Gas fuel pressure regulator diagnostic system and diagnostic control method

Abstract

The present application relates to the technical field of pressure regulator diagnosis, and specifically relates to a gas fuel pressure regulator diagnosis system and a diagnosis control method, which comprises a control module, a diagnosis module, a solenoid valve, a high-pressure pressure sensor, a low-pressure pressure sensor and a pressure regulator; the solenoid valve, the high-pressure pressure sensor, the pressure regulator and the low-pressure pressure sensor are sequentially connected through pipelines; the control module is electrically connected with the diagnosis module, the solenoid valve, the high-pressure pressure sensor, the low-pressure pressure sensor and the pressure regulator; the high-pressure pressure sensor is used for measuring the pressure value of high-pressure gas in the pipeline between the solenoid valve and the pressure regulator; and the low-pressure pressure sensor is used for measuring the pressure value of low-pressure gas at the outlet of the pressure regulator after the gas passes through the pressure regulator.

Description

Technical Field

[0001] This invention relates to the field of pressure regulator diagnostics, specifically to a diagnostic system and control method for a gas fuel pressure regulator. Background Technology

[0002] With increasing global focus on environmental protection and energy efficiency, gas-fueled vehicles, as a green alternative to traditional gasoline vehicles, are gradually becoming an important development direction for the automotive industry. In these new modes of transportation, the pressure regulator, as a key component, is responsible for adjusting the gas in the high-pressure gas cylinder to a pressure level suitable for engine combustion. Its performance directly affects the vehicle's safety, emissions levels, and fuel economy.

[0003] Existing gas fuel pressure regulators typically rely on mechanical structures for pressure regulation, but their built-in diagnostic mechanisms are relatively simple and cannot complete comprehensive fault detection in a short time. This delay may result in problems not being detected in a timely manner, increasing safety hazards. Consequently, existing diagnostic methods often only identify obvious hardware faults, failing to accurately diagnose subtle changes in the regulator's internal operating state or potential problems, leading to inefficient troubleshooting.

[0004] Therefore, there is an urgent need for a diagnostic system and control method for gas fuel pressure regulators that can detect hardware faults and faults in the operating state of the pressure regulator, thereby achieving comprehensive and rapid fault diagnosis of the pressure regulator. Summary of the Invention

[0005] One of the objectives of this invention is to provide a diagnostic system and control method for a gas fuel pressure regulator, which can detect hardware faults of the pressure regulator and detect faults in the operating state of the pressure regulator, thereby achieving comprehensive and rapid fault diagnosis of the pressure regulator.

[0006] To achieve the above objectives, a gas fuel pressure regulator diagnostic system is provided, including a control module, a diagnostic module, a solenoid valve, a high-pressure sensor, a low-pressure sensor, and a pressure regulator.

[0007] The solenoid valve, high-pressure sensor, pressure regulator, and low-pressure sensor are connected sequentially via pipelines; the control module is electrically connected to the diagnostic module, solenoid valve, high-pressure sensor, low-pressure sensor, and pressure regulator, respectively.

[0008] The high-pressure sensor is used to measure the pressure value corresponding to the high-pressure gas in the pipeline between the solenoid valve and the pressure regulator.

[0009] The low-pressure sensor is used to measure the pressure value of the low-pressure gas at the outlet of the regulator after passing through the regulator.

[0010] The diagnostic module is used to perform hardware fault detection on the solenoid valve, high pressure sensor, low pressure sensor, and pressure regulator when the solenoid valve is in the closed state, and to determine whether the corresponding equipment is faulty. If so, the first fault information is output; if not, the first safety information is output.

[0011] The control module is used to activate the solenoid valve when the corresponding first safety information is output. At this time, the solenoid valve is in the open state. Based on the preset fault diagnosis strategy, the control module collects the pressure value corresponding to the high pressure sensor and the pressure value corresponding to the low pressure sensor, performs fault detection on the pressure regulator, and generates the corresponding second fault information.

[0012] The technical principle and effects of this solution are as follows: In this solution, high-pressure gas in the pipeline sequentially passes through a solenoid valve, a high-pressure sensor, a pressure regulator, and a low-pressure sensor. The control module, as the core of the entire system, is responsible for receiving data collected by each sensor and controlling the opening and closing of the solenoid valve. The high-pressure sensor is located on the pipeline between the solenoid valve and the pressure regulator to monitor the pressure value of the high-pressure gas before pressure regulation, while the low-pressure sensor is located at the outlet of the pressure regulator to monitor the pressure value of the low-pressure gas after pressure regulation.

