insulation device and method for the air path of a hydrogen fuel cell proposed in this invention have the following advantages compared with the prior art:

[0027] This invention, by incorporating a solenoid valve in the air intake path of the fuel cell stack, can cut off the supply of external cold air when the vehicle is stationary, thus avoiding the effects of low temperatures. Simultaneously, a heating valve and heater are installed on the internal air pipeline, and closed-loop electronic control is implemented through a precision temperature sensor to ensure that the air temperature entering the fuel cell stack is always above 5°C. The temperature sensor monitors and feeds back data in real time, and the electronic control system dynamically adjusts the operating status of the heating valve and the power output of the heater, forming a precise and energy-saving temperature control loop. This solves the technical challenges of air heating and insulation in low-temperature environments in existing hydrogen fuel cell vehicles, achieving precise control of the intake air temperature of the fuel cell stack, improving the stability and energy efficiency of fuel cell vehicles under complex climatic conditions, and also optimizing the intelligence level and energy utilization rate of the overall thermal management system. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the heating and insulation device for the air path of the hydrogen fuel cell of the present invention.

[0029] Figure 2 This is a flowchart of the heating and insulation method of the heating and insulation device for the air path of the hydrogen fuel cell of the present invention;

[0030] In the diagram: 1. Fuel cell stack air intake path; 2. Solenoid valve; 3. Internal air pipeline; 4. Heating valve; 5. Heater; 6. Temperature sensor; 7. Microprocessor control module; 8. Signal receiving module; 9. Actuator; 10. Energy recovery device; 11. Waste heat recovery unit; 12. Heat exchanger; 13. Controller module; 14. Microprocessor; 15. Memory; 16. Input / output interface; 17. Heater overheat protection mechanism; 18. Temperature compensation control module; 19. Remote monitoring module; 20. Electronic control system. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] This invention provides, for example Figure 1The diagram illustrates a heating and insulation device for the air path of a hydrogen fuel cell. In hydrogen fuel cell vehicles, this device is a key component ensuring the efficient and stable operation of the fuel cell stack. The device mainly includes core components such as a fuel cell stack air intake path 1, a solenoid valve 2, an internal air pipeline 3, a heating valve 4, a heater 5, and a temperature sensor 6.

[0033] First, the air intake passage 1 of the fuel cell stack, serving as a channel between the external environment and the fuel cell stack, is specifically designed with a solenoid valve 2. The solenoid valve 2 is an intelligent control element that operates based on a preset program or real-time vehicle status information. When the hydrogen fuel cell vehicle stops operating, the solenoid valve 2 automatically cuts off the supply of external cold air to the fuel cell stack, preventing the low-temperature environment from adversely affecting the stack's performance, such as reduced efficiency and difficulty in starting.

[0034] The internal air duct 3 is responsible for pre-treating the air before it enters the fuel cell stack. It is equipped with a heating valve 4 and a heater 5 that works closely with it. The heating valve 4 has a precise control function, which can turn the heating process on or off according to actual needs, ensuring that the temperature of the air delivered to the fuel cell stack through the internal air duct 3 is always above the critical threshold of 5°C, so as to maintain the optimal operating conditions of the stack.

[0035] To achieve precise regulation of the internal air temperature, the device incorporates temperature sensors 6, which are positioned at different locations in the fuel cell stack's air intake path 1 to monitor and acquire accurate air temperature data from multiple points. These sensors are designed with high sensitivity and fast response, enabling them to detect the actual air temperature at the intake in real time and transmit this data to the electronic control system 20.

[0036] The electronic control system 20, acting as the core brain of the entire heating and insulation device, dynamically adjusts the operating states of the solenoid valve 2 and the heating valve 4, as well as the output power of the heater 5, based on the received ambient temperature, air temperature, and other parameters that may affect the system's operation (such as vehicle speed and battery charge). This is achieved through an advanced closed-loop control algorithm. Specifically, when the air temperature detected by the temperature sensor 6 is lower than a set threshold, the electronic control system 20 instructs the heating valve 4 to start the heating process and increases the power output of the heater 5 as needed. Conversely, it appropriately reduces the workload of the heater 5 or shuts off the heating process, thereby achieving both energy-saving and efficient air heating and insulation.

