Hydrogen sensor for hydrogen internal combustion engine and assembly process of hydrogen sensor

Abstract

The invention relates to the field of hydrogen internal combustion engine detection devices, in particular to a hydrogen sensor for a hydrogen internal combustion engine and an assembly process thereof.The hydrogen sensor comprises a main control module and a detection probe, the detection probe is used for being installed on a crankshaft pipeline of the hydrogen internal combustion engine and used for detecting hydrogen and outputting a detection signal, and the detection probe is connected with the main control module; the main control module is connected with an automobile ECU and controls the automobile ECU to give an alarm when the hydrogen concentration exceeds the safety range. It is guaranteed that the hydrogen concentration in the crankcase is within the safety range, and the probability of accidents such as explosion and fire caused by hydrogen leakage is reduced.

Description

Technical Field

[0001] This application relates to the field of hydrogen internal combustion engine detection devices, and particularly to a hydrogen gas sensor for a hydrogen internal combustion engine and its assembly process. Background Art

[0002] In recent years, with the popularization of environmental protection concepts and the increasingly prominent impact of climate change, hydrogen energy, as an efficient and clean new energy, has attracted much attention. In China, the development process of hydrogen energy has gradually shown a trend of rapid development. Hydrogen energy, as a secondary energy source with rich sources, green and low-carbon, and wide applications, is of great significance for building a clean, low-carbon, safe and efficient energy system. In the field of hydrogen energy applications, in addition to hydrogen fuel cell technology, hydrogen internal combustion engines are also an important application direction. Hydrogen internal combustion engines have significant advantages such as zero carbon emissions, high efficiency, high reliability, and low cost. Compared with hydrogen fuel cell technology, hydrogen internal combustion engines not only have a relatively strong manufacturing foundation, but also have lower requirements for the purity of hydrogen fuel. Many automobile enterprises at home and abroad, especially in the commercial vehicle field, are accelerating the research and development of hydrogen fuel internal combustion engines.

[0003] A hydrogen internal combustion engine directly burns hydrogen as the fuel of the engine. Compared with other fuels such as gasoline, propane, and natural gas, hydrogen is more likely to leak, and at the same time has greater buoyancy (rapid upward movement) and greater diffusivity (lateral movement). Therefore, piston ring blow-by is very likely to occur during the operation of the engine, resulting in the accumulation of hydrogen in the engine crankcase. If a large amount of hydrogen accumulates in the crankcase, the excessive hydrogen concentration will not only affect the performance and efficiency of the internal combustion engine, but once the volume fraction reaches 4.0%, it will reach the explosion limit of hydrogen, posing a serious threat to personal and property safety.

[0004] Therefore, existing hydrogen internal combustion engines lack measures to detect the hydrogen concentration in the crankcase in real time. If the hydrogen concentration in the crankcase exceeds the safe range, accidents such as hydrogen leakage leading to explosion and fire will occur. Summary of the Invention

[0005] In a first aspect, in order to ensure that the hydrogen concentration in the crankcase is within a safe range and reduce the probability of accidents such as hydrogen leakage leading to explosion and fire, this application provides a hydrogen gas sensor for a hydrogen internal combustion engine.

[0006] A hydrogen gas sensor for a hydrogen internal combustion engine provided by this application adopts the following technical solutions: A hydrogen gas sensor for a hydrogen internal combustion engine includes a main control module and a detection probe. The detection probe is used to be installed on the crankshaft pipeline of the hydrogen internal combustion engine for hydrogen detection and output a detection signal. The detection probe is connected to the main control module, and the main control module is connected to an automotive ECU. The main control module controls the automotive ECU to alarm when the hydrogen concentration exceeds the safe range.

[0007] By adopting the above technical solution, the detection probe can monitor the hydrogen concentration in real time, timely detect abnormal hydrogen concentration, and ensure that the hydrogen concentration does not exceed the safe range. When the concentration is too high, the main control module will control the vehicle ECU to send an alarm signal, thus reminding the driver or the system to take emergency measures to avoid safety accidents such as hydrogen leakage.

[0008] Preferably, it further includes a main control board. The detection probe is connected to the main control module through a cable. The main control module is arranged on the main control board. An analog-to-digital conversion interface and a signal output circuit are also arranged on the main control board. The main control module is connected to the detection probe through the analog-to-digital conversion interface, and the main control module is connected to the vehicle ECU through the signal output circuit.

