High-power integrated heavy truck fuel cell system

Abstract

The invention discloses a high-power integrated heavy truck fuel cell system, and relates to the field of fuel cells. Comprising an air system, and the air system comprises an electric pile, an air compressor, an intercooler, a humidifier dry gas inlet, a humidifier dry gas outlet, a dilution valve, a dehumidification valve, a bypass valve, a humidifier, a humidifier moisture inlet, a humidifier moisture outlet and a back pressure valve; the hydrothermal system comprises a water pump, an electronic three-way valve, a PTC (Positive Temperature Coefficient) and a hydrothermal exhaust port; in the auxiliary heat dissipation system, the auxiliary heat dissipation system comprises an auxiliary waterway water inlet, a boosting DCDC and an air compressor controller; the hydrogen system comprises a gas-water separator, a hydrogen circulating pump and a tail gas discharge port; and the electrical system comprises a voltage electrical system and a low-voltage control system. The integrated structure arrangement is adopted, so that the system size is reduced, and the system weight is reduced.

Description

Technical Field

[0001] The present invention relates to the field of fuel cells, and in particular to a high-power integrated heavy-duty truck fuel cell system. Background Art

[0002] With the increasing attention paid to environmental protection and sustainable development around the world, fuel cell technology, as a clean and efficient energy conversion method, has gradually become one of the important ways to solve traffic pollution and energy dependence. The fuel cell system uses hydrogen and oxygen to undergo redox reactions in electrochemical cells to generate electricity, achieving zero emissions and low noise for vehicles, which is an ideal clean energy source. Especially in the field of transportation, fuel cell systems have huge application potential and can meet the needs of long-distance transport vehicles for high power, long mileage and fast refueling. However, there are still some problems and limitations when traditional fuel cell systems are used in high-power integrated tractors. For example, fuel cell systems are usually composed of multiple independent components. The low degree of integration between the components leads to problems such as heavy system weight, large volume, and difficult maintenance, which restricts its widespread application in actual transportation.

[0003] To this end, the present invention proposes a high-power integrated heavy-duty truck fuel cell system. Summary of the invention

[0004] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a high-power integrated heavy-duty truck fuel cell system.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A high-power integrated heavy-duty truck fuel cell system, comprising:

[0007] An air system, the air system comprising a fuel cell stack, an air compressor, an intercooler, a humidifier dry gas inlet, a humidifier dry gas outlet, a dilution valve, a dehumidification valve, a bypass valve, a humidifier, a humidifier wet gas inlet, a humidifier wet gas outlet and a back pressure valve;

[0008] A hydrothermal system, the hydrothermal system comprising a water pump, an electronic three-way valve, a PTC and a hydrothermal exhaust port;

[0009] In the auxiliary cooling system, the auxiliary cooling system includes an auxiliary water inlet, a boost DCDC and an air compressor controller;

[0010] A hydrogen system, comprising a gas-water separator, a hydrogen circulation pump and a tail outlet;

[0011] An electrical system includes a high-voltage electrical system and a low-voltage control system.

[0012] Preferably: in the air system, the air flows from the air compressor at the bottom of the system to the intercooler and then to the dry air inlet of the humidifier, and then from the dry air outlet of the humidifier to the air intake controlled by the throttle valve, and then enters the air-water plate interface and is connected to the intake manifold of the stack through a food-grade silicone tube to enter the stack; if the air humidity in the stack is too high, the air humidity of the stack is reduced by controlling the opening of the dehumidification valve to mix dry air with wet air, and some excess dry air is directly discharged from the system through the bypass valve. After the reaction, the exhaust gas from the outlet manifold of the stack enters the humidifier wet air inlet of the humidifier, and then to the humidifier wet outlet of the humidifier to discharge the exhaust gas through the back pressure valve.

[0013] Preferably: in the hydrothermal system, the coolant flows from the water inlet to the water pump inlet for pressure, and enters the air-water through-plate interface to enter the battery stack and the intercooler water inlet respectively. After the coolant flows through the battery stack to dissipate heat, it flows out from the battery stack outlet and the intercooler outlet. The coolant converges in the electronic three-way valve and flows out of the system through the large circulation of the electronic three-way valve to enter the radiator for heat dissipation. When the ambient temperature is low, the electronic three-way valve 27 rotates to a small circulation, and the coolant flows from the filter into the PTC heating and enters the battery stack until the battery stack reaches the normal operating temperature. The coolant flows out from the battery stack outlet to the water pump to form a circulation inside the system; the air in the system hydrothermal is discharged through the hydrothermal exhaust port connected to the radiator.

