Fault diagnosis and processing method and system for fuel cell system

Abstract

The invention discloses a fault diagnosis and processing method and system for a fuel cell system, and the method comprises the steps: obtaining the output current of a to-be-detected fuel cell system, the state data of a fuel cell controller, the fault diagnosis data of each sub-controller, the operation data of a sensor, and the operation parameter data of a fuel cell in real time; obtaining a fault type and a fault level of the to-be-tested fuel cell system according to a pre-constructed fault database; when it is determined that the to-be-detected fuel cell system does not have the fuel cell operation fault, an operation deviation index is obtained based on the operation parameter data, and whether fuel cell operation early warning is carried out on the to-be-detected fuel cell system or not is judged according to an operation deviation index threshold value corresponding to the output current; and executing a preset fault processing operation on the to-be-tested fuel cell system according to the judgment result of the fuel cell operation early warning, the fault level and the fault type so as to improve the accuracy of fault diagnosis and processing.

Description

Technical Field

[0001] The present invention relates to the technical field of fuel cells, and in particular, to a method and system for fault diagnosis and processing of a fuel cell system. Background Art

[0002] A fuel cell is a system that directly converts chemical energy into electrical energy through a chemical reaction, and has the characteristics of high efficiency, cleanliness, and environmental friendliness. It is widely used in new energy vehicles, backup power supplies, portable devices and other fields. With the progress of fuel cell technology and the expansion of the application scope, ensuring its safe, reliable and efficient operation is particularly important. However, during the operation of a fuel cell system, faults may occur due to various reasons, such as material aging, improper operating conditions, environmental impacts, etc. Among them, faults caused by different reasons will not only affect the performance of the system, but may also pose safety hazards. Therefore, real-time and effective fault diagnosis and corresponding fault handling are of great significance for the stable operation of the fuel cell system.

[0003] In the process of fault diagnosis and processing of fuel cells in the prior art, most of them diagnose and analyze a specific fault, and do not diagnose and process different types of faults of the entire fuel cell system according to the level of the fuel cell system, thus being unable to comprehensively diagnose and process the faults of the fuel cell system, and then reducing the accuracy of fault diagnosis and fault handling of the fuel cell system.

[0004] At the same time, when the prior art conducts fault handling, all faults of the fuel cell system are generally summarized as BOP faults, that is, control faults or operating parameter faults, without a clear and detailed definition of fault classification, and without classifying and corresponding processing according to the impact of different faults on the overall operation of the system, thus making the effect of fault handling unable to adapt to the overall operation of the fuel cell system. Summary of the Invention

[0005] In order to solve the above technical problems, the present invention discloses a method and system for fault diagnosis and processing of a fuel cell system, which is used to improve the accuracy of fault diagnosis and processing.

[0006] In order to achieve the above object, the present invention discloses a method for fault diagnosis and processing of a fuel cell system, characterized by including:

[0007] Real-time obtain the output current of the fuel cell system to be measured, the status data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of each sub-controller, the operation data of the sensor, and the operation parameter data of the fuel cell;

[0008] Obtain the fault type and fault level of the fuel cell system to be tested based on the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data, and a pre-constructed fault database;

[0009] When it is determined that there is no fuel cell operation fault in the fuel cell system to be tested, obtain an operation deviation index based on the operation parameter data, and determine whether to perform a fuel cell operation warning on the fuel cell system to be tested according to the operation deviation index and the operation deviation index threshold corresponding to the output current;

[0010] Execute a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level, and the fault type.

[0011] A fault diagnosis and handling method for a fuel cell system disclosed by the present invention first obtains in real time the status data of a fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of sensors, and the operation parameter data of the fuel cell, and obtains different types of data according to the functional areas of the fuel cell system to comprehensively diagnose various faults in the fuel cell system and improve the accuracy of fault diagnosis. Secondly, when performing specific fault diagnosis, a pre-constructed fault database is used to identify the fault type and fault level of the currently real-time collected data in a refined manner, so as to improve the accuracy of fault handling by improving the refinement of fault diagnosis. Among them, when it is determined through fault diagnosis that there is no fuel cell operation fault in the fuel cell system to be tested, a determination of fuel cell operation warning is performed on the fuel cell system to be tested to avoid potential risks and thus improve the effect of fault handling. Finally, a preset fault handling operation is performed on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level, and the fault type, improving the accuracy of fault handling.

[0012] As a preferred example, the real-time obtaining of the output current of the fuel cell system to be tested and the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of sensors, and the operation parameter data of the fuel cell includes:

[0013] Obtain the current status of the fuel cell controller in real time; wherein, the current status includes standby, cold start, start, operation, and shutdown;

[0014] Time the current status to obtain the response duration of the fuel cell controller staying in the current status;

[0015] Take the current status and the response duration as the status data of the fuel cell controller.

[0016] In the above solution, based on the fuel cell controller being in different states at different time periods according to the internally predefined state phases, the normal operation of the fuel cell system is ensured. If the fuel cell controller stalls in a certain state and cannot jump out normally, a fault will occur. To this end, in order to accurately identify whether the fuel cell controller has a fault, the current state of the fuel cell controller and the response duration staying in the current state can be obtained, so as to accurately identify whether the fuel cell controller can perform state jump normally according to the current state and the response duration in the subsequent process.

[0017] As a preferred example, the real-time acquisition of the output current of the fuel cell system to be measured, the state data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of each sub-controller, the operation data of the sensor, and the operation parameter data of the fuel cell includes:

[0018] Determine a number of accessory devices with controllers in the fuel cell system to be measured, and use the controller corresponding to each accessory device as the sub-controller of the fuel cell system to be measured;

[0019] Real-time acquisition of the fault information obtained by each sub-controller after fault diagnosis of its corresponding accessory device and the heartbeat signal of the sub-controller itself;

[0020] Use the fault information and the heartbeat signal as the fault diagnosis data of each sub-controller.