[0013] After the entire system is powered on, the control module first activates the diagnostic module. With the solenoid valve closed, it performs hardware fault detection on the solenoid valve, high-pressure sensor, low-pressure sensor, and pressure regulator to determine if the corresponding equipment is faulty. If so, it outputs the first fault information; otherwise, it outputs the first safety information. To determine if there is an open circuit, short to ground fault, or short to power fault, when the first fault information is output, the operator will repair or replace the corresponding equipment until there is no fault. After the first safety information is output, it indicates that the corresponding equipment hardware is not faulty.

[0014] Then the control module starts the solenoid valve, at which point the high-pressure gas will flow out from the outlet of the pressure regulating valve through the pipeline. During this process, based on the preset fault diagnosis strategy, the pressure value corresponding to the high-pressure sensor and the pressure value corresponding to the low-pressure sensor are collected, and the fault detection and diagnosis of the pressure regulator are completed, thereby outputting the second fault information, and thus realizing accurate and rapid diagnosis of the fault of the gas fuel pressure regulator.

[0015] In this solution, by configuring control and diagnostic modules, hardware checks are performed on all critical components (such as solenoid valves, high-pressure sensors, low-pressure sensors, and pressure regulators) during the initial system startup (with solenoid valves closed). This allows potential faults to be detected before they affect normal operation. This preventative maintenance effectively avoids safety accidents caused by equipment malfunction. Once the hardware is confirmed to be fault-free and the system enters operating mode, it continuously monitors the pressure regulator's operating status to ensure stable operation according to preset parameters. In case of any abnormalities, rapid action can be taken to ensure the system's safety and reliability.

[0016] The entire fault detection process is divided into two stages: first, a hardware integrity check under static conditions, and second, a performance evaluation under dynamic conditions. This design allows each stage to focus on a specific type of fault, thereby improving the accuracy and reliability of diagnostic results. It relies not only on data from a single sensor but also combines information from multiple sensors (such as high-pressure and low-pressure sensors) for comprehensive analysis. This helps to understand system behavior more comprehensively, reduce false alarm rates, and more accurately locate the fault source. In other words, it enables the detection of hardware faults in the voltage regulator while simultaneously detecting faults in the regulator's operational state, thus achieving comprehensive and rapid fault diagnosis of the voltage regulator.

[0017] Furthermore, the high-pressure gas in the pipeline includes one of natural gas, hydrogen, and ammonia, or a mixture of at least two of the above gases in any proportion.

[0018] Beneficial effects: This solution incorporates multiple types of high-pressure gas within the pipeline, enabling the system to handle various types of gaseous fuels and support arbitrary mixing ratios between these gases. This multi-fuel compatibility allows the system to flexibly adapt to different application scenarios and changing requirements, performing well in both single-fuel and mixed-fuel environments.

[0019] Furthermore, the voltage regulator includes a mechanical voltage regulator or an electronically controlled voltage regulator.

[0020] Beneficial effects: It provides two different voltage regulation solutions, namely mechanical voltage regulator and electronic voltage regulator, so that the system can flexibly choose the most suitable voltage regulation method according to actual application needs, cost considerations or environmental conditions.

[0021] Furthermore, the diagnostic module is also used to acquire the pressure value P corresponding to the high-pressure sensor when the solenoid valve is in the closed state. H 1 and the pressure value P corresponding to the low-pressure sensor at this time. L 1. And determine P H 1 and P L1. Is it within the preset reasonable range? If yes, then the corresponding sensor is not faulty; otherwise, the corresponding sensor is faulty.

[0022] Beneficial Effects: By monitoring pressure under static conditions during system startup or in non-operating states, potential faults can be detected before they affect normal operation. This preventative maintenance effectively avoids safety accidents or performance degradation caused by sensor malfunctions. The design of acquiring pressure values ​​from high-pressure and low-pressure sensors with the solenoid valve closed and making reasonable judgments not only enhances the system's reliability and safety but also significantly improves the accuracy and precision of diagnostics, providing users with a more intelligent, reliable, and efficient solution. This mechanism ensures that the system is built on a stable and accurate foundation from the outset, providing a solid guarantee for subsequent operations.