[0014] Preferably: in the auxiliary heat dissipation system, the coolant flows into the boost DCDC and the air compressor controller from the auxiliary water inlet, the coolant flowing out of the air compressor controller flows into the air compressor, and finally the coolant flowing through the air compressor merges with the boost DCDC outlet to form an auxiliary heat dissipation circuit, and an exhaust port is left for heat dissipation.

[0015] Preferably: in the hydrogen system, the external high-pressure hydrogen enters the mounting block of the electronic three-way valve through the hydrogen inlet after being reduced in pressure by the proportional valve and then enters the hydrogen inlet of the stack. The unreacted hydrogen is blown out from the hydrogen outlet of the stack and the hydrogen separated by the gas-water separator enters the pressurization of the hydrogen circulation pump. The hydrogen circulation pump controller adjusts the speed of the hydrogen circulation pump according to the power segment and re-enters the stack for reaction and circulation. The water generated by the reaction in the stack flows into the tail outlet through the slope in the hydrogen circulation pump and the gas-water separator and is uniformly discharged outside the system. When the pressure of the external hydrogen to the hydrogen inlet is too high, the over-pressure hydrogen is discharged through the pressure relief valve to ensure the hydrogen pressure entering the system; if an emergency stop failure occurs, the system and the external hydrogen will be cut off through the stop valve.

[0016] Preferably: the high-voltage electrical system comprises a positive copper busbar, a negative copper busbar, a high-voltage positive plug-in and a high-voltage negative plug-in.

[0017] Preferably: in the high-voltage electrical system, the positive side and the negative side of the stack current collector respectively transmit current to the high-voltage positive plug-in and the high-voltage negative plug-in through the positive copper bus and the negative copper bus, and then output current to the boost DCDC through the high-voltage line, and the boost DCDC then supplies power to the air compressor, hydrogen circulation pump, water pump, and PTC respectively.

[0018] Preferably: the low-pressure control system includes an FCU controller, a water inlet and outlet temperature and pressure integrated sensor, a back pressure valve, a hydrogen concentration sensor, a pressure sensor 1, a stop valve, a pressure relief port and a proportional valve.

[0019] Preferably: in the low-pressure control system, after the fuel cell system is started, the internal high pressure is self-supplied and supplies power to the required load through the boost DCDC, and the internal components are controlled by the FCU controller through CAN communication. When the temperature signal value is fed back to the FCU controller, the water inlet and outlet temperature and pressure integrated sensor of the water circuit feeds back the pressure and temperature signal values ​​to the FCU controller, and adjusts the speed of the water pump to adjust the flow rate of the cooling water. The temperature and pressure sensors in the air system and the hydrothermal system can monitor the changes in the temperature and pressure of the air and coolant in the system. The pressure signal value in the air pipeline is fed back to the FCU controller, and the speed of the air compressor and the opening of the dilution valve and the back pressure valve are adjusted through the air compressor controller to ensure the stable operating pressure of the air module and the humidity of the stack. A hydrogen concentration sensor is left inside the system to monitor the hydrogen concentration inside the system shell. When the hydrogen concentration sensor detects the hydrogen concentration inside the shell When the gas concentration reaches the set threshold, the signal will be fed back to the system FCU controller to send a shutdown command, and the shell will be purged and blown out from the exhaust plate interface; in addition, a hydrogen concentration sensor is added to the system cover to monitor whether the hydrogen concentration above the system is too high. When external high-pressure hydrogen enters the hydrogen supply port, the pressure sensor monitors the pressure of the external hydrogen, and the pressure signal value is fed back to the system FCU controller. When the temperature or pressure exceeds the limit, the FCU controller adjusts the shut-off valve in the hydrogen inlet module to work. The high-pressure hydrogen exceeding the system requirement is discharged to the tail exhaust port through the pipeline connected to the pressure relief port and then discharged from the system. Under normal working conditions, the hydrogen pressure is adjusted by the proportional valve, and the hydrogen circulation pump circulates and adjusts to the required hydrogen pressure of the system.

[0020] Preferably: the high-power integrated heavy-duty truck fuel cell system further includes:

[0021] Communication interface, used to make waterproof connection between the sensor inside the transition housing and the main wiring harness outside the housing;

[0022] Low voltage fuse box, used for over-current protection;

[0023] Pressure sensor 2: The air after the fuel cell stack reaction is monitored by pressure sensor 2 to adjust the opening of the back pressure valve.