[0021] In the above preferred solution, a controller is set in the accessory device based on the fuel cell system to perform fault diagnosis of the accessory device through the controller. To this end, the fault diagnosis of the accessory device can be performed by acquiring the fault diagnosis information uploaded by each controller, thereby improving the refinement of fault diagnosis. Among them, when performing fault diagnosis on the accessory device, in order to realize the fault diagnosis of the controller itself, the heartbeat signal of the controller can be acquired to perform fault diagnosis on the controller itself, so as to improve the comprehensiveness of fault diagnosis.

[0022] As a preferred example, the real-time acquisition of the output current of the fuel cell system to be measured, the state data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of each sub-controller, the operation data of the sensor, and the operation parameter data of the fuel cell includes:

[0023] Real-time acquisition of the measurement value of each sensor, and use the measurement value as the operation data of the sensor;

[0024] Obtain the electrical operation data, anode-side operation data, cathode-side operation data, and cooling circuit operation data of the fuel cell in real time; wherein, the electrical operation data includes the output current, output voltage, and insulation detection value of the fuel cell; the anode-side operation data includes the pre-stage hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack, and the pressure difference between the inlet and outlet of the stack; the cathode-side operation data includes the air flow rate of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack, and the air temperature leaving the stack; the cooling circuit operation data includes the water temperature entering the stack when the stack dissipates heat, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack, and the air-water pressure difference of the stack.

[0025] In the above preferred solution, obtaining the measured values of the sensors can quickly and accurately diagnose the faults of the sensors. When obtaining the operation data of the fuel cell, based on the operation process of the fuel cell, obtain the operation data on different sides of the fuel cell in an all-round way, so as to improve the accuracy of fuel cell fault diagnosis through the refinement of the obtained operation data.

[0026] As a preferred example, obtaining the fault type and fault level of the fuel cell system to be tested according to the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data, and the pre-constructed fault database includes:

[0027] Obtain multiple fault types from the fault database; wherein, the multiple fault types include state transition faults, equipment faults, sensor faults, and fuel cell operation faults;

[0028] Obtain multiple fault thresholds corresponding to each fault type from the fault database; wherein, the fault thresholds include the state transition fault threshold corresponding to the state transition fault, the equipment fault threshold corresponding to the equipment fault, the sensor fault threshold corresponding to the sensor fault, and the operation fault threshold corresponding to the fuel cell operation fault;

[0029] Obtain the fault level corresponding to each of the fault thresholds from the fault database;

[0030] Obtain the fault current corresponding to each of the operation fault thresholds from the fault database.

[0031] In the above preferred solution, all possible fault types in the fuel cell system are stored in detail in the fault database, including equipment faults, sensor faults, and operating parameter faults, etc., so as to finely cover various faults that may occur during the operation of the fuel cell system through the fault types, providing a basis for accurate fault diagnosis and handling. Among them, the fault types are associated with the fault levels in the fault database, so that while quickly identifying the fault types, accurate fault handling operations can be determined according to the fault levels corresponding to the fault types, thereby improving the effect of fault handling.

[0032] As a preferred example, the obtaining of the fault type and fault level of the fuel cell system to be tested according to the output current, the state data, the fault diagnosis data, the operation data, the operation parameter data, and the pre-constructed fault database includes:

[0033] Obtaining a first comparison result between the state data and each state jump fault threshold;

[0034] Obtaining a second comparison result between the fault diagnosis data and each equipment fault threshold;

[0035] Obtaining a third comparison result between the operation data of the sensor and each sensor fault threshold;

[0036] Based on the matching result between the fault current and the output current of the fuel cell system to be tested, several first operation fault thresholds are selected from multiple operation fault thresholds;

[0037] Obtaining a fourth comparison result between the operation parameter data and each of the first operation fault thresholds;

[0038] According to the first comparison result, the second comparison result, the third comparison result, and the fourth comparison result, determining whether the fuel cell system to be tested has a state jump fault, an equipment fault, a sensor fault, or a fuel cell operation fault;

[0039] When it is determined that the fuel cell system to be tested has a state jump fault, an equipment fault, a sensor fault, or a fuel cell operation fault, the highest fault level is selected from the fault levels corresponding to the state jump fault threshold, the equipment fault threshold, the sensor fault threshold, and the first operation fault threshold that are currently being compared as the fault level of the fuel cell system to be tested.

[0040] In the above solution, based on the fault types stored in the fault database, the fault thresholds corresponding to each fault type, and the fault levels corresponding to each fault threshold, it is possible to accurately identify the fault type while obtaining the fault level of the current fault type, so as to adopt corresponding fault handling operations according to the fault level, thereby improving the effect of fault handling.

[0041] As a preferred example, obtaining the operation deviation index based on the operation parameter data, and determining whether to give a fuel cell operation warning to the fuel cell system to be tested according to the operation deviation index and the operation deviation index threshold corresponding to the output current, includes:

[0042] When it is determined according to the fourth comparison result that the fuel cell system to be tested does not have the fuel cell operation fault, obtain the sampling time of the operation parameter data, so as to obtain a number of historical operation parameter data based on a preset sampling step and the sampling time;

[0043] Obtain a number of the historical operation parameter data, the real-time mean value of the operation parameters, and the real-time variance of the operation parameters corresponding to the operation parameter data;

[0044] Obtain the standard real-time mean value of the operation parameters, the standard real-time variance of the operation parameters, and the operation deviation index threshold corresponding to the output current from a preset operation parameter mean value table, a preset operation parameter variance table, and a preset operation deviation index threshold table;

[0045] According to the real-time mean value of the operation parameters, the real-time variance of the operation parameters, the standard real-time mean value of the operation parameters, and the standard real-time variance of the operation parameters, obtain the operation deviation index;

[0046] Obtain the comparison result between the operation deviation index and the operation deviation index threshold, so as to determine whether to give a fuel cell operation warning to the fuel cell system to be tested according to the comparison result.