[0023] Furthermore, the preset fault diagnosis strategy is as follows:

[0024] Determine whether the voltage regulator is a mechanical or electronically controlled voltage regulator;

[0025] When the pressure regulator is a mechanical regulator, read the pressure value PH2 corresponding to the high-pressure sensor and the pressure value P corresponding to the low-pressure sensor. L 2;

[0026] When P H 2 <P H 1 and |P H 2-P H 1| <Y H If P = 1, the solenoid valve is faulty and cannot be opened; otherwise, the solenoid valve is not faulty and can be opened normally. L 2>P L 1 and |P L 2-P L 1|<Y L 1a, or P L 2≥Y L If 1b is selected, it is determined that there is a fault in the mechanical pressure regulator, and the corresponding second fault information is output.

[0027] When the pressure regulator is an electronically controlled pressure regulator, the control module starts the electronically controlled pressure regulator and reads the pressure value P corresponding to the high-pressure sensor at this time. H 3, and the pressure value P corresponding to the low-pressure sensor. L 3;

[0028] When P H 3 < P H 1 and |P H 3-P H 1| <Y HIf P is positive, the solenoid valve is faulty and cannot be opened; otherwise, the solenoid valve is functioning correctly and can be opened normally. L 3>P L 1 and |P L 3-P L 1|<Y L 2a, or P L 3≥Y L If 2b is selected, it is determined that there is a fault in the electronically controlled voltage regulator, and the corresponding second fault information is output.

[0029] Beneficial effects: Different start-up methods and testing standards are employed for different types of pressure regulators (mechanical and electronic). This customized diagnostic logic can more accurately reflect the operating status of each regulator, avoiding misjudgments that may arise from general methods. By reading the pressure values ​​of the high-pressure and low-pressure sensors under actual operating conditions and comparing them with the baseline values ​​under initial static conditions, the functional status of the pressure regulator and solenoid valve can be more realistically evaluated, improving the reliability of the diagnostic results.

[0030] Furthermore, it also includes a maintenance module, which is used to formulate corresponding fault maintenance plans based on the output of the first fault information or the second fault information.

[0031] Beneficial effects: In this solution, a fault repair plan is formulated as soon as the fault information is output, which can quickly provide repair personnel with repair direction and greatly improve repair efficiency.

[0032] The present invention also provides a diagnostic control method for a gas fuel pressure regulator, using the above-described gas fuel pressure regulator diagnostic system. Attached Figure Description

[0033] Figure 1 This is a logic block diagram of the gas fuel pressure regulator diagnostic system and diagnostic control method in Embodiment 1 of the present invention.

[0034] Figure 2 This is a pipeline connection diagram corresponding to the electronically controlled voltage regulator in Embodiment 1 of the present invention;

[0035] Figure 3 This is a pipeline connection diagram corresponding to the mechanical pressure regulator in Embodiment 1 of the present invention. Detailed Implementation

[0036] The following detailed description illustrates the specific implementation method:

[0037] The markings in the accompanying drawings include: pipeline 1, solenoid valve 2, high pressure sensor 3, electronic pressure regulator 4, low pressure sensor 5, and mechanical pressure regulator 6.

[0038] Example 1

[0039] Gas fuel pressure regulator diagnostic system, basically as follows Figure 1 As shown, it includes a control module, a diagnostic module, a solenoid valve 2, a high-pressure sensor 3, a low-pressure sensor 5, and a pressure regulator;

[0040] The solenoid valve 2, high-pressure sensor 3, pressure regulator, and low-pressure sensor 5 are connected in sequence through pipeline 1; the control module is electrically connected to the diagnostic module, solenoid valve 2, high-pressure sensor 3, low-pressure sensor 5, and pressure regulator respectively; in this embodiment, the high-pressure sensor 3 and low-pressure sensor 5 also integrate corresponding temperature sensors, thereby realizing dual detection of the temperature and pressure of the gas in pipeline 1.

[0041] The high-pressure sensor 3 is used to measure the pressure value corresponding to the high-pressure gas in the pipeline 1 between the solenoid valve 2 and the pressure regulator; the high-pressure gas in the pipeline 1 includes one of natural gas, hydrogen and ammonia, or a mixed gas composed of at least two of the above gases in any proportion.

[0042] The low-pressure sensor 5 is used to measure the pressure value of the low-pressure gas at the outlet of the regulator after passing through the regulator; the regulator includes a mechanical regulator 6 or an electronically controlled regulator 4.