[0024] A hydrogen concentration sensor, used to detect the hydrogen concentration outside the system;

[0025] CVM, monitors the voltage of the fuel cell stack and evaluates its performance and maintenance;

[0026] Lifting points, which are convenient for installing and repairing the system, and the entire system can be lifted through the lifting points;

[0027] CVM through-board plug-in is used to make waterproof connection between the wiring harness inside the transition shell and the wiring harness of CVM outside the shell;

[0028] The water inlet is the water inlet of the high-power integrated heavy-duty truck fuel cell system and is connected to the water outlet of the radiator;

[0029] Fixing points for fixing the entire high-power integrated heavy-duty truck fuel cell system;

[0030] The air compressor inlet is the air inlet of the high-power integrated heavy-duty truck fuel cell system;

[0031] The stack output-DC positive pole and the stack output-DC negative pole are connected to the boost DCDC using a high-voltage wiring harness;

[0032] Hydrogen and water discharge solenoid valve, which is used to drain water and prevent water from accumulating in parts;

[0033] Air entering the pile temperature and pressure integrated sensor: monitors the pressure and temperature of the air entering the pile;

[0034] The housing upper cover, the housing bottom plate, the housing left side plate, the housing front side plate, the housing right side plate, and the housing rear side plate together constitute the housing;

[0035] DCDC-air compressor controller, DCDC-PTC, hydrogen pump water pump, which are connected to the high-voltage socket on the boost DCDC.

[0036] The beneficial effects of the present invention are:

[0037] 1. The present invention adopts an integrated structural layout to integrate all the components of the fuel cell system around the shell through brackets or directly fixed on the shell; the optimized structural design eliminates the system fixing frame to reduce the system volume and reduce the system weight.

[0038] 2. The present invention adopts a highly integrated design, integrating the fuel cell stack, air, water heating, high and low voltage electrical systems inside the fuel cell system, simplifying the system structure and improving the overall stability and reliability of the system.

[0039] 3. The present invention adopts a compact design to reduce the size and weight of the system. The size of the suspension shock absorber can be adjusted according to the usage scenario, so that it can be better arranged in the engine compartment of the tractor and has a wider adaptability.

[0040] 4. The components that need to be replaced and maintained regularly are placed on both sides of the system for easy operation by later personnel. The system also has built-in lifting points for loading and unloading, which reduces maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 This is a front view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0042] Figure 2 This is a right view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0043] Figure 3 This is a left view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0044] Figure 4 A bottom view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0045] Figure 5 A top view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0046] Figure 6 This is a rear view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention;

[0047] Figure 7 This is an isometric view of a high-power integrated heavy-duty truck fuel cell system proposed by the present invention. DETAILED DESCRIPTION

[0048] The technical solution of the present invention is further described in detail below in conjunction with specific implementation methods.

[0049] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected or set, or detachably connected or set, or integrally connected or set. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0050] Embodiment 1:

[0051] A high-power integrated heavy-duty truck fuel cell system, comprising:

[0052] An air system, the air system comprising a fuel cell stack 60, an air compressor 41, an intercooler 42, a humidifier dry gas inlet 50, a humidifier dry gas outlet 46, a dilution valve 47, a dehumidification valve 39, a bypass valve 39, a humidifier 44, a humidifier wet gas inlet 46, a humidifier wet gas outlet 48 and a back pressure valve 43;

[0053] A hydrothermal system, the hydrothermal system comprising a water pump 40, an electronic three-way valve 27, a PTC 34 and a hydrothermal exhaust port 14;

[0054] In the auxiliary heat dissipation system, the auxiliary heat dissipation system includes an auxiliary water inlet 15, a boost DCDC1 and an air compressor controller 6;

[0055] A hydrogen system, the hydrogen system comprising 10, a gas-water separator 3, a hydrogen circulation pump 4 and a tail outlet 33;

[0056] An electrical system includes a high-voltage electrical system and a low-voltage control system.

[0057] In the air system, the air flows from the air compressor 41 at the bottom of the system to the intercooler 42 and then to the humidifier dry air inlet 50, and then from the humidifier dry air outlet 46 to the throttle 47 to control the air intake, and then enters the air-water plate interface and is connected to the intake manifold of the stack 60 through a food-grade silicone tube to enter the stack 60; if the air humidity in the stack 60 is too high, the air humidity of the stack 60 is reduced by controlling the opening of the dehumidification valve 39 to mix dry air and wet air, and some excess dry air is controlled to be directly discharged from the system through the bypass valve 38. After the reaction, the exhaust gas of the outlet manifold of the stack 60 enters the humidifier wet air inlet 45 of the humidifier 44, and then to the humidifier wet air outlet 48 of the humidifier 44 to control the exhaust gas through the back pressure valve 43.