[0009] By adopting the above technical solution, the detection probe is connected to the main control module through a cable, and the signal output circuit ensures stable signal transmission between the main control module and the vehicle ECU. And through the analog-to-digital conversion interface, the analog signal (from the hydrogen detection probe) can be converted into a digital signal, which is convenient for the main control module to process. This conversion ensures that the system can accurately and efficiently obtain hydrogen concentration data and perform subsequent analysis and processing, improving the accuracy and response speed of the system.

[0010] Preferably, the detection probe includes a housing, a fairing, and a hydrogen-sensitive unit. The hydrogen-sensitive unit is arranged inside the fairing, and a plurality of detection holes are opened at one end of the fairing close to the hydrogen-sensitive unit. The fairing sleeve is installed inside the housing, and the hydrogen-sensitive unit is connected to the main control module through a cable.

[0011] By adopting the above technical solution, a plurality of detection holes are arranged inside the fairing, which helps the inflow of air and hydrogen, ensuring that hydrogen can smoothly enter the hydrogen-sensitive unit, thus improving the detection efficiency of hydrogen. The housing provides physical protection for the entire detection probe, buffering the impact of gas on the hydrogen-sensitive unit in the working environment of the crankshaft.

[0012] Preferably, it further includes a signal amplification circuit. The analog-to-digital conversion interface is communicatively connected to the hydrogen-sensitive unit of the detection probe through the signal amplification circuit.

[0013] By adopting the above technical solution, the signal amplification circuit can amplify the detection signal, avoiding signal attenuation and loss when the detection signal is transmitted to the main control circuit board; the signal amplification circuit can speed up the signal processing speed and ensure that small changes in hydrogen concentration can be quickly captured by the system. The enhanced signal can enter the analog-to-digital conversion interface more quickly, reducing the processing delay, enabling the system to respond more quickly to changes in hydrogen concentration in the environment, and improving the real-time monitoring ability of the probe.

[0014] Preferably, an installation base is sleeved outside the rectifying sleeve, an installation thread is arranged outside the installation base, an assembly thread is arranged on the inner wall at one end of the housing, and the installation thread is matched with the assembly thread.

[0015] By adopting the above technical solution, the cooperation of the installation thread and the assembly thread provides a firm and stable connection method. Through the threaded connection, the firm assembly between the rectifying sleeve and the housing can be ensured, avoiding the loosening or displacement of the components caused by vibration or external forces, thereby enhancing the stability and reliability of the device.

[0016] Preferably, a sealing and damping rubber is filled in the rectifying cover, and the sealing and damping rubber is used to improve the sealing performance of the detection probe and reduce vibration.

[0017] By adopting the above technical solution, the sealing and damping rubber can effectively fill the gaps between the rectifying cover and other components, preventing external moisture, dust, gas or pollutants from entering the device. This can improve the protection performance of the detection probe, protect sensitive internal components from the external environment, ensure the long-term stable operation of the probe, and the sealing and damping rubber can absorb and reduce external vibration or mechanical shock, reducing the impact of vibration on the precision components inside the probe.

[0018] Preferably, it further includes a rigid connecting wire and a signal amplification circuit PCB board. An installation cover plate is arranged at one end of the housing away from the installation base. The signal amplification circuit is arranged on the signal amplification circuit PCB board. A flexible wire is arranged on the signal amplification circuit PCB board. The flexible wire passes through the installation cover plate and is connected to a cable. One end of the rigid connecting wire passes through the sealing and damping rubber and is connected to the hydrogen-sensitive unit, and the other end of the rigid connecting wire is connected to the signal amplification circuit PCB board outside the rectifying cover to realize the electrical connection between the hydrogen-sensitive unit and the signal amplification circuit.

[0019] By adopting the above technical solution, the rigid connecting wire is used to connect the hydrogen-sensitive unit and the signal amplification circuit PCB board, ensuring a stable and firm electrical connection between the hydrogen-sensitive unit and the circuit, preventing poor contact caused by vibration or external force interference; after the rigid wire passes through the sealing and damping rubber, it not only provides protection but also has a damping effect, reducing the impact of external vibration on the hydrogen-sensitive unit and the circuit board; the design of the signal amplification circuit PCB board integrates the signal amplification function on the circuit board, which not only saves space but also facilitates the maintenance and management of the circuit board.