[0037] Furthermore, the hydrogen fuel cell vehicle air circuit heating and insulation device, through a combination of sophisticated structural design and intelligent control strategy, not only achieves precise control of the temperature of the air entering the fuel cell stack, ensuring the efficient and stable operation of the stack under various operating conditions, but also cleverly utilizes waste heat recovery technology, greatly improving the energy efficiency ratio of the entire system and reducing energy consumption.

[0038] Specifically, in the air circuit heating and insulation device of a hydrogen fuel cell vehicle, the solenoid valve 2 plays a crucial role. It integrates a temperature sensing module, which employs advanced temperature sensing and signal processing technologies. When the external ambient temperature sensor detects that the ambient temperature is lower than a preset threshold (e.g., below freezing or close to the minimum intake air temperature required for normal operation of the fuel cell stack), the temperature sensing module can quickly capture this change and convert the temperature data into an electrical signal, which is then sent to the electronic control system 20 in real time.

[0039] Upon receiving the low-temperature signal, the electronic control system 20 immediately instructs the solenoid valve 2 to switch to the closed state according to the pre-programmed logic control strategy. In this way, cold outside air cannot directly enter the fuel cell stack air intake passage 1 and internal air pipeline 3, thereby effectively avoiding the adverse effects of cold air on the performance of the fuel cell stack, such as reducing stack efficiency and causing icing.

[0040] Meanwhile, solenoid valve 2, heating valve 4, and heater 5 are linked through precise electronic connections and control algorithms. When solenoid valve 2 closes due to low ambient temperature, the electronic control system 20 simultaneously activates heating valve 4 and adjusts the operating mode of heater 5, initiating the heating process of the air in the internal air duct 3. Heating valve 4 opens gradually according to a set program, ensuring that the air flowing through heater 5 is fully preheated, so that the temperature of the air entering the fuel cell stack is always kept above a safe range of 5°C.

[0041] In practice, heater 5 may employ high-efficiency PTC ceramic heating elements or other heating technologies adapted to the vehicle environment to ensure rapid and stable heat delivery in low-temperature conditions. The power output of heater 5 is dynamically adjusted based on real-time air temperature data collected by temperature sensor 6, and precise calculations and commands are issued by a microprocessor to achieve fine-grained control of heating intensity.

[0042] In this hydrogen fuel cell vehicle air circuit heating and insulation device, the synergistic effect of the solenoid valve 2, temperature sensing module and electronic control system 20, combined with intelligent temperature regulation strategy and waste heat recovery technology, not only effectively solves the air heating and insulation problem in low temperature environment, but also greatly improves energy utilization and overall operating efficiency of fuel cell vehicle, ensuring the reliability and durability of vehicle under various climatic conditions.

[0043] Specifically, the heater 5 integrates a microprocessor control module 7 and a signal receiving module 8, which together constitute the core of the heater's intelligent regulation.

[0044] First, temperature sensors 6 are precisely positioned at the inlet and outlet of the fuel cell stack. The air temperature data they monitor and collect in real time is transmitted to the signal receiving module 8 via a standardized interface. This module has efficient data processing capabilities, enabling it to quickly identify, analyze, and integrate signals from multiple temperature sensors, ensuring that accurate temperature information is transmitted to the microprocessor control module 7.

[0045] The microprocessor control module 7, acting as the brain of the entire heating system, performs in-depth analysis and calculation of the temperature data received from the signal receiving module 8 based on advanced embedded control algorithms. According to the preset temperature control strategy (such as segmented control or proportional-integral-derivative PID control), the microprocessor accurately calculates the optimal heating power requirement and the operating status instructions of the heating valve 4 based on the current and historical temperature data trends.

[0046] In addition, an actuator 9 is connected to the microprocessor control module 7, which is responsible for actually controlling the changes in the operating state of the heater 5. When the microprocessor outputs a command to adjust the operating state of the heater, the actuator 9 responds quickly, possibly by changing the current magnitude, adjusting the on-time or intensity of the heating element, etc., to precisely control the actual heating effect of the heater 5 and ensure that the air temperature entering the fuel cell stack is always kept within the ideal range.