[0058] In the hydrothermal system, the coolant flows from the water inlet to the inlet of the water pump 40 for pressure, and enters the air-water through-plate interface to enter the battery stack 60 and the water inlet of the intercooler 42 respectively. After the coolant flows through the battery stack 60 to dissipate heat, it flows out from the water outlet of the battery stack and the water outlet of the intercooler 42. The coolant converges in the electronic three-way valve 27 and flows out of the system through the large circulation of the electronic three-way valve 27 to enter the radiator for heat dissipation. When the ambient temperature is low, the electronic three-way valve 27 rotates to a small circulation, and the coolant flows from the filter into the PTC34 for heating and enters the battery stack 60 until the battery stack 60 reaches the normal operating temperature. The coolant flows out from the outlet of the battery stack to the water pump 40 to form a circulation inside the system; the air in the system hydrothermal is discharged through the hydrothermal exhaust port 14 connected to the radiator.

[0059] In the auxiliary heat dissipation system, the coolant flows into the boost DCDC1 and the air compressor controller 6 from the auxiliary water inlet 15, and the coolant flowing out of the air compressor controller 6 flows into the air compressor 41. Finally, the coolant flowing through the air compressor 41 merges with the boost DCDC1 outlet to form an auxiliary heat dissipation circuit, and an exhaust port is left for heat dissipation.

[0060] In the hydrogen system, external high-pressure hydrogen enters the mounting block of the electronic three-way valve 27 through the hydrogen inlet 10 after being reduced in pressure by the proportional valve, and then enters the hydrogen inlet 10 of the stack 60. The unreacted hydrogen blown out from the hydrogen outlet of the stack 60 passes through the gas-water separator 3 and is pressurized by the hydrogen circulation pump 4. The hydrogen circulation pump controller 2 adjusts the speed of the hydrogen circulation pump according to the power stage and re-enters the stack 60 for reaction and circulation. The water generated by the reaction in the stack 60 flows into the tail outlet 33 through the slope in the hydrogen circulation pump 4 and the gas-water separator 3 and is uniformly discharged outside the system. When the pressure of the external hydrogen to the hydrogen inlet is too high, the over-pressure hydrogen is discharged through the pressure relief valve 9 to ensure the hydrogen pressure entering the system; if an emergency stop failure occurs, the system and the external hydrogen will be cut off through the stop valve.

[0061] The high-voltage electrical system includes a positive copper busbar 51 , a negative copper busbar 62 , a high-voltage positive plug-in 35 and a high-voltage negative plug-in 31 .

[0062] In the high-voltage electrical system, the positive and negative sides of the current collector of the stack 60 transmit current to the high-voltage positive plug-in 35 and the high-voltage negative plug-in 31 through the positive copper bus 51 and the negative copper bus 62 respectively, and then output current to the boost DCDC1 through the high-voltage line. The boost DCDC1 then supplies power to the air compressor 41, the hydrogen circulation pump 4, the water pump 40, and the PTC34 respectively.

[0063] The low-pressure control system includes an FCU controller 7, a water inlet and outlet temperature and pressure integrated sensor 57, a back pressure valve 43, a hydrogen concentration sensor 55, a pressure sensor 13, a stop valve 11, a pressure relief port 18 and a proportional valve 12.

[0064] In the low-pressure control system, after the fuel cell system is started, the internal high pressure is self-supplied and supplies power to the required load through the boost DCDC1. The internal components are controlled by the FCU controller 7 through CAN communication. When the temperature signal value is fed back to the FCU controller 7, the water inlet and outlet temperature and pressure integrated sensor 57 of the water circuit feeds back the pressure and temperature signal values ​​to the FCU controller 7, and adjusts the speed of the water pump 40 to adjust the flow rate of the cooling water. The temperature and pressure sensors in the air system and the hydrothermal system can monitor the changes in the temperature and pressure of the air and coolant in the system. The pressure signal value in the air pipeline is fed back to the FCU controller 7, and the speed of the air compressor 41 and the opening of the dilution valve 47 and the back pressure valve 43 are adjusted through the air compressor controller 6 to ensure the stable operating pressure of the air module and the humidity of the fuel cell stack 60. A hydrogen concentration sensor 55 is left inside the system to monitor the hydrogen concentration inside the system shell. When the hydrogen concentration sensor 55 detects the hydrogen concentration inside the shell When the gas concentration reaches the set threshold, the signal will be fed back to the system FCU controller 7 to send a shutdown command, and the shell will be purged and blown out from the exhaust plate interface 65; in addition, a hydrogen concentration sensor 55 is added to the system cover to monitor whether the hydrogen concentration above the system is too high. When external high-pressure hydrogen enters the hydrogen supply port 10, the pressure sensor 13 monitors the pressure of the external hydrogen, and the pressure signal value is fed back to the system FCU controller 7. When the temperature or pressure exceeds the limit, the FCU controller 7 adjusts the shut-off valve 11 in the hydrogen inlet module to work, and the high-pressure hydrogen exceeding the system requirement is discharged to the tail outlet 33 through the pipeline connected to the pressure relief port 18 to be discharged from the system. Under normal working conditions, the hydrogen pressure is adjusted by the proportional valve 12, and the hydrogen circulation pump 4 circulates and adjusts to the required hydrogen pressure of the system.