[0020] Preferably, a communication interface is further installed on the main control board. The main control module is connected to the communication interface through a signal output circuit, and the communication interface is connected to the vehicle ECU.

[0021] By adopting the above technical solution, the main control module is connected to the communication interface through the signal output circuit, enabling the main control board to communicate effectively with the vehicle ECU (Electronic Control Unit). This connection method can ensure the real-time transmission of data between the system and the vehicle control system, and the standardized design of the communication interface helps the main control board to be compatible and docked with vehicle ECUs of different brands and models.

[0022] Preferably, the hydrogen sensor unit adopts a palladium alloy metal thin film type or a catalytic combustion type.

[0023] By adopting the above technical solution, the palladium alloy metal thin film type hydrogen sensor unit has a high hydrogen adsorption capacity and can quickly respond to changes in hydrogen, thus achieving high-sensitivity detection of hydrogen concentration; the catalytic combustion type hydrogen sensor unit relies on the action of the catalyst, enabling hydrogen to react with oxygen at a certain temperature to generate heat and an electrical signal.

[0024] In a second aspect, in order to ensure that the hydrogen concentration in the crankcase is within a safe range and reduce the probability of accidents such as explosion and fire caused by hydrogen leakage, the present application provides an assembly process.

[0025] An assembly process includes: Pass the rigid connecting wire connected with the hydrogen sensor unit through the sealing and damping rubber to form a first component; Pass the first component through the fairing, and use a press to shrink and compress the fairing near the hydrogen sensor unit end to form a second component; Install the second component into the mounting base, and its mounting thread is consistent with the assembly thread of the fairing. At the same time, use a press to press the other end of the mounting base to press the fairing and the mounting base together; Pass the flexible wire on the signal amplification circuit PCB through the mounting cover plate and connect it to the cable, and weld the signal amplification circuit PCB to the rigid connecting wire; Rotate and install the circular cover plate on the housing; Connect the cable to the main control board.

[0026] By adopting the above technical solution, passing the rigid connecting wire connected with the hydrogen-sensitive unit through the sealed shock-absorbing rubber can effectively reduce the influence of vibration and external impact on the hydrogen-sensitive unit. Moreover, the hydrogen-sensitive unit is isolated from other components by the shock-absorbing rubber, which also reduces the interference of the external environment on the hydrogen-sensitive unit. The shrinkage and compression of the fairing can ensure the seal between the hydrogen-sensitive unit end and the fairing, preventing air or external pollutants from affecting the accuracy of hydrogen detection. The step of rotatably installing the circular cover plate on the housing can effectively enclose the internal circuit and components, preventing the intrusion of external factors (such as dust, moisture, etc.) into the circuit board. Through such an assembly process, effective protection of the hydrogen-sensitive unit can be achieved, the sealing and protection performance can be enhanced, the stability of electrical connection can be improved, and the installation process of the entire device can be made more simple and efficient.

[0027] In summary, the present application includes at least one of the following beneficial technical effects: 1. The detection probe monitors the hydrogen concentration in real time, can timely detect abnormal hydrogen concentration, and ensure that the hydrogen concentration does not exceed the safe range. When the concentration is too high, the main control module will control the vehicle ECU to send an alarm signal, thereby reminding the driver or the system to take emergency measures to avoid safety accidents such as hydrogen leakage. 2. The detection probe is connected to the main control module through a cable, and the signal output circuit ensures the stable transmission of signals between the main control module and the vehicle ECU. And through the analog-to-digital conversion interface, the analog signal (from the hydrogen detection probe) can be converted into a digital signal, which is convenient for the main control module to process. This conversion ensures that the system can accurately and efficiently obtain hydrogen concentration data and perform subsequent analysis and processing, improving the accuracy and response speed of the system. 3. Multiple detection holes are provided in the fairing, which helps the inflow of air and hydrogen, ensuring that hydrogen can smoothly enter the hydrogen-sensitive unit, thereby improving the detection efficiency of hydrogen. The housing provides physical protection for the entire detection probe, buffering the impact of gas in the crankshaft working environment on the hydrogen-sensitive unit. Brief Description of the Drawings

[0028] Figure 1 is the overall structural schematic diagram of the hydrogen sensor for hydrogen internal combustion engines according to the embodiment of the present application.