[0047] In the above solution, there is a close correlation between the operation parameters of the fuel cell system and its output current. Therefore, standard parameters corresponding to each output current are preset for early warning reference. Among them, sometimes the fuel cell system does not show an obvious fault state, but there are some abnormalities in its operation parameters, such as the feedback value not converging or there is a certain steady-state error between the reference value and the actual value. For this, in order to diagnose the faults of this part of the abnormalities, compare the parameters obtained in real time with the standard parameters to improve the comprehensiveness and accuracy of fault diagnosis.

[0048] As a preferred example, performing a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level, and the fault type, includes:

[0049] When it is determined to give a fuel cell operation warning to the fuel cell system to be tested, output the warning information corresponding to the operation parameter data;

[0050] Obtain the fault handling operations corresponding to the fault level from the fault database, and execute the fault handling operations on the fuel cell system to be tested; wherein, the fault handling operations include load reduction, shutdown or emergency stop.

[0051] In the above solution, obtain the fault handling operation with the highest fault level from the above fault classification, so as to execute the fault handling operation on the fuel cell system to be tested, thereby improving the safety of system operation.

[0052] On the other hand, the present invention discloses a fault diagnosis and processing system for a fuel cell system, including a data acquisition module, a fault diagnosis module, an operation warning module and a fault processing module;

[0053] The data acquisition module is used to acquire the output current of the fuel cell system to be tested in real time and the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell;

[0054] The fault diagnosis module is used to obtain the fault type and fault level of the fuel cell system to be tested according to the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data and a pre-constructed fault database;

[0055] The operation warning module is used to obtain an operation deviation index based on the operation parameter data when it is determined that the fuel cell system to be tested has no fuel cell operation fault, so as to determine whether to give a fuel cell operation warning to the fuel cell system to be tested according to the operation deviation index and the operation deviation index threshold corresponding to the output current;

[0056] The fault processing module is used to execute a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level and the fault type.

[0057] A fault diagnosis and processing system for a fuel cell system disclosed by the present invention first obtains in real time the status data of a fuel cell controller, the fault diagnosis data of each sub-controller, the operation data of sensors, and the operation parameter data of the fuel cell in the fuel cell system to be measured, so as to obtain different types of data according to the functional areas of the fuel cell system, comprehensively diagnose various faults in the fuel cell system, and improve the accuracy of fault diagnosis. Secondly, when performing specific fault diagnosis, a pre-constructed fault database is used to finely identify the fault types and fault levels of the currently real-time collected data, so as to improve the accuracy of fault handling by improving the refinement of fault diagnosis. Among them, when it is determined through fault diagnosis that there is no fuel cell operation fault in the fuel cell system to be measured, a determination of fuel cell operation early warning is performed on the fuel cell system to be measured to avoid potential risks and thus improve the effect of fault handling. Finally, a preset fault handling operation is executed on the fuel cell system to be measured according to the determination result of the fuel cell operation early warning, the fault level, and the fault type, improving the accuracy of fault handling.

[0058] As a preferred example, the data acquisition module includes a device unit, a status unit, a sensor unit, and an operation unit;

[0059] The status unit is used to obtain in real time the current status of the fuel cell controller; wherein, the current status includes standby, cold start, start, operation, and shutdown; time the current status to obtain the response duration of the fuel cell controller staying in the current status; and use the current status and the response duration as the status data of the fuel cell controller.

[0060] The device unit is used to determine several accessory devices with controllers in the fuel cell system to be measured, and use the controller corresponding to each accessory device as the sub-controller of the fuel cell system to be measured; obtain in real time the fault information obtained by each sub-controller after performing fault diagnosis on its corresponding accessory device and the heartbeat signal of the sub-controller itself; and use the fault information and the heartbeat signal as the fault diagnosis data of each sub-controller.

[0061] The sensor unit is used to obtain in real time the measured value of each sensor, and use the measured value as the operation data of the sensor.

[0062] The operating unit is used to obtain the electrical operating data, anode-side operating data, cathode-side operating data, and cooling circuit operating data of the fuel cell in real time; among them, the electrical operating data includes the output current, output voltage, and insulation detection value of the fuel cell; the anode-side operating data includes the pre-stage hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack, and the pressure difference between the inlet and outlet of the stack; the cathode-side operating data includes the air flow rate of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack, and the air temperature leaving the stack; the cooling circuit operating data includes the water temperature entering the stack during heat dissipation of the stack, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack, and the air-water pressure difference of the stack.

[0063] In the above solution, the data acquisition module obtains the real-time operating data in different functional areas based on the functional area division, so as to realize the comprehensive fault diagnosis of the fuel cell system through the real-time operating data and the functional area division, thereby improving the effect of fault diagnosis. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] Figure 1 : It is a schematic flow chart of a method for fault diagnosis and processing of a fuel cell system disclosed in an embodiment of the present invention;

[0065] Figure 2 : It is a schematic structural diagram of a fault diagnosis and processing system for a fuel cell system disclosed in an embodiment of the present invention;

[0066] Figure 3 : It is a schematic flow chart of a method for fault diagnosis and processing of a fuel cell system disclosed in another embodiment of the present invention;

[0067] Figure 4 : It is a schematic diagram of fault division for a fuel cell system disclosed in another embodiment of the present invention;

[0068] Figure 5 : It is a flow chart for determining the fuel cell operation warning of a fuel cell system disclosed in another embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0069] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0070] Embodiment 1

[0071] This embodiment discloses a fault diagnosis and processing method for a fuel cell system to improve the accuracy of fault diagnosis and processing. Specifically, for the specific implementation process of the fault diagnosis and processing method, please refer to Figure 1 , which mainly includes steps 101 to 104, and the steps are as follows:

[0072] Step 101: Real-time obtain the output current of the fuel cell system to be measured, the status data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of each sub-controller, the operation data of the sensors, and the operation parameter data of the fuel cell.