[0065] Embodiment 2:

[0066] A high-power integrated heavy-duty truck fuel cell system, comprising:

[0067] An air system, the air system comprising a fuel cell stack 60, an air compressor 41, an intercooler 42, a humidifier dry gas inlet 50, a humidifier dry gas outlet 46, a dilution valve 47, a dehumidification valve 39, a bypass valve 39, a humidifier 44, a humidifier wet gas inlet 46, a humidifier wet gas outlet 48 and a back pressure valve 43;

[0068] A hydrothermal system, the hydrothermal system comprising a water pump 40, an electronic three-way valve 27, a PTC 34 and a hydrothermal exhaust port 14;

[0069] In the auxiliary heat dissipation system, the auxiliary heat dissipation system includes an auxiliary water inlet 15, a boost DCDC1 and an air compressor controller 6;

[0070] A hydrogen system, the hydrogen system comprising 10, a gas-water separator 3, a hydrogen circulation pump 4 and a tail outlet 33;

[0071] An electrical system includes a high-voltage electrical system and a low-voltage control system.

[0072] In the air system, the air flows from the air compressor 41 at the bottom of the system to the intercooler 42 and then to the humidifier dry air inlet 50, and then from the humidifier dry air outlet 46 to the throttle 47 to control the air intake, and then enters the air-water plate interface and is connected to the intake manifold of the stack 60 through a food-grade silicone tube to enter the stack 60; if the air humidity in the stack 60 is too high, the air humidity of the stack 60 is reduced by controlling the opening of the dehumidification valve 39 to mix dry air and wet air, and some excess dry air is controlled to be directly discharged from the system through the bypass valve 38. After the reaction, the exhaust gas of the outlet manifold of the stack 60 enters the humidifier wet air inlet 45 of the humidifier 44, and then to the humidifier wet air outlet 48 of the humidifier 44 to control the exhaust gas through the back pressure valve 43.

[0073] In the hydrothermal system, the coolant flows from the water inlet to the inlet of the water pump 40 for pressure, and enters the air-water through-plate interface to enter the battery stack 60 and the water inlet of the intercooler 42 respectively. After the coolant flows through the battery stack 60 to dissipate heat, it flows out from the water outlet of the battery stack and the water outlet of the intercooler 42. The coolant converges in the electronic three-way valve 27 and flows out of the system through the large circulation of the electronic three-way valve 27 to enter the radiator for heat dissipation. When the ambient temperature is low, the electronic three-way valve 27 rotates to a small circulation, and the coolant flows from the filter into the PTC34 for heating and enters the battery stack 60 until the battery stack 60 reaches the normal operating temperature. The coolant flows out from the outlet of the battery stack to the water pump 40 to form a circulation inside the system; the air in the system hydrothermal is discharged through the hydrothermal exhaust port 14 connected to the radiator.

[0074] In the auxiliary heat dissipation system, the coolant flows into the boost DCDC1 and the air compressor controller 6 from the auxiliary water inlet 15, and the coolant flowing out of the air compressor controller 6 flows into the air compressor 41. Finally, the coolant flowing through the air compressor 41 merges with the boost DCDC1 outlet to form an auxiliary heat dissipation circuit, and an exhaust port is left for heat dissipation.

[0075] In the hydrogen system, external high-pressure hydrogen enters the mounting block of the electronic three-way valve 27 through the hydrogen inlet 10 after being reduced in pressure by the proportional valve, and then enters the hydrogen inlet 10 of the stack 60. The unreacted hydrogen blown out from the hydrogen outlet of the stack 60 passes through the gas-water separator 3 and is pressurized by the hydrogen circulation pump 4. The hydrogen circulation pump controller 2 adjusts the speed of the hydrogen circulation pump according to the power stage and re-enters the stack 60 for reaction and circulation. The water generated by the reaction in the stack 60 flows into the tail outlet 33 through the slope in the hydrogen circulation pump 4 and the gas-water separator 3 and is uniformly discharged outside the system. When the pressure of the external hydrogen to the hydrogen inlet is too high, the over-pressure hydrogen is discharged through the pressure relief valve 9 to ensure the hydrogen pressure entering the system; if an emergency stop failure occurs, the system and the external hydrogen will be cut off through the stop valve.

[0076] The high-voltage electrical system includes a positive copper busbar 51 , a negative copper busbar 62 , a high-voltage positive plug-in 35 and a high-voltage negative plug-in 31 .