[0047] In practice, to achieve more precise temperature control and energy-saving optimization, the microprocessor control module 7 may also dynamically adjust the heating strategy by combining other vehicle operating parameters, such as battery charge, vehicle speed, and ambient humidity. Simultaneously, the system also has self-learning and adaptive functions, enabling it to gradually optimize its control algorithm as usage time and operating conditions change, thereby improving the overall system's energy efficiency ratio and lifespan.

[0048] In summary, by integrating the microprocessor control module 7 and the signal receiving module 8, and combining them with the real-time monitoring of the high-precision temperature sensor 6, the heater 5 achieves intelligent and precise control of the air temperature at the inlet and outlet of the fuel cell stack. This effectively ensures the stable and efficient operation of the fuel cell stack under various operating conditions, minimizes energy consumption, and improves the performance and reliability of the entire fuel cell vehicle.

[0049] Furthermore, to improve energy efficiency and reduce the energy consumption required for direct heating, heater 5 is specially equipped with an energy recovery device 10. The core component of this device is a waste heat recovery unit 11, the model of which can be selected from high-efficiency and reliable models on the market according to vehicle specifications and design requirements, such as shell-and-tube or plate heat exchangers using high-performance heat transfer media.

[0050] The waste heat recovery unit 11 is closely connected to the fuel cell stack via a heat transfer medium (such as coolant or specially designed phase change material) with excellent heat transfer properties, collecting waste heat generated during fuel cell operation in real time. Driven by a circulation pump (e.g., a high-temperature resistant, low-noise electric circulation pump), the heat transfer medium flows continuously in a closed loop, transferring waste heat from the fuel cell stack to the heat exchanger 12.

[0051] As a key component integrated into the internal air duct 3 adjacent to the heating valve 4, the heat exchanger 12 can be equipped with a high-efficiency heat exchange structure such as finned tube or plate-fin type to ensure that waste heat can be fully utilized for preheating when cold air flows through it. The advantage of this design is that when the external ambient temperature is low, the air entering the fuel cell stack first passes through the heat exchanger 12, absorbing the waste heat delivered from the waste heat recovery unit 11 through heat exchange, thereby significantly reducing the energy required for direct heating by the heater 5.

[0052] In addition, the entire energy recovery device 10 is equipped with a complete monitoring system, including hardware devices such as temperature sensors, pressure sensors, and controllers. The controller can use a high-performance embedded microprocessor, such as the STM32 series or other industrial-grade controllers suitable for automotive applications. This monitoring system can monitor the operating status of the waste heat recovery unit 11 in real time, including key parameters such as the temperature change of the heat transfer medium, the operating frequency and flow rate of the circulating pump, and calculate the heat exchange efficiency.

[0053] Based on real-time data collection, the monitoring system automatically adjusts the operating frequency of the circulation pump to optimize the waste heat recovery rate and works in conjunction with heater 5. That is, when there is sufficient waste heat, waste heat preheating is used first, while when there is insufficient waste heat, it intelligently switches to heater 5 for supplementary heating to ensure that the air temperature entering the fuel cell stack is always maintained above the safety threshold of 5°C.

[0054] By configuring an energy recovery device 10 in the heater 5 of the air circuit heating and insulation device of a hydrogen fuel cell vehicle, and collecting and transferring waste heat from the fuel cell to the heat exchanger 12 via a waste heat recovery unit 11, combined with an advanced monitoring system to achieve dynamic adjustment and coordinated control, not only is the overall system energy efficiency ratio improved and energy consumption reduced, but the stable operation of the fuel cell under various operating conditions is also effectively guaranteed. Furthermore, in specific implementation, suitable and high-performance hardware models must be selected according to the actual vehicle model and manufacturer requirements to ensure the reliability and durability of the entire system.

[0055] Furthermore, the temperature sensor 6 employs a multi-point distributed layout to achieve accurate temperature monitoring at different locations within the air inlet, outlet, and internal air duct 3. This design ensures comprehensive and real-time acquisition and analysis of temperature data at key nodes throughout the entire air handling path.

[0056] In practice, a high-performance NTC (negative temperature coefficient) thermistor temperature sensor, such as the MAX31855 or DS18B20, is installed at the air inlet of the air inlet path 1 of the fuel cell stack. These sensors are characterized by fast response, high accuracy and strong stability, and can effectively capture the actual temperature of cold air before it enters the system. At the air outlet, a temperature sensor of the same type or with equivalent performance, such as the KTY81-110, is configured to monitor the temperature of the gas discharged after the fuel cell reaction, so as to evaluate the working status and efficiency of the stack.