[0073] Step 102: Obtain the fault type and fault level of the fuel cell system to be measured according to the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data, and a pre-constructed fault database.

[0074] Step 103: When it is determined that there is no fuel cell operation fault in the fuel cell system to be measured, obtain an operation deviation index based on the operation parameter data, and determine whether to perform a fuel cell operation warning on the fuel cell system to be measured according to the operation deviation index and the operation deviation index threshold corresponding to the output current.

[0075] Step 104: Perform a preset fault handling operation on the fuel cell system to be measured according to the determination result of the fuel cell operation warning, the fault level, and the fault type.

[0076] In the above solution, different operation data of the fuel cell system are obtained from different functional areas of the fuel cell, such as the status data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of each sub-controller, the operation data of the sensors, and the operation parameter data of the fuel cell, so as to comprehensively analyze the fuel cell system based on the above data. Among them, when performing the analysis, the fault data corresponding to each fault in the pre-constructed fault database is compared with the obtained real-time data to improve the accuracy of fault diagnosis. At the same time, the fault level corresponding to each fault threshold is also saved in the fault database, so as to perform a fault handling operation to ensure the safe operation of the fuel cell system on the fuel cell system according to the fault level, thereby improving the accuracy of fault handling.

[0077] In a certain implementation manner of this embodiment, the accuracy of fault diagnosis is improved by increasing the diversity and comprehensiveness of the status data. Specifically, the status data is obtained through the following steps:

[0078] Step 1011: Real-time obtain the current status of the fuel cell controller; wherein, the current status includes standby, cold start, start, operation, and shutdown.

[0079] Step 1012: Time the current state to obtain the response duration for which the fuel cell controller stays in the current state.

[0080] Step 1013: Use the current state and the response duration as the state data of the fuel cell controller.

[0081] In the above steps, based on the internal predefined state phases of the fuel cell controller, it will be in different states at different times to ensure the normal operation of the fuel cell system. If the fuel cell controller stalls in a certain state and cannot jump out normally, a fault will occur. To this end, in order to accurately identify whether the fuel cell controller has a fault, the current state of the fuel cell controller and the response duration for staying in the current state can be obtained, so as to accurately identify whether the fuel cell controller can perform state jump normally according to the current state and the response duration in the follow-up.

[0082] In a certain implementation manner of this embodiment, based on the accessory devices with controllers in the fuel cell system, and the controllers of the accessory devices diagnose the faults of the accessory devices regularly or irregularly. Therefore, in order to diagnose the faults of each accessory device in the fuel cell system, the fault diagnosis data stored in the controllers of the accessory devices can be obtained to finely divide the sources of device faults. Among them, in addition to obtaining the fault conditions of the accessory devices themselves, the controllers of the accessory devices also need to be diagnosed for faults to improve the accuracy of fault diagnosis. Specifically, when obtaining the fault diagnosis data of the controller to diagnose the faults of the accessory devices and the controller itself, it can be achieved through the following steps:

[0083] Step 1014: Determine several accessory devices with controllers in the fuel cell system to be tested, and use the controller corresponding to each accessory device as a sub-controller of the fuel cell system to be tested.

[0084] Step 1015: Real-time obtain the fault information obtained by each sub-controller for fault diagnosis of its corresponding accessory device and the heartbeat signal of the sub-controller itself.

[0085] Step 1016: Use the fault information and the heartbeat signal as the fault diagnosis data of each sub-controller.

[0086] In the above steps, a controller is provided in the accessory device based on the fuel cell system to perform fault diagnosis of the accessory device through the controller. In this regard, fault diagnosis of the accessory device can be carried out by obtaining the fault diagnosis information uploaded by each controller, thereby improving the refinement of fault diagnosis. Among them, when performing fault diagnosis on the accessory device, in order to realize the fault diagnosis of the controller itself, the heartbeat signal of the controller can be obtained to perform fault diagnosis on the controller itself, so as to improve the comprehensiveness of fault diagnosis.

[0087] In a certain implementation manner of this embodiment, when performing fault diagnosis on the sensors of the fuel cell system and diagnosing the operation faults of the fuel cell, various data to be obtained correspondingly can be determined according to the internal operation principle of the fuel cell, so as to improve the accuracy of fault diagnosis. Specifically, when obtaining the operation data of the sensors and the operation parameter data of the fuel cell, the following steps can be used to obtain them:

[0088] Step 1017: Obtain the measurement value of each sensor in real time, and use the measurement value as the operation data of the sensor.

[0089] Step 1018: Obtain the electrical operation data, anode-side operation data, cathode-side operation data, and cooling circuit operation data of the fuel cell in real time; among them, the electrical operation data includes the output current, output voltage, and insulation detection value of the fuel cell; the anode-side operation data includes the pre-stage hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack, and the pressure difference between the inlet and outlet of the stack; the cathode-side operation data includes the air flow rate of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack, and the air temperature leaving the stack; the cooling circuit operation data includes the water temperature entering the stack when the stack dissipates heat, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack, and the air-water pressure difference of the stack.