[0077] In the high-voltage electrical system, the positive and negative sides of the current collector of the stack 60 transmit current to the high-voltage positive plug-in 35 and the high-voltage negative plug-in 31 through the positive copper bus 51 and the negative copper bus 62 respectively, and then output current to the boost DCDC1 through the high-voltage line. The boost DCDC1 then supplies power to the air compressor 41, the hydrogen circulation pump 4, the water pump 40, and the PTC34 respectively.

[0078] The low-pressure control system includes an FCU controller 7, a water inlet and outlet temperature and pressure integrated sensor 57, a back pressure valve 43, a hydrogen concentration sensor 55, a pressure sensor 13, a stop valve 11, a pressure relief port 18 and a proportional valve 12.

[0079] In the low-pressure control system, after the fuel cell system is started, the internal high pressure is self-supplied and supplies power to the required load through the boost DCDC1. The internal components are controlled by the FCU controller 7 through CAN communication. When the temperature signal value is fed back to the FCU controller 7, the water inlet and outlet temperature and pressure integrated sensor 57 of the water circuit feeds back the pressure and temperature signal values ​​to the FCU controller 7, and adjusts the speed of the water pump 40 to adjust the flow rate of the cooling water. The temperature and pressure sensors in the air system and the hydrothermal system can monitor the changes in the temperature and pressure of the air and coolant in the system. The pressure signal value in the air pipeline is fed back to the FCU controller 7, and the speed of the air compressor 41 and the opening of the dilution valve 47 and the back pressure valve 43 are adjusted through the air compressor controller 6 to ensure the stable operating pressure of the air module and the humidity of the fuel cell stack 60. A hydrogen concentration sensor 55 is left inside the system to monitor the hydrogen concentration inside the system shell. When the hydrogen concentration sensor 55 detects the hydrogen concentration inside the shell When the gas concentration reaches the set threshold, the signal will be fed back to the system FCU controller 7 to send a shutdown command, and the shell will be purged and blown out from the exhaust plate interface 65; in addition, a hydrogen concentration sensor 55 is added to the system cover to monitor whether the hydrogen concentration above the system is too high. When external high-pressure hydrogen enters the hydrogen supply port 10, the pressure sensor 13 monitors the pressure of the external hydrogen, and the pressure signal value is fed back to the system FCU controller 7. When the temperature or pressure exceeds the limit, the FCU controller 7 adjusts the shut-off valve 11 in the hydrogen inlet module to work, and the high-pressure hydrogen exceeding the system requirement is discharged to the tail outlet 33 through the pipeline connected to the pressure relief port 18 to be discharged from the system. Under normal working conditions, the hydrogen pressure is adjusted by the proportional valve 12, and the hydrogen circulation pump 4 circulates and adjusts to the required hydrogen pressure of the system.

[0080] The high-power integrated heavy-duty truck fuel cell system also includes:

[0081] Communication interface 5, used to make waterproof connection between the sensor inside the transition housing and the main wiring harness outside the housing;

[0082] Low voltage fuse box 8, used for overcurrent protection;

[0083] Pressure sensor 2 56 , the air reacted by the stack 60 is monitored by the pressure sensor 2 56 to adjust the opening of the back pressure valve 43 ;

[0084] A hydrogen concentration sensor 19, used to detect the hydrogen concentration outside the system;

[0085] CVM21, monitors the voltage of the fuel cell stack and evaluates its performance and maintenance;

[0086] Lifting point 22, convenient for installation and maintenance of the system, through which the entire system can be lifted;

[0087] CVM through-board plug-in 23, used to transition the wiring harness inside the housing to the wiring harness of CVM21 outside the housing for waterproof connection;

[0088] The water supply port 25 is the water inlet of the high-power integrated heavy-duty truck fuel cell system and is connected to the water outlet of the radiator;

[0089] The fixing point 26 is used to fix the entire high-power integrated heavy-duty truck fuel cell system;

[0090] The air compressor inlet 32 ​​is the air inlet of the high-power integrated heavy-duty truck fuel cell system;

[0091] The stack output-DC positive electrode 36 and the stack output-DC negative electrode 37 are connected to the boost DC C D 1 by a high voltage harness;

[0092] A hydrogen and water discharge solenoid valve 49, which is used to discharge water and prevent water from accumulating in parts;

[0093] Air entering the stack temperature and pressure integrated sensor 54: monitors the pressure and temperature of the air entering the stack;

[0094] The housing upper cover 24, the housing bottom plate 53, the housing left side plate 52, the housing front side plate 58, the housing right side plate 59, and the housing rear side plate 61 together constitute the housing;

[0095] The DCDC-air compressor controller 28, DCDC-PTC 29, and hydrogen pump water pump 30 are connected to the high-pressure socket on the boost DCDC1.