[0043] The diagnostic module is used to perform hardware fault detection on the solenoid valve 2, high pressure sensor 3, low pressure sensor 5, and pressure regulator when the solenoid valve 2 is in the closed state, and to determine whether the corresponding equipment is faulty. If so, the first fault information is output; if not, the first safety information is output.

[0044] The diagnostic module is also used to acquire the pressure value P corresponding to the high-pressure sensor 3 when the solenoid valve 2 is in the closed state. H 1 and the pressure value P corresponding to the low-pressure sensor 5 at this time. L 1. And determine P H 1 and P L 1. Is it within the preset reasonable range? If yes, then the corresponding sensor is not faulty; otherwise, the corresponding sensor is faulty.

[0045] The control module is used to activate solenoid valve 2 when the corresponding first safety information is output. At this time, solenoid valve 2 is in the open state. Based on the preset fault diagnosis strategy, it collects the pressure value corresponding to the high pressure sensor 3 and the pressure value corresponding to the low pressure sensor 5, performs fault detection on the pressure regulator, and generates the corresponding second fault information.

[0046] The preset fault diagnosis strategy is as follows:

[0047] By opening solenoid valve 2 through the control module, it can be determined whether the pressure regulator is a mechanical pressure regulator 6 or an electronically controlled pressure regulator 4.

[0048] like Figure 2 As shown, when the pressure regulator is a mechanical pressure regulator 6, the pressure value P corresponding to the high-pressure sensor 3 is read. H 2, and the pressure value P corresponding to the low-pressure sensor 5. L 2;

[0049] When P H 2 < P H 1 and |P H 2-P H 1| <Y H If P 1, then solenoid valve 2 is faulty and cannot be opened; otherwise, solenoid valve 2 is not faulty and can be opened normally. L 2>P L 1 and |P L 2-P L 1|<Y L 1a, or P L 2≥Y L If 1b is found, it is determined that there is a fault in the mechanical pressure regulator 6, and the corresponding second fault information is output.

[0050] like Figure 3 As shown, when the pressure regulator is an electronically controlled pressure regulator 4, the control module starts the electronically controlled pressure regulator 4 and reads the pressure value P corresponding to the high-pressure sensor 3 at this time. H 3, and the pressure value P corresponding to the low-pressure sensor 5. L 3;

[0051] When P H 3 < P H 1 and |P H 3-P H 1| <Y H If P 2 is present, then solenoid valve 2 is faulty and cannot be opened; otherwise, solenoid valve 2 is not faulty and can be opened normally. L 3>P L 1 and |P L 3-P L 1|<Y L 2a, or P L 3≥Y L If 2b is detected, it is determined that the electronically controlled voltage regulator 6 is faulty, and the corresponding second fault information is output. In this embodiment, Y H 1, Y H 2 represents the first high-pressure threshold and the second high-pressure threshold corresponding to the high-pressure sensor 3, respectively. L 1a, Y L1b represents the first low-pressure threshold and the second low-pressure threshold corresponding to the low-pressure sensor 5, Y L 2a, Y L 2b represents the third and fourth low-pressure thresholds corresponding to the low-pressure sensor 5.

[0052] It also includes a maintenance module, which is used to formulate corresponding fault maintenance plans based on the output of the first fault information or the second fault information.

[0053] First, the control module is powered on. Then, the control module reads the pressure values ​​corresponding to the high-pressure sensor 3 and the low-pressure sensor 5. The diagnostic module checks the solenoid valve 2, the pressure regulator, and the pressure sensors for open circuits, short circuits to power, and short circuits to ground. At the same time, the read pressure values ​​are used to determine whether the pressure values ​​of the two sensors are within a reasonable range. If they are too high or too low, it indicates that the pressure sensors are faulty. If any of the above devices are faulty, the diagnostic module will output the first fault information. If there are no problems, the first safety information will be output.

[0054] After outputting the first safety information, the control module opens the solenoid valve 2, reads the pressure values ​​corresponding to the high-pressure sensor 3 and the low-pressure sensor 5, and then executes the corresponding fault diagnosis strategy. In this embodiment, when the corresponding pressure regulator is an electronically controlled pressure regulator 4, the circuit fault of the pressure regulator is first diagnosed to determine whether there is a hardware fault in the corresponding electronically controlled pressure regulator 4. If there is, the third fault information is output; if not, the electronically controlled pressure regulator 4 is driven, and then the subsequent reading and judgment of pressure values ​​continue, thereby achieving an accurate and comprehensive diagnosis of the fault of the electronically controlled pressure regulator 4.