[0090] In the above steps, obtaining the measurement value of the sensor can quickly and accurately perform fault diagnosis on the sensor. When obtaining the operation data of the fuel cell, based on the operation process of the fuel cell, the operation data on different sides of the fuel cell is obtained in all directions, so as to improve the accuracy of fuel cell fault diagnosis through the refinement of the obtained operation data.

[0091] In a certain implementation manner of this embodiment, since the data for fault diagnosis is obtained according to the functional division of the fuel cell system, therefore, for the technical purpose of performing fault diagnosis to execute corresponding fault handling operations and thus ensure the operation safety of the fuel cell system, a fault level can be set that can reflect the degree of influence of the current fault type on the operation of the fuel cell system obtained from the fault database. In this regard, when obtaining the fault type and fault level of the fuel cell system to be tested according to the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data, and the pre-constructed fault database, it can be achieved through the following steps:

[0092] Step 1021: Obtain multiple fault types from the fault database; among them, the multiple fault types include status jump faults, equipment faults, sensor faults, and fuel cell operation faults; obtain multiple fault thresholds corresponding to each fault type from the fault database; among them, the fault thresholds include the status jump fault threshold corresponding to the status jump fault, the equipment fault threshold corresponding to the equipment fault, the sensor fault threshold corresponding to the sensor fault, and the operation fault threshold corresponding to the fuel cell operation fault; obtain the fault level corresponding to each of the fault thresholds from the fault database; obtain the fault current corresponding to each of the operation fault thresholds from the fault database.

[0093] Step 1023: Obtain the first comparison result between the status data and each status jump fault threshold; obtain the second comparison result between the fault diagnosis data and each equipment fault threshold; obtain the third comparison result between the operation data of the sensor and each sensor fault threshold; based on the matching result between the fault current and the output current of the fuel cell system to be tested, select several first operation fault thresholds from the multiple operation fault thresholds; obtain the fourth comparison result between the operation parameter data and each of the first operation fault thresholds.

[0094] Step 1024: According to the first comparison result, the second comparison result, the third comparison result, and the fourth comparison result, determine whether the fuel cell system to be tested has a status jump fault, an equipment fault, a sensor fault, or a fuel cell operation fault; when it is determined that the fuel cell system to be tested has a status jump fault, an equipment fault, a sensor fault, or a fuel cell operation fault, select the highest fault level from the fault levels corresponding to the status jump fault threshold, the equipment fault threshold, the sensor fault threshold, and the first operation fault threshold that are currently being compared as the fault level of the fuel cell system to be tested.

[0095] In the above steps, all possible fault types in the fuel cell system are saved in detail in the fault database, including equipment faults, sensor faults, and operating parameter faults, etc., so as to finely cover various faults that may occur during the operation of the fuel cell system through the fault types, providing a basis for accurate diagnosis and handling of faults. Among them, the fault types are associated with the fault levels in the fault database, so that while quickly identifying the fault types, accurate fault handling operations can be determined according to the fault levels corresponding to the fault types, thereby improving the effect of fault handling.

[0096] In some embodiments of this embodiment, although the fuel cell system does not show an obvious fault state, there are some abnormalities in its operating parameters, such as the feedback value not converging or there being a certain steady-state error between the reference value and the actual value. This is usually caused by some actuator jams, and long-term operation will affect the durability of the system. In response to this, in order to diagnose this part of the hidden faults, the following steps can be used to determine whether there are latent faults:

[0097] Step 1031: When it is determined according to the fourth comparison result that the fuel cell system to be tested does not have the fuel cell operation fault, obtain the sampling moment of the operating parameter data, so as to obtain a number of historical operating parameter data based on a preset sampling step and the sampling moment.

[0098] Step 1032: Obtain the real-time mean value and real-time variance of the operating parameters corresponding to a number of the historical operating parameter data and the operating parameter data.

[0099] Step 1033: Obtain the standard real-time mean value of the operating parameters, the standard real-time variance of the operating parameters, and the operating deviation index threshold corresponding to the output current from a preset operating parameter mean value table, a preset operating parameter variance table, and a preset operating deviation index threshold table.

[0100] Step 1034: Obtain the operating deviation index according to the real-time mean value of the operating parameters, the real-time variance of the operating parameters, the standard real-time mean value of the operating parameters, and the standard real-time variance of the operating parameters.

[0101] Step 1035: Obtain the comparison result between the operating deviation index and the operating deviation index threshold, so as to determine whether to give a fuel cell operation warning to the fuel cell system to be tested according to the comparison result.

[0102] In the above solution, the operating parameters of the fuel cell system are closely related to its output current. Therefore, standard parameters corresponding to each output current are preset. Among them, sometimes the fuel cell system does not show an obvious fault state, but there are some abnormalities in its operating parameters, such as the feedback value not converging or there being a certain steady-state error between the reference value and the actual value. In this regard, in order to perform fault diagnosis on the abnormalities in this part, the parameters obtained in real time are compared with the standard parameters to improve the comprehensiveness and accuracy of fault diagnosis.

[0103] In some embodiments of this embodiment, when performing a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level, and the fault type, it can be achieved through the following steps:

[0104] Step 1041: When it is determined to perform a fuel cell operation warning on the fuel cell system to be tested, output the warning information corresponding to the operating parameter data.

[0105] Step 1042: Obtain the fault handling operation corresponding to the fault level from the fault database, and perform the fault handling operation on the fuel cell system to be tested; where the fault handling operation includes load reduction, shutdown, or emergency stop.

[0106] In the above steps, obtain the fault handling operation with the highest fault level from the above fault classification to perform the fault handling operation on the fuel cell system to be tested, thereby improving the safety of system operation.

[0107] On the other hand, this embodiment also discloses a fault diagnosis and processing system for a fuel cell system. For the specific structural composition of the system, please refer to Figure 2 , including a data acquisition module 201, a fault diagnosis module 202, an operation warning module 203, and a fault handling module 204.