[0096] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A high-power integrated heavy-duty truck fuel cell system, characterized in that: include: An air system, the air system comprising a fuel cell stack (60), an air compressor (41), an intercooler (42), a humidifier dry gas inlet (50), a humidifier dry gas outlet (46), a dilution valve (47), a dehumidification valve (39), a bypass valve (39), a humidifier (44), a humidifier wet gas inlet (46), a humidifier wet gas outlet (48) and a back pressure valve (43); A hydrothermal system, the hydrothermal system comprising a water pump (40), an electronic three-way valve (27), a PTC (34) and a hydrothermal exhaust port (14); In the auxiliary heat dissipation system, the auxiliary heat dissipation system comprises an auxiliary water inlet (15), a boost DCDC (1) and an air compressor controller (6); A hydrogen system, the hydrogen system comprising (10), a gas-water separator (3), a hydrogen circulation pump (4) and a tail outlet (33); An electrical system, the electrical system comprising a high-voltage electrical system and a low-voltage control system; The low-pressure control system comprises an FCU controller (7), a water inlet and outlet temperature and pressure integrated sensor (57), a back pressure valve (43), a hydrogen concentration sensor (55), a pressure sensor 1 (13), a stop valve (11), a pressure relief port (18) and a proportional valve (12); In the low-pressure control system, after the fuel cell system is started, the internal high pressure is self-supplied and the required load is supplied with power through the boost DCDC (1), and the internal components are controlled by the FCU controller (7) through CAN communication. When the temperature signal value is fed back to the FCU controller (7), the water inlet and outlet temperature and pressure integrated sensor (57) of the water circuit feeds back the pressure and temperature signal values ​​to the FCU controller (7), and adjusts the speed of the water pump (40) to adjust the flow rate of the cooling water. The temperature and pressure sensors in the air system and the water heating system can monitor the changes in the temperature and pressure of the air and coolant in the system. The pressure signal value in the air pipeline is fed back to the FCU controller (7), and the speed of the air compressor (41) and the opening of the dilution valve (47) and the back pressure valve (43) are adjusted through the air compressor controller (6) to ensure the stable operating pressure of the air module and the humidity of the fuel cell stack (60). A hydrogen concentration sensor (55) is left inside the system to monitor the hydrogen concentration inside the system shell. When the hydrogen concentration sensor (55) detects that the hydrogen concentration inside the shell is too high, the hydrogen concentration sensor (55) is used to monitor the hydrogen concentration inside the shell. When the gas concentration reaches the set threshold, the signal will be fed back to the system FCU controller (7) to send a shutdown command, and the shell will be purged and blown out from the exhaust plate interface (65); in addition, a hydrogen concentration sensor (55) is added to the system cover to monitor whether the hydrogen concentration above the system is too high. When external high-pressure hydrogen enters the hydrogen supply port (10), the pressure sensor 1 (13) monitors the pressure of the external hydrogen, and the pressure signal value is fed back to the system FCU controller (7). When the temperature or pressure exceeds the limit, the FCU controller (7) adjusts the shut-off valve (11) in the hydrogen inlet module to work, and the high-pressure hydrogen exceeding the system requirement is discharged to the tail outlet (33) through the pipeline connected to the pressure relief port (18) to be discharged from the system. Under normal working conditions, the hydrogen pressure is adjusted by the proportional valve (12), and the hydrogen circulation pump (4) circulates and adjusts to the required hydrogen pressure of the system; The high-power integrated heavy-duty truck fuel cell system also includes: A communication interface (5) is used to waterproofly connect the sensor inside the transition housing to the main wiring harness outside the housing; A low voltage fuse box (8), used for overcurrent protection; Pressure sensor 2 (56), the air reacted by the battery stack (60) is monitored by pressure sensor 2 (56) to adjust the opening of the back pressure valve (43); A hydrogen concentration sensor (19) for detecting the hydrogen concentration outside the system; CVM (21), monitors the voltage of the fuel cell stack and evaluates its performance and maintenance; A lifting point (22) is provided to facilitate installation and maintenance of the system, and the entire system can be lifted through the lifting point (22); A CVM through-board plug-in (23) is used to waterproofly connect the wiring harness inside the transition housing to the wiring harness of the CVM (21) outside the housing; A water supply port (25), which is a water inlet of the high-power integrated heavy-duty truck fuel cell system and is connected to a water outlet of the radiator; A fixing point (26) for fixing the entire high-power integrated heavy-duty truck fuel cell system; An air compressor air inlet (32), which is the air inlet of a high-power integrated heavy-duty truck fuel cell system; A stack output-DC positive electrode (36) and a stack output-DC negative electrode (37), which are connected to a boost DCC (1) by a high-voltage wiring harness; A hydrogen and water discharge solenoid valve (49) is used to discharge water and prevent water from accumulating in parts; Air entering the stack temperature and pressure integrated sensor (54): monitors the pressure and temperature of the air entering the stack; The housing upper cover (24), the housing bottom plate (53), the housing left side plate (52), the housing front side plate (58), the housing right side plate (59), and the housing rear side plate (61) together constitute the housing; The DCDC-air compressor controller (28), DCDC-PTC (29), and hydrogen pump water pump (30) are connected to the high-voltage socket on the boost DCDC (1).