[0057] As for the key locations of the internal air duct 3, multiple wireless temperature sensor nodes with signal conversion and transmission functions can be arranged, such as microcontroller integrated temperature sensor modules that support Bluetooth Low Energy (BLE) communication, such as Texas Instruments (TI) CC2640R2F, or PT100 platinum resistance temperature sensors with RS485 bus interfaces. The analog signals are converted into digital signals through signal conditioning circuits to achieve long-distance transmission to the electronic control system 20.

[0058] Each temperature sensor node features a dustproof and waterproof design and a wide operating temperature range, enabling long-term stable operation in harsh environments. Furthermore, the sensor data output frequency can be flexibly configured according to actual needs, ensuring real-time performance while reducing unnecessary communication load.

[0059] The electronic control system 20 receives and integrates data from various temperature sensor nodes through a preset communication protocol (such as CAN bus, LIN bus or wireless BLE protocol), performs comprehensive analysis using advanced control algorithms, and then dynamically adjusts the working state of solenoid valve 2, heating valve 4 and heater 5 to ensure that the air temperature is always kept within a range suitable for the efficient operation of the fuel cell stack, thereby improving the reliability and energy efficiency ratio of the entire system.

[0060] For example, the heating and insulation device for the air path of a hydrogen fuel cell described above further includes a controller module 13. The controller module 13 serves as the central brain of the entire system, responsible for receiving, processing, and issuing commands. This controller module employs a high-performance microprocessor 14, such as the STM32F7 series microcontroller based on the ARM Cortex-M series, which possesses powerful data processing capabilities and abundant peripheral interface resources, enabling it to quickly and accurately perform temperature control algorithm calculations and monitor equipment status.

[0061] The controller module 13 integrates a memory 15, which can use a large-capacity, non-volatile flash memory such as SPI NORF flash (e.g., MX25R6435F) to store firmware programs and necessary operating parameters. It also includes SRAM (e.g., IS62WV5128EBLL-55BLI) to temporarily store real-time acquired data and calculation results. This configuration ensures that critical settings are maintained and operations are quickly restored even after a power outage and restart of the vehicle.

[0062] To enable communication with the temperature sensor 6, solenoid valve 2, heating valve 4, and heater 5, the controller module 13 is equipped with multiple input / output interfaces 16, including an analog signal input interface for receiving analog voltage signals transmitted by the temperature sensor, such as an ADC channel; a digital signal input / output interface (such as GPIO) for controlling the state of the solenoid valve and heating valve; and, in addition, high-speed and reliable communication with the heater and other vehicle-mounted equipment may be achieved through a CAN bus interface (such as TJA1051T).

[0063] In practice, the temperature sensor 6 (such as DS18B20 or MAX31855) converts the real-time monitored air temperature data into an electrical signal and transmits it to the microprocessor 14 of the controller module 13 through the input interface. The microprocessor analyzes and processes this data according to the preset control strategy and algorithm, accurately calculates the current heating power requirement, and dynamically adjusts the on / off state of the solenoid valve 2 and the heating valve 4 according to the actual working conditions.

[0064] Once the calculations are complete, the microprocessor sends corresponding control command signals to solenoid valve 2 and heating valve 4 through its output interface. For example, it can drive the solenoid valve to open and close via a PWM (Pulse Width Modulation) signal, or control the operating mode of the heating valve via a digital signal. For heater 5, the controller module can send the heating power setting value via the CAN bus interface, and the microprocessor control module 7 within the heater will execute the corresponding heating strategy.

[0065] The controller module 13, with the help of advanced hardware and intelligent control technology, realizes precise control and efficient management of the air circuit heating and insulation system of hydrogen fuel cell vehicles, ensuring that the fuel cell can be supplied with air at a suitable temperature under various operating conditions, thereby effectively guaranteeing the stable operation and overall performance of the fuel cell system.