[0108] The data acquisition module 201 is used to obtain in real time the output current of the fuel cell system to be tested, the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor, and the operation parameter data of the fuel cell.

[0109] The fault diagnosis module 202 is used to obtain the fault type and fault level of the fuel cell system to be tested according to the output current, the status data, the fault diagnosis data, the operation data, the operation parameter data, and a pre-constructed fault database.

[0110] The operation warning module 203 is configured to obtain an operation deviation index based on the operation parameter data when it is determined that there is no fuel cell operation fault in the fuel cell system to be tested, so as to determine whether to perform a fuel cell operation warning on the fuel cell system to be tested according to the operation deviation index and the operation deviation index threshold corresponding to the output current.

[0111] The fault handling module 204 is configured to perform a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level, and the fault type.

[0112] In this embodiment, the data acquisition module 201 includes a device unit, a status unit, a sensor unit, and an operation unit.

[0113] The status unit is configured to obtain the current status of the fuel cell controller in real time; wherein, the current status includes standby, cold start, start, operation, and shutdown; time the current status to obtain the response duration of the fuel cell controller staying in the current status; and use the current status and the response duration as the status data of the fuel cell controller.

[0114] The device unit is configured to determine a plurality of accessory devices with controllers in the fuel cell system to be tested, and use the controller corresponding to each accessory device as a sub-controller of the fuel cell system to be tested; obtain the fault information obtained by each sub-controller after performing a fault diagnosis on its corresponding accessory device and the heartbeat signal of the sub-controller itself in real time; and use the fault information and the heartbeat signal as the fault diagnosis data of each sub-controller.

[0115] The sensor unit is configured to obtain the measurement value of each sensor in real time and use the measurement value as the operation data of the sensor.

[0116] The operation unit is configured to obtain the electrical operation data, the anode-side operation data, the cathode-side operation data, and the cooling circuit operation data of the fuel cell in real time; wherein, the electrical operation data includes the output current, output voltage, and insulation detection value of the fuel cell; the anode-side operation data includes the pre-stage hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack, and the pressure difference between the inlet and outlet of the stack; the cathode-side operation data includes the air flow rate of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack, and the air temperature leaving the stack; the cooling circuit operation data includes the water temperature entering the stack when the stack dissipates heat, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack, and the air-water pressure difference of the stack.

[0117] A fault diagnosis and processing method and system for a fuel cell system disclosed in this embodiment first obtains in real time the status data of the fuel cell controller, the fault diagnosis data of each sub-controller, the operation data of sensors, and the operation parameter data of the fuel cell in the fuel cell system to be measured, so as to obtain different types of data according to the functional areas of the fuel cell system, comprehensively diagnose various faults in the fuel cell system, and improve the accuracy of fault diagnosis. Secondly, when performing specific fault diagnosis, the pre-constructed fault database is used to identify the refined fault types and fault levels of the currently collected real-time data, so as to improve the accuracy of fault processing by improving the refinement of fault diagnosis. Among them, when it is determined through fault diagnosis that there is no fuel cell operation fault in the fuel cell system to be measured, a determination of fuel cell operation early warning is performed on the fuel cell system to be measured to avoid potential risks and thus improve the effect of fault processing. Finally, a preset fault processing operation is executed on the fuel cell system to be measured according to the determination result of the fuel cell operation early warning, the fault level, and the fault type, improving the accuracy of fault processing.

[0118] Embodiment 2

[0119] When the prior art performs fault diagnosis and processing on a fuel cell system, it mainly detects whether a fault exists, and does not classify and perform corresponding processing according to the impact of the fault on the system operation, resulting in poor final fault processing effect. Further, the prior art does not explain the specific impact of different faults on the system operation, and only sends the fault situation to the vehicle controller for processing. Without a systematic fault database, the fault diagnosis mechanism may only be able to identify some preset fault types, and faults outside the preset range are easily ignored.

[0120] To solve the above technical problems and improve the accuracy of fault diagnosis and the effect of fault processing, this embodiment discloses a fault diagnosis and processing method for a fuel cell system based on fault division according to the functional areas of the fuel cell system. Specifically, the specific implementation process of the fault diagnosis and processing method is as follows Figure 3 , mainly including steps 301 to 304:

[0121] Step 301: Obtain the fault data of the experimental fuel cell system to construct a fault database according to the fault data; wherein, the experimental fuel cell system is of the same type as the fuel cell system to be measured.

[0122] In this embodiment, when constructing the fault database, in order to accurately perform fault diagnosis on the fuel cell system to be measured based on the fault database, a fuel cell system of the same type as the fuel cell system to be measured can be selected for fault experiments, and then the fault database is constructed using the results of the fault experiments.

[0123] During the process of conducting fault experiments on a fuel cell system, the faults are classified according to the functional areas of the fuel cell system. The fault types of the fuel cell system are classified into equipment faults, hard-wired sensor faults, anode-side operation faults, cathode-side operation faults, cooling circuit faults, and electrical faults. Then, the sources of each type of fault are sorted out to obtain a fault database that basically covers all possible faults of the fuel cell system.

[0124] Specifically, during the fault experiment process, first, sorting out the sources of each type of fault shows that several types of fault sources included in each type of fault are as Figure 4 shown.