2. A high-power integrated heavy-duty truck fuel cell system according to claim 1, characterized in that: In the air system, air flows from the air compressor (41) at the bottom of the system to the intercooler (42) and then to the humidifier dry air inlet (50), and then from the humidifier dry air outlet (46) to the throttle valve (47) to control the air intake volume, and then enters the air-water plate interface and is connected to the intake manifold of the stack (60) through a food-grade silicone tube to enter the stack (60); if the air humidity in the stack (60) is too high, the air humidity of the stack (60) is reduced by controlling the opening of the dehumidification valve (39) to mix dry air and wet air, and part of the excess dry air is controlled to be directly discharged from the system through the bypass valve (38). After the reaction, the exhaust gas of the outlet manifold of the stack (60) enters the humidifier wet air inlet (45) of the humidifier (44), and then to the humidifier wet air outlet (48) of the humidifier (44) to control the exhaust gas through the back pressure valve (43).

3. A high-power integrated heavy-duty truck fuel cell system according to claim 1, characterized in that: In the hydrothermal system, the coolant flows from the water inlet to the water pump (40) for pressurization, and enters the air-water through-plate interface to enter the battery stack (60) and the intercooler (42) water inlet respectively. After the coolant flows through the battery stack (60) to dissipate heat, it flows out from the battery stack outlet and the intercooler (42) outlet. The coolant converges in the electronic three-way valve (27) and flows out of the large circulation system through the electronic three-way valve (27) to enter the radiator for heat dissipation. When the ambient temperature is low, the electronic three-way valve 27 rotates to a small circulation, and the coolant flows from the filter into the PTC (34) to heat and enter the battery stack (60) until the battery stack (60) reaches the normal operating temperature. The coolant flows out from the battery stack outlet to the water pump (40) to form a circulation inside the system; the air in the system hydrothermal is connected to the radiator through the hydrothermal exhaust port (14) and discharged.

4. The high-power integrated heavy-duty truck fuel cell system according to claim 1, characterized in that: In the auxiliary heat dissipation system, the coolant flows from the auxiliary water channel water inlet (15) into the boost DCDC (1) and the air compressor controller (6), the coolant flowing out of the air compressor controller (6) flows into the air compressor (41), and finally the coolant flowing through the air compressor (41) merges with the outlet of the boost DCDC (1) to form an auxiliary heat dissipation circuit, with an exhaust port reserved for heat dissipation.

5. The high-power integrated heavy-duty truck fuel cell system according to claim 1, characterized in that: In the hydrogen system, external high-pressure hydrogen enters the mounting block of the electronic three-way valve (27) through the hydrogen inlet (10) and is reduced in pressure by the proportional valve, and then enters the hydrogen inlet (10) of the stack (60). The unreacted hydrogen is blown out from the hydrogen outlet of the stack (60), and the hydrogen separated by the gas-water separator (3) enters the hydrogen circulation pump (4) for pressurization. The hydrogen circulation pump controller (2) adjusts the speed of the hydrogen circulation pump according to the power stage, and re-enters the stack (60) for reaction and circulation. The water generated by the reaction in the stack (60) flows into the tail outlet (33) through the slope in the hydrogen circulation pump (4) and the gas-water separator (3) and is uniformly discharged to the outside of the system. When the pressure of the external hydrogen to the hydrogen inlet is too high, the over-pressure hydrogen is discharged through the pressure relief valve (9) to ensure the hydrogen pressure entering the system; if an emergency stop failure occurs, the system and the external hydrogen will be cut off through the stop valve.

6. The high-power integrated heavy-duty truck fuel cell system according to claim 1, characterized in that: The high-voltage electrical system comprises a positive copper busbar (51), a negative copper busbar (62), a high-voltage positive plug-in (35) and a high-voltage negative plug-in (31).

7. A high-power integrated heavy-duty truck fuel cell system according to claim 6, characterized in that: In the high-voltage electrical system, the positive and negative sides of the current collector of the battery stack (60) transmit current to the high-voltage positive plug-in (35) and the high-voltage negative plug-in (31) respectively through the positive copper busbar (51) and the negative copper busbar (62), and then output current to the boost DCDC (1) through the high-voltage line. The boost DCDC (1) then supplies power to the air compressor (41), the hydrogen circulation pump (4), the water pump (40), and the PTC (34).

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