[0066] For example, the heating and insulation device for the air path of a hydrogen fuel cell described above further includes: an overheat protection mechanism 17 for the heater, consisting of a temperature detection element, a signal processor, and an actuator, which together ensure the safe and reliable operation of the system. Specific implementation details are as follows:

[0067] First, the temperature sensing element uses a high-performance thermistor or a non-contact infrared temperature sensor, such as the PT100 platinum resistance temperature sensor or the MLX90614 infrared temperature sensor. These are installed in key locations inside the heater to monitor the actual temperature inside the air duct in real time.

[0068] When the temperature in the air duct exceeds a preset safety threshold for some reason (such as control malfunction or poor heat dissipation), the temperature detection element quickly detects this change and converts the real-time temperature data into an electrical signal, which is then transmitted to the signal processor. The signal processor can be a microcontroller with fast response and high-precision data processing capabilities, such as the STM32F0 series microcontroller. It can determine whether an overheating state has been reached based on pre-programmed logic and immediately generate the corresponding overheating signal.

[0069] Once overheating is confirmed, the signal processor sends an overheat signal to the controller module 13 via its built-in communication interface. Upon receiving this signal, the controller module 13 performs rapid analysis and decision-making based on its internal microprocessor 14 (such as the STM32F7 series). To ensure safety, the controller module 13 immediately instructs the actuator to adjust the operating state of the heater 5. The actuator may be a power semiconductor device, such as a solid-state relay (e.g., Omron G3VM-61YR) or a smart driver chip (e.g., IR2110), to cut off or reduce the current to the heater's power supply circuit, thereby avoiding potential safety hazards caused by the heater's continuous high temperature.

[0070] In addition, to further improve the overheat protection mechanism, the system may also be equipped with a fault alarm function. When overheating occurs, the controller module 13 will not only adjust the working status of the heater, but also display a warning message to the driver's instrument panel through the vehicle communication network and upload the fault code to the vehicle diagnostic system (OBD) so as to detect and deal with the problem in a timely manner.

[0071] An overheat protection mechanism 17 is installed inside the heater of the air circuit heating and insulation system of a hydrogen fuel cell vehicle. Through the cooperation of precise temperature detection elements, efficient signal processors and reliable actuators, it can effectively prevent equipment damage and safety accidents caused by overheating, and greatly improve the stability and service life of the entire system.

[0072] For example, the heating and insulation device for the air path of a hydrogen fuel cell described above further includes a temperature compensation control module 18, which achieves precise and real-time information interaction and control with the solenoid valve 2 and the heating valve 4 in the system through advanced data bus technology. Specific implementation details are as follows:

[0073] The temperature compensation control module 18 uses a high-performance microprocessor as its core, such as the TMS320F28379D series digital signal controller manufactured by Texas Instruments (TI). It possesses powerful computing capabilities and abundant analog and digital interface resources to meet the needs of precise temperature control in complex environments. This module integrates a high-precision A / D converter to receive data from multiple temperature sensors distributed along the air duct. These temperature sensors can be one-wire digital temperature sensors such as the DS18B20, which provide accurate and stable temperature readings.

[0074] The temperature compensation control module 18 communicates with the solenoid valve 2 and the heating valve 4 via a CAN bus or a LIN bus. For example, it uses a Microchip MCP2515 as the CAN controller chip, paired with a corresponding CAN transceiver, and combined with a solid-state drive circuit to control the operation of the solenoid valves. The solenoid valve model can be selected according to the actual application, such as the Bosch 0280150281 model or other compatible automotive-grade solenoid valves, to ensure rapid response and high reliability.

[0075] For heating valve 4, it can also receive commands from temperature compensation control module 18 in a similar manner. For example, it can use Infineon's intelligent power device (IPM) to precisely adjust the power output of the heater, thereby adjusting the air temperature entering the fuel cell stack and ensuring the working efficiency and stability of the fuel cell. The controller used by the heating valve may be Infineon's XMC4000 series microcontroller, which can perform fine-grained management of the heater's operating status, including advanced control strategies such as PWM modulation.

[0076] The main function of the temperature compensation control module 18 is to dynamically calculate the optimal valve opening or heater power output value based on the actual monitored air temperature and the set target temperature range. Then, by controlling the opening and closing time of the solenoid valve 2 and the power distribution of the heating valve 4, the temperature compensation control of the entire air supply system is achieved, ensuring that the hydrogen fuel cell can always operate efficiently in a suitable temperature environment, extending battery life and improving the overall system performance.