[0125] Referring to Figure 4 it can be seen that the equipment faults mainly refer to accessory equipment with controllers such as air compressors, water pumps, hydrogen pumps, and PTCs, etc.; the controllers of these devices will perform fault diagnosis on themselves and send fault information and heartbeat signals to the FCU, i.e., the fuel cell controller; the hard-wired sensor faults mainly refer to some analog input sensors such as flow, pressure, temperature, current, and voltage. During the actual system operation, sensor disconnection may occur due to vibration or external stress; the state transition faults mainly refer to some predefined state stages inside the FCU, such as standby, cold start, start, operation, and shutdown, etc. When some operating conditions are not met, the FCU stalls at a certain link and cannot normally jump out, resulting in faults. The anode-side faults mainly refer to the faults caused by abnormal pre-stage hydrogen pressure, hydrogen pressure into the stack, hydrogen pressure out of the stack, hydrogen-air pressure difference, and pressure difference between in and out of the stack during the operation of the stack; the cathode-side faults mainly refer to the faults caused by abnormal air flow, air pressure into the stack, air temperature at the outlet of the intercooler, and air temperature between in and out of the stack during the operation of the stack; the cooling circuit faults mainly refer to the faults caused by abnormal operating parameters such as water temperature into and out of the stack, water pressure into the stack, and water pressure difference between air and water during the heat dissipation of the stack; the electrical faults refer to the faults caused by abnormal output current, output voltage, and system insulation detection value.

[0126] Referring to Figure 4Perform a fault experiment on the fuel cell system according to the shown fault type classification and several fault sources included in each type of fault, so as to collect the fault thresholds corresponding to each type of fault when the fuel cell system is in each type of fault, and obtain the degree of influence of the fault thresholds on the operation of the fuel cell system, so as to formulate the fault level corresponding to the fault thresholds according to the degree of influence. Among them, when collecting the fault thresholds corresponding to anode-side faults, cathode-side faults, cooling circuit faults, and electrical faults, since the operating parameters of the fuel cell system are closely related to its output current, when the output current of the fuel cell system is different, the fault thresholds corresponding to the anode-side faults, cathode-side faults, cooling circuit faults, and electrical faults are also different. Therefore, when performing the fault experiment, it is also necessary to control the fuel cell system to output different current values, so as to obtain the fault thresholds corresponding to the anode-side faults, cathode-side faults, cooling circuit faults, and electrical faults respectively when the fuel cell system is at each output current value.

[0127] In some embodiments of this embodiment, when formulating the fault level corresponding to the fault threshold, according to the influence of the fault on the system, it is divided into four situations, namely operation parameter warning, first-level fault, second-level fault, and third-level fault. Among them, the operation parameter warning means that there is a deviation between the real-time operation parameters of the system and the historical operation parameters of the normal operation of the system, but it has no actual impact on the system operation.

[0128] The first-level fault is defined as a fault situation that can be restored by load shedding. In this case, there is no need to directly shut down the machine, and the system output can be maintained by reducing the load. The setting of the threshold is on the one hand artificially set through the description of the fault level, and on the other hand is the limit value in the stack manual. For example, if the water temperature is 3°C higher, it is considered that there is an abnormality but it is not very serious and can be solved by reducing the load. The first-level fault threshold of the water temperature can be set to not exceed 3°C; the second-level fault is a functional fault of the BOP accessory, that is, there is a fault in the accessory equipment with a controller, cannot communicate normally, sensor fault or abnormal real-time operation data, and the fault that needs to be shut down for processing and cannot be solved by reducing the load; the third-level fault is that the BOP accessory is in a serious fault situation, the insulation value is too low, the hydrogen concentration is too high or the real-time data exceeds the limit value in the stack manual, and continuous operation may cause irreversible losses to the system or dangerous situations.

[0129] Among them, the warning mainly detects the system operation parameters. The first-level, second-level, and third-level faults are applicable to all fault sources. According to the definition description of the fault level, Figure 1 Define the fault thresholds and corresponding fault levels for various faults in [], and form a predefined fault library. In addition, various faults can be numbered to form fault codes and store the fault codes in the predefined fault library.

[0130] Step 302: Obtain the output current of the fuel cell system to be measured, the status data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of the sub-controllers corresponding to each accessory device, the operation data of the sensors, and the operation parameter data of the fuel cells in real time.

[0131] In this embodiment, since the operation parameters of the fuel cell system are closely related to its output current, the output current of the fuel cell system to be measured can be obtained from the fuel cell controller of the fuel cell system to be measured, so as to identify whether the fuel cell system to be measured has an operation parameter fault according to the output current and the operation parameters subsequently.

[0132] Specifically, when obtaining the status data of the fuel cell controller in the fuel cell system to be measured, the fault diagnosis data of the sub-controllers corresponding to each accessory device, the operation data of the sensors, and the operation parameter data of the fuel cells, based on Figure 4 the classification of fault types and the sorting of fault sources, the current status of the fuel cell controller in the fuel cell system to be measured is obtained in real time, and the current status is timed to obtain the response duration of the fuel cell controller staying in the current status; the current status and the response duration are used as the status data of the fuel cell controller. Wherein, the current status includes standby, cold start, start, operation, and shutdown.

[0133] When obtaining the fault diagnosis data of each sub-controller, determine several accessory devices with controllers in the fuel cell system to be measured, and use the controller corresponding to each accessory device as the sub-controller of the fuel cell system to be measured; obtain the fault information obtained by each sub-controller for fault diagnosis of its corresponding accessory device and the heartbeat signal of the sub-controller itself in real time; use the fault information and the heartbeat signal as the fault diagnosis data of each sub-controller.

[0134] When obtaining the operation data of the sensors, obtain the measurement value of each sensor in real time, and use the measurement value as the operation data of the sensor.

[0135] When obtaining the operating parameter data of the fuel cell, the output current, output voltage, and insulation detection value of the fuel cell are obtained as the electrical operating data of the fuel cell; the pre-stage hydrogen pressure of the stack in the fuel cell, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack, and the pressure difference between the inlet and outlet of the stack are obtained as the anode-side operating data of the fuel cell; the air flow rate of the stack in the fuel cell, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack, and the air temperature leaving the stack are obtained as the cathode-side operating data of the fuel cell; the water temperature entering the stack, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack, and the water-air pressure difference of the stack when the stack in the fuel cell dissipates heat are obtained as the operating data of the cooling circuit of the fuel cell.