[0055] This embodiment also discloses a diagnostic control method for a gas fuel pressure regulator, using the aforementioned gas fuel pressure regulator diagnostic system.

[0056] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, based on the guidance provided in this application, improve and implement this solution in combination with their own capabilities. Some typical well-known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A diagnostic system for gas fuel pressure regulators, characterized in that: Includes control module, diagnostic module, solenoid valve, high pressure sensor, low pressure sensor, pressure regulator, and maintenance module; The solenoid valve, high-pressure sensor, pressure regulator, and low-pressure sensor are connected sequentially via pipelines; the control module is electrically connected to the diagnostic module, solenoid valve, high-pressure sensor, low-pressure sensor, and pressure regulator, respectively. The high-pressure sensor is used to measure the pressure value corresponding to the high-pressure gas in the pipeline between the solenoid valve and the pressure regulator. The low-pressure sensor is used to measure the pressure value of the low-pressure gas at the outlet of the regulator after passing through the regulator; and the high-pressure sensor and the low-pressure sensor are integrated with temperature sensors to achieve dual detection of the temperature and pressure of the gas in the pipeline. The high-pressure gas in the pipeline includes one of natural gas, hydrogen and ammonia, or a mixture of at least two of the above gases in any proportion. The diagnostic module is used to perform hardware fault detection on the solenoid valve, high pressure sensor, low pressure sensor and regulator when the solenoid valve is in the closed state. The hardware fault detection range includes open circuit fault, short to ground fault and short to power fault. It determines whether the corresponding equipment has a fault. If so, it outputs the first fault information. If not, it outputs the first safety information. The control module is used to activate the solenoid valve when the corresponding first safety information is output. At this time, the solenoid valve is in the open state, and based on a preset fault diagnosis strategy, it collects the pressure value corresponding to the high-pressure sensor and the pressure value corresponding to the low-pressure sensor to perform fault detection on the pressure regulator. The preset fault diagnosis strategy is as follows: Determine whether the voltage regulator is a mechanical or electronically controlled voltage regulator; When the pressure regulator is a mechanical regulator, read the pressure value corresponding to the high-pressure sensor at this time. and the pressure value corresponding to the low-pressure pressure sensor. ; when and , This is the pressure value corresponding to the high-pressure sensor when the solenoid valve is in the closed state. If the pressure is below the first high-pressure threshold corresponding to the high-pressure sensor, the solenoid valve is determined to be faulty and cannot be opened; otherwise, the solenoid valve is determined to be fault-free and can be opened normally. and ,or , This is the pressure value corresponding to the low-pressure sensor when the solenoid valve is in the closed state. , If the first low-pressure threshold and the second low-pressure threshold are the values ​​corresponding to the low-pressure sensor, then it is determined that there is a fault in the mechanical pressure regulator, and the corresponding second fault information is output. When the pressure regulator is an electronically controlled pressure regulator, the control module starts the electronically controlled pressure regulator and reads the pressure value corresponding to the high-pressure sensor at this time. and the pressure value corresponding to the low-pressure pressure sensor. ; when and , If the pressure is below the second high-pressure threshold corresponding to the high-pressure sensor, the solenoid valve is determined to be faulty and cannot be opened; otherwise, the solenoid valve is determined to be fault-free and can be opened normally. and ,or , , If the third and fourth low-pressure thresholds are the values ​​corresponding to the low-pressure sensor, then it is determined that the electronically controlled voltage regulator is faulty, and the corresponding second fault information is output. The maintenance module is used to formulate corresponding fault maintenance plans based on the output of the first fault information or the second fault information.

2. The gas fuel pressure regulator diagnostic system according to claim 1, characterized in that: The diagnostic module is also used to acquire the pressure value corresponding to the high-pressure sensor when the solenoid valve is in the closed state. And the pressure value corresponding to the low-pressure sensor at this time. and judge and If the sensor is within a preset reasonable range, then the corresponding sensor is not faulty; otherwise, the corresponding sensor is faulty.

3. A diagnostic and control method for gas fuel pressure regulators, characterized in that: The gas fuel pressure regulator diagnostic system according to any one of claims 1 to 2.

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