[0077] Through the precisely designed temperature compensation control module 18, combined with the targeted selection of hardware, the air management system of the hydrogen fuel cell vehicle can achieve high-precision control of air temperature under complex operating conditions, effectively ensuring the stability and safety of the vehicle's energy system.

[0078] For example, the heating and insulation device for the air path of a hydrogen fuel cell described above further includes a remote monitoring module 19, which integrates advanced vehicle communication technology, cloud computing technology and user terminal applications to realize real-time remote monitoring and management of vehicle status information and temperature data at various points in the air path.

[0079] The vehicle-mounted communication module is one of the core components of the remote monitoring system. It can adopt 4G / 5G cellular communication modules, such as the Huawei ME909T series or Quecte 1AG35, which are high-performance, low-power embedded communication modules. These modules have powerful wireless transmission capabilities and can send various real-time data collected by the vehicle's internal electronic control system 20 and controller module 13 (including but not limited to the temperature at various points in the air pipeline, the operating status of solenoid valves and heating valves, the operating status of the fuel cell stack, etc.) to the cloud server through a secure and reliable encryption protocol.

[0080] The cloud server serves as the data processing center, and can be selected from elastic computing and storage services provided by well-known cloud service providers such as Alibaba Cloud, AWS, and Azure, such as Alibaba Cloud ECS instances paired with RDS database services. The server is responsible for receiving data sent by the vehicle communication module, performing real-time analysis, processing, and storage, and providing users with detailed vehicle status reports and fault warning notifications.

[0081] On the user terminal side, data interaction with the cloud server can be achieved through customized applications on smartphones or other mobile devices. For example, an app based on Android or iOS can be developed to obtain real-time monitoring data pushed by the cloud server using API interfaces, allowing users to view the vehicle's current operating status, temperature changes at various locations in the air duct, and the operating status and maintenance suggestions of the heating and insulation system anytime, anywhere.

[0082] Furthermore, to ensure secure data transmission and privacy protection, the entire remote monitoring system should employ encryption protocols such as TLS / SSL for communication, combined with an authentication mechanism to ensure that only authorized users can access the relevant data. Simultaneously, the onboard communication module should have the ability to automatically switch network connections; when 4G / 5G signals are weak, it can automatically switch to Wi-Fi or other available networks to ensure the continuity and stability of data uploads. By integrating the onboard communication module, cloud server, and user terminal, the remote monitoring module 19 can achieve comprehensive, real-time remote monitoring of the air circuit heating and insulation system of hydrogen fuel cell vehicles, not only improving the system's intelligence level but also greatly facilitating users' daily management and maintenance.

[0083] For example, the heating and insulation device for the air path of a hydrogen fuel cell described above further includes an energy-saving optimization and state prediction module, which employs advanced power management and data analysis technologies to achieve efficient energy utilization and intelligent control of the entire system.

[0084] The power management module is a crucial component of this system, responsible for optimizing the power supply and energy consumption of various devices. For example, Texas Instruments' (TI) BQ25895 series power management IC can be used, featuring high-efficiency charging, dynamic power path management, and low quiescent current, ensuring that components such as solenoid valve 2, heating valve 4, and temperature sensor 6 receive accurate and efficient power supply under different operating conditions, while reducing unnecessary energy loss.

[0085] The data analysis module is designed based on high-performance microprocessors and machine learning algorithms. For example, NVIDIA Jetson Xavier NX is selected as the core processing unit, and a data analysis model is built using the Python programming environment and the TensorFlow library to receive and analyze multi-point temperature data transmitted from temperature sensor 6 in real time. These temperature sensors can be industrial-grade digital temperature sensors such as the DS18B20, which feature high accuracy and wide temperature range measurement.

[0086] By integrating advanced condition prediction algorithms, the data analysis module can accurately predict future air temperature trends based on historical temperature data trends and external environmental parameters (such as weather forecast information) received by the vehicle communication module. Once a temperature change that may affect the operation of the fuel cell stack is predicted, the module will immediately adjust the operating modes of solenoid valve 2 and heating valve 4, for example, by turning heater 5 on or off in advance, or by adjusting its power output, to keep the air temperature within a suitable range, thereby achieving energy saving and consumption reduction, and ensuring the stable operation of the fuel cell system.