[0029] Figure 2 is the structural block diagram of the hydrogen sensor for hydrogen internal combustion engines according to the embodiment of the present application.

[0030] Figure 3 is the cross-sectional schematic diagram of the detection probe according to the embodiment of the present application.

[0031] Explanation of the reference numerals: 1. Main control board; 11. Communication interface; 12. Cable; 2. Detection probe; 21. Housing; 22. Fairing; 23. Hydrogen sensitive unit; 24. Mounting base; 25. Sealing shock-absorbing rubber; 26. Rigid connecting wire; 27. Signal amplification circuit PCB board; 28. Flexible wire; 29. ​​Mounting cover. DETAILED DESCRIPTION

[0032] The present application is further described in detail below in conjunction with all the accompanying drawings.

[0033] The present application embodiment discloses a hydrogen sensor for a hydrogen internal combustion engine. Figure 1 , Figure 2 A hydrogen sensor for a hydrogen internal combustion engine includes a main control board 1 and a detection probe 2. The main control board 1 is equipped with a main control module, which is installed at a position far away from the internal combustion engine, and the detection probe 2 is installed on the crankshaft pipe of the internal combustion engine. The main control module and the detection probe 2 are connected by a cable 12. The length of the cable 12 can be customized according to the distance of the actual installation position to ensure the best signal transmission effect and reliability. The main control module is connected to the automobile ECU. When the hydrogen concentration exceeds the safety range, the main control module controls the automobile ECU to display an alarm sign and sound an alarm. The safety range is input in advance by the designer.

[0034] Specifically, a control box is provided on the main control board 1, and the size of the control box is 60*40*15mm. The main control module is arranged in the control box, and the main control module includes an MCU control module. Commonly used MCUs include STM32 series and AVR series. The MCU control module is responsible for sensor temperature control and detection signal processing. An analog-to-digital conversion interface and a signal output circuit are also provided in the control box. The analog-to-digital conversion interface is used for communication connection and converts analog signals into digital signals for MCU to process and analyze. Common analog-to-digital converters include ADC0809 and ADS1115, etc. The main control module is connected to the detection probe 2 through the analog-to-digital conversion interface. The control box is also equipped with a communication interface 11. The main control module is connected to the communication interface 11 through the signal output circuit. The communication interface 11 is connected to the automobile ECU. The signal output circuit can send the processed data to the automobile ECU to realize real-time monitoring and feedback of the data. The signal output circuit can adopt CAN bus or LIN bus communication protocol to meet the needs of different models. The communication interface 11 can adopt a conventional interface.

[0035] Reference Figure 1 , Figure 3, Additionally, the detection probe 2 includes a hydrogen-sensing unit 23, a sealing and damping rubber 25, a signal amplification circuit, a fairing 22, and a housing 21. The hydrogen-sensing unit 23 is used to detect the hydrogen concentration and can be of two types: palladium alloy metal film type or catalytic combustion type. The palladium alloy metal film type hydrogen-sensing unit 23 can use a MEMS model palladium alloy hydrogen-sensing unit 23, which reflects the presence of hydrogen through the change in resistance and has high sensitivity and stability; the catalytic combustion type hydrogen-sensing unit 23 indirectly measures the hydrogen concentration by measuring the heat generated by the reaction of hydrogen and oxygen and is suitable for monitoring in high-temperature environments. Both types of hydrogen-sensing units 23 can be equipped with a heating unit to improve the detection accuracy and response speed.