[0136] Step 303: Identify the fault type and fault level of the fuel cell system to be tested according to the fault database, the output current, the status data, the fault diagnosis data, the operating data, and the operating parameter data.

[0137] In this embodiment, several anode-side fault thresholds corresponding to the anode-side faults at the current output current and the anode-side fault level corresponding to each anode-side fault threshold are obtained from the fault database.

[0138] Several cathode-side fault thresholds corresponding to the cathode-side faults at the current output current and the cathode-side fault level corresponding to each cathode-side fault threshold are obtained from the fault database.

[0139] Several cooling circuit fault thresholds corresponding to the cooling circuit faults at the current output current and the cooling circuit fault level corresponding to each cooling circuit fault threshold are obtained from the fault database.

[0140] Several electrical fault thresholds corresponding to the electrical faults at the current output current and the electrical fault level corresponding to each electrical fault threshold are obtained from the fault database.

[0141] Several fault information thresholds and several heartbeat signal thresholds corresponding to the equipment faults, the equipment fault level corresponding to each fault information threshold, and the equipment fault level corresponding to each heartbeat signal threshold are obtained from the fault database.

[0142] Several sensor fault thresholds corresponding to the hardwired sensor faults and the sensor fault level corresponding to each sensor fault threshold are obtained from the fault database.

[0143] Obtain the response duration threshold corresponding to each of the several state stages corresponding to the state transition fault from the fault database, and obtain the state transition fault level corresponding to each response duration threshold.

[0144] Compare the response duration with each of the response duration thresholds to determine whether there is a state transition fault in the fuel cell system under test according to the comparison result, and when it is determined that there is the state transition fault, obtain the state transition fault level corresponding to the response duration threshold currently being compared.

[0145] Compare the fault information and heartbeat signal sent by each sub - controller with the fault information threshold and the heartbeat signal threshold respectively to determine whether there is a device fault in the fuel cell system under test according to the comparison result, and when it is determined that there is the device fault, obtain the device fault level corresponding to the fault information threshold and the heartbeat signal threshold currently being compared.

[0146] Compare the operating data of the sensor with the sensor fault threshold to determine whether there is a sensor fault in the fuel cell system under test according to the comparison result, and when it is determined that there is the sensor fault, obtain the sensor fault level corresponding to the sensor fault threshold currently being compared.

[0147] Compare the electrical operating data, anode - side operating data, cathode - side operating data, and cooling circuit operating data with their corresponding electrical fault threshold, anode - side fault threshold, cathode - side fault threshold, and cooling circuit fault threshold respectively to determine whether there are electrical faults, anode - side faults, cathode - side faults, and cooling circuit faults in the fuel cell system under test according to the comparison result;

[0148] When it is determined that there are electrical faults, anode - side faults, cathode - side faults, and cooling circuit faults, obtain the electrical fault level, anode - side fault level, cathode - side fault level, and cooling circuit fault level corresponding to the electrical fault threshold, anode - side fault threshold, cathode - side fault threshold, and cooling circuit fault threshold currently being compared respectively.

[0149] Step 304: When it is determined that the fuel cell system under test has no operating parameter faults, calculate the operating deviation index of the operating parameter data, and obtain the operating deviation index threshold from a preset operating deviation index threshold table based on the output current, so as to determine whether to give an operating parameter warning for the fuel cell system under test according to the operating deviation index and the operating deviation index threshold.

[0150] In this embodiment, sometimes the operation parameter data of the fuel cell system does not show an obvious fault state, but there may be some abnormalities inside, such as the feedback value not converging or there being a certain steady-state error between the reference value and the actual value. This is usually caused by some actuator jams, and long-term operation will affect the durability of the system. Therefore, in order to diagnose hidden faults, it is possible to determine whether to give an operation warning to the fuel cell system to be tested according to Figure 5 the operation warning determination process shown.

[0151] Specifically, referring to Figure 5 , first, according to the sampling time of the operation parameter data and the preset sampling step, several historical operation parameter data of the previous N sampling steps of the operation parameter data are obtained, so as to calculate the operation deviation index according to the operation parameter data and the historical operation parameter data. Among them, the calculation expression of the operation deviation index is:

[0152]

[0153] where m is the real-time mean value of the operation parameters of the operation parameter data and the historical operation parameter data; v is the real-time variance of the operation parameters of the operation parameter data and the historical operation parameter data; a is the mean weight, b is the variance weight, and a + b = 1; for operation parameters without disturbance quantities, such as the inlet stack air pressure, the mean weight can be enlarged compared with the variance weight; for operation parameters with disturbance quantities, such as the inlet stack hydrogen pressure, the variance weight can be enlarged compared with the mean weight. f(I) is the operation parameter mean value obtained by looking up a preset two-dimensional table of current-operation parameter mean values according to the output current; g(I) is the operation parameter variance obtained by looking up a preset two-dimensional table of current-operation parameter variances according to the output current.

[0154] In this embodiment, before giving an operation warning for the operation parameter data, the anode side, cathode side, cooling circuit, and electrical operation parameters under normal operation of the fuel cell system at each current point can be collected, the mean value m and variance v of the operation parameters at each current point are calculated, and a two-dimensional look-up table of current-operation parameter mean value f(I) and current-operation parameter variance g(I) is established.

[0155] After obtaining the operation deviation index, a predefined two-dimensional table of current-operation deviation index thresholds can be looked up according to the output current to obtain the operation deviation index threshold d(i) corresponding to the output