[0087] Furthermore, to ensure the safety and reliability of the entire system, the energy-saving optimization and status prediction module should also have fault detection and self-recovery functions. When an anomaly is detected in any part, the system can quickly identify the problem, take timely countermeasures, and send relevant alarm information to the cloud server and user terminal through the vehicle communication module, facilitating remote diagnosis and maintenance by operation and maintenance personnel.

[0088] The energy-saving optimization and condition prediction module integrates efficient power management technology, intelligent data analysis algorithms, and reliable hardware equipment, realizing automated control and energy-saving optimization of the air circuit heating and insulation system of hydrogen fuel cell vehicles, effectively improving the overall energy efficiency ratio and operational stability of the vehicle.

[0089] On the other hand, this embodiment also provides a heating and insulation method for a heating and insulation device for the air path of a hydrogen fuel cell, including the following steps:

[0090] When starting a hydrogen fuel cell vehicle, air enters the internal air pipe 3 through the fuel cell stack air intake 1. When the vehicle stops running, the solenoid valve 2 automatically cuts off or connects the external air supply based on the external ambient temperature detected by the temperature sensing module.

[0091] The heating valve 4 works in conjunction with the heater 5. Through the temperature sensor 6 connected to the internal air pipeline 3, the temperature of the air entering the fuel cell stack is monitored in real time and precisely adjusted to be higher than 5°C. The temperature sensor 6 transmits the data to the electronic control system 20 to form a closed-loop control, so as to dynamically adjust the valve opening and closing status and the heater power output.

[0092] The microprocessor control module 7 acquires the air temperature data at the inlet and outlet of the fuel cell stack through the signal receiving module 8, and analyzes and calculates the optimal control command based on this data. The actuator 9 adjusts the working state of the heater according to the command.

[0093] The energy recovery device 10 uses the waste heat recovery unit 11 to collect the waste heat generated by the fuel cell stack, and drives the heat transfer medium to the heat exchanger 12 through the circulation pump to preheat the cold air entering the air pipeline. At the same time, the monitoring system ensures that the air temperature is always kept above 5°C.

[0094] In summary, this invention, by incorporating a solenoid valve in the air intake path of the fuel cell stack, can cut off the supply of external cold air when the vehicle is not in operation, thus avoiding the effects of low temperatures. Simultaneously, a heating valve and heater are installed on the internal air pipeline, and closed-loop electronic control is achieved through a precision temperature sensor to ensure that the air temperature entering the fuel cell stack is always above 5°C. The temperature sensor monitors and feeds back data in real time, and the electronic control system dynamically adjusts the operating state of the heating valve and the power output of the heater, forming a precise and energy-saving temperature control loop. This solves the technical challenge of air heating and insulation in low-temperature environments in existing hydrogen fuel cell vehicles, achieving precise control of the intake air temperature of the fuel cell stack, improving the stability and energy efficiency of fuel cell vehicles under complex climatic conditions, and also optimizing the intelligence level and energy utilization rate of the overall thermal management system.

[0095] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A heating and insulation device for the air path of a hydrogen fuel cell, comprising an air inlet path (1) of the fuel cell stack, a solenoid valve (2), an internal air pipeline (3), a heating valve (4), a heater (5), and a temperature sensor (6), characterized in that: The fuel cell stack air intake passage (1) is equipped with a solenoid valve (2) for cutting off the external air supply when the vehicle is stopped. The internal air pipeline (3) is equipped with a heating valve (4) and a heater (5) connected thereto. The heating valve (4) controls the heating process of the internal air pipeline (3) to ensure that the air temperature entering the fuel cell stack is higher than 5°C; the heating valve (4) is electronically controlled by the temperature sensor (6) to regulate the internal air temperature; the temperature sensor (6) is located at the air inlet (1) of the fuel cell stack to monitor the air temperature in real time and automatically adjust the heater power output according to the data. The solenoid valve (2), heating valve (4) and temperature sensor (6) form a closed-loop control circuit through electronic control system (20), which dynamically adjusts the valve opening and closing status of the air pipeline and the working mode of the heater (5) according to the ambient temperature and air temperature. The heater (5) includes an energy recovery device (10), which includes a waste heat recovery unit (11) connected to the fuel cell stack via a heat transfer medium and transfers the collected waste heat to a heat exchanger (12). The heat exchanger (12) is integrated in the internal air duct (3) at the position of the heating valve (4); The energy recovery device (10) also includes a monitoring system for monitoring the working status and heat exchange efficiency of the waste heat recovery unit (11), adjusting the working frequency of the circulating pump and the cooperative working mode with the heater (5).

2. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 1, characterized in that, The solenoid valve (2) includes a temperature sensing module. When the external ambient temperature is detected to be lower than the preset threshold, the temperature sensing module sends a signal to the electronic control system (20) to automatically close the solenoid valve (2) to prevent cold air from entering the internal air pipe (3) and to link the working status of the heating valve (4) and the heater (5).

3. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 1, characterized in that, The heater (5) includes a microprocessor control module (7) and a signal receiving module (8), and the microprocessor control module (7) and the signal receiving module (8) are connected to a temperature sensor (6) for acquiring air temperature data at the inlet and outlet of the fuel cell stack. An actuator (9) is connected to the microprocessor control module (7), and the actuator (9) adjusts the working state of the heater (5) according to the instructions.

4. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 1, characterized in that, The temperature sensor (6) is arranged in a multi-point distributed layout. Multiple temperature sensor nodes are set at the air inlet, air outlet and internal air pipeline (3) of the fuel cell stack air inlet path (1). Each node has signal conversion and transmission functions. Each temperature sensor (6) is connected to the electronic control system (20).

5. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 4, further comprising: The controller module (13) is characterized in that it includes a microprocessor (14), a memory (15) and multiple input / output interfaces (16); the controller module (13) is electrically connected to a temperature sensor (6), a solenoid valve (2), a heating valve (4) and a heater (5) through the input / output interfaces (16); The temperature sensor (6) transmits real-time air temperature data to the input port of the controller module (13), calculates the heating power requirement and valve opening and closing status through the microprocessor (14), and sends command signals to the solenoid valve (2) and the heating valve (4) through the output port.

6. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 5 further includes: The overheat protection mechanism (17) of the heater is characterized in that the overheat protection mechanism (17) of the heater is integrated inside the heater (5) and includes a temperature detection element, a signal processor and an actuator; The temperature sensing element monitors the actual temperature inside the air duct in real time.

7. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 1, further comprising: The temperature compensation control module (18) is characterized in that the temperature compensation control module (18) is connected to the solenoid valve (2) and the heating valve (4) via a data bus.

8. The heating and insulation device for the air path of a hydrogen fuel cell according to claim 5, further comprising: The remote monitoring module (19) is characterized in that it includes an in-vehicle communication module, a cloud server and a user terminal. The in-vehicle communication module is integrated into the electronic control system (20) and is bidirectionally connected to the controller module (13). It uploads vehicle status information, air path temperature data and heating and insulation system status to the cloud server through wireless communication.

9. A heating and heat preservation method for a heating and heat preservation device for the air path of a hydrogen fuel cell according to any one of claims 1-8, characterized in that, include: When the hydrogen fuel cell vehicle is started, air enters the internal air pipeline (3) through the fuel cell stack air intake passage (1). When the vehicle stops running, the solenoid valve (2) automatically cuts off or connects the external air supply according to the external ambient temperature detected by the temperature sensing module. The heating valve (4) works in conjunction with the heater (5). Through the temperature sensor (6) connected to the internal air pipeline (3), the temperature of the air entering the fuel cell stack is monitored in real time and precisely adjusted to be higher than 5°C. The temperature sensor (6) transmits the data to the electronic control system (20) to form a closed-loop control, so as to dynamically adjust the valve opening and closing status and the heater power output. The microprocessor control module (7) obtains the air temperature data at the inlet and outlet of the fuel cell stack through the signal receiving module (8), and analyzes and calculates the control command accordingly. The actuator (9) adjusts the working state of the heater according to the command. The energy recovery device (10) uses the waste heat recovery unit (11) to collect the waste heat generated by the fuel cell stack, and drives the heat transfer medium to the heat exchanger (12) through the circulation pump to preheat the cold air entering the air pipeline. At the same time, the monitoring system ensures that the air temperature is always kept above 5°C.

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