[0036] The hydrogen-sensing unit 23 is arranged inside the fairing 22, and multiple detection holes are opened at one end of the fairing 22 close to the hydrogen-sensing unit 23. The fairing sleeve is installed inside the housing 21. The diameter of the hydrogen-sensing unit 23 is 8 mm, and it is connected with a rigid connecting wire 26. There are 7 rigid connecting wires with a diameter of 0.5 mm and a length of 50 mm, which are circularly distributed. Among them, there is a group of heating wires, a group of temperature detection wires, and a group of hydrogen detection signal wires. The analog-to-digital conversion interface is communicatively connected to the hydrogen-sensing unit 23 of the detection probe 2 through the signal amplification circuit. A signal amplification circuit PCB board 27 is also arranged inside the housing 21. An installation cover plate 29 is arranged at one end of the housing 21 away from the installation base 24. The signal amplification circuit is arranged on the signal amplification circuit PCB board 27. The diameter of the signal amplification circuit board is 10 mm, and it is externally connected with a 6-core flexible wire 28, a group of power supply wires, and two groups of signal wires. The flexible wire 28 passes through the installation cover plate 29 and is connected to the cable 12 to realize the connection between the signal amplification circuit and the cable 12. One end of the rigid connecting wire 26 passes through the sealing and damping rubber 25 and is connected to the hydrogen-sensing unit 23, and the other end of the rigid connecting wire 26 is connected to the signal amplification circuit PCB board 27 outside the fairing 22 to realize the electrical connection between the hydrogen-sensing unit 23 and the signal amplification circuit.

[0037] The fairing 22 is filled with the sealing and damping rubber 25. The sealing and damping rubber 25 is cylindrical. The inner diameter of the fairing 22 is 8 mm, the inner diameter of the opening part is 10 mm, the wall thickness is 0.35 mm, and the length is 40 mm. The diameter of the sealing and damping rubber 25 is 8 mm, the length is 30 mm, and the pore diameter is 0.5 mm. The sealing and damping rubber 25 is used to improve the sealing performance of the detection probe 2 and damp vibration.

[0038] An installation base 24 is sleeved outside the fairing sleeve. The middle part of the installation base 24 is a hexagonal nut, and an installation thread is arranged outside the installation base 24. The hexagonal nut can move on the installation base 24. The inner diameter of the installation base 24 is 9 mm, and the length is 30 mm. An assembly thread is arranged on the inner wall of one end of the housing 21, and the installation thread and the assembly thread cooperate with each other.

[0039] The implementation principle of the hydrogen sensor for hydrogen internal combustion engines in the embodiments of this application is as follows: By installing the detection probe 2 on the crankshaft pipeline of the internal combustion engine, the hydrogen concentration in the crankcase can be monitored in real time. The main control circuit is installed away from the internal combustion engine, reducing the impact of vibration and high temperature on the circuit stability. The design of the sealed shock-absorbing rubber 25 and the signal amplification circuit improves the reliability and accuracy of the detection probe 2, and the encapsulation housing provides the necessary physical protection and support. The overall system has a reasonable structural design and perfect functions, can work stably under harsh working conditions, and effectively guarantees the safe operation of the hydrogen internal combustion engine.

[0040] The embodiments of this application disclose an assembly process.

[0041] An assembly process includes: passing the rigid connecting wire connected to the hydrogen-sensitive unit 23 through the sealed shock-absorbing rubber 25, and making its pins extend 10 mm, finally forming the first component; Passing the first component through the fairing 22, and using a press to shrink and compress the end of the fairing 22 close to the hydrogen-sensitive unit 23, with a necking length of 8 mm and a depth of 1 mm, forming the second component; Installing the second component into the mounting base 24, and making its mounting thread consistent with the assembly thread of the fairing 22. At the same time, using a press to press the other end of the mounting base 24 to press the fairing 22 and the mounting base 24 together; Passing the flexible wire 28 on the signal amplification circuit PCB board 27 through the mounting cover plate 29 to connect with the cable 12, and soldering the signal amplification circuit PCB board 27 to the rigid connecting wire; Rotating and installing the circular cover plate at one end of the housing 21 and fastening it; Connecting the cable 12 to the control box of the main control board 1.

[0042] The above are all the preferred embodiments of this application. Without restricting the protection scope of this application accordingly, therefore: All equivalent changes made according to the structure, shape, and principle of this application shall be covered within the protection scope of this application.

Claims

1. A hydrogen sensor for a hydrogen internal combustion engine, characterized in that: The invention comprises a main control module and a detection probe (2), wherein the detection probe (2) is used to be installed on a crankshaft pipe of a hydrogen internal combustion engine and is used to detect hydrogen and output a detection signal, wherein the detection probe (2) is connected to the main control module, and the main control module is connected to an automobile ECU, and the main control module controls the automobile ECU to alarm when the hydrogen concentration exceeds a safe range.

2. A hydrogen sensor for a hydrogen internal combustion engine according to claim 1, characterized in that: The invention also comprises a main control board (1), wherein the detection probe (2) is connected to the main control module via a cable (12), the main control module is arranged on the main control board (1), and an analog-to-digital conversion interface and a signal output circuit are also arranged on the main control board (1), the main control module is connected to the detection probe (2) via the analog-to-digital conversion interface, and the main control module is connected to the automobile ECU via the signal output circuit.

3. A hydrogen sensor for a hydrogen internal combustion engine according to claim 2, characterized in that: The detection probe (2) comprises a housing (21), a fairing (22) and a hydrogen-sensitive unit (23); the hydrogen-sensitive unit (23) is arranged in the fairing (22); the fairing sleeve is detachably mounted in the housing (21); and the hydrogen-sensitive unit (23) is connected to a main control module via a cable (12).

4. A hydrogen sensor for a hydrogen internal combustion engine according to claim 3, characterized in that: It also includes a signal amplification circuit, and the analog-to-digital conversion interface is communicatively connected to the hydrogen sensitive unit (23) of the detection probe (2) via the signal amplification circuit.

5. A hydrogen sensor for a hydrogen internal combustion engine according to claim 3, characterized in that: The fairing sleeve outer shell is provided with a mounting base (24), the mounting base (24) is provided with a mounting thread on the outside, and an assembly thread is provided on the inner wall of one end of the outer shell (21), and the mounting thread cooperates with the assembly thread.

6. A hydrogen sensor for a hydrogen internal combustion engine according to claim 4, characterized in that: The fairing (22) is filled with sealing and shock-absorbing rubber (25), and the sealing and shock-absorbing rubber (25) is used to improve the sealing performance of the detection probe (2) and reduce vibration.

7. A hydrogen sensor for a hydrogen internal combustion engine according to claim 6, characterized in that: It also comprises a rigid connecting wire (26) and a signal amplifying circuit PCB board (27); an installation cover (29) is provided at one end of the housing (21) away from the installation base (24); the signal amplifying circuit is provided on the signal amplifying circuit PCB board (27); a flexible wire (28) is provided on the signal amplifying circuit PCB board (27); the flexible wire (28) passes through the installation cover board (29) and is connected to the cable (12); one end of the rigid connecting wire (26) passes through the sealing shock-absorbing rubber (25) and is connected to the hydrogen sensitive unit (23); the other end of the rigid connecting wire (26) is connected to the signal amplifying circuit PCB board (27) outside the fairing (22) to achieve electrical connection between the hydrogen sensitive unit (23) and the signal amplifying circuit.

8. A hydrogen sensor for a hydrogen internal combustion engine according to claim 2, characterized in that: The main control board (1) is also equipped with a communication interface (11); the main control module is connected to the communication interface (11) via a signal output circuit; and the communication interface (11) is connected to an automobile ECU.

9. A hydrogen sensor for a hydrogen internal combustion engine according to claim 3, characterized in that: The hydrogen sensitive unit (23) is of a palladium alloy metal film type or a catalytic combustion type.

10. An assembly process for assembling the hydrogen sensor for a hydrogen internal combustion engine according to any one of claims 1 to 9, characterized in that: include: Passing a rigid connecting line connected to a hydrogen-sensitive unit (23) through a sealing and shock-absorbing rubber (25) to form a first assembly; Passing the first component through the fairing (22), and shrinking and pressing the fairing (22) near the end of the hydrogen sensitive unit (23) using a press to form a second component; The second component is installed into the mounting base (24), and its mounting thread is consistent with the assembly thread of the fairing (22), and at the same time, the other end of the mounting base (24) is pressed together by a press to press the fairing (22) and the mounting base (24) together; Passing the flexible wire (28) on the signal amplifying circuit PCB board (27) through the mounting cover plate (29) to connect with the cable (12), and soldering the signal amplifying circuit PCB board (27) to the rigid connecting wire; Rotate and install the circular cover plate onto the housing (21); Connect the cable (12) to the main control board (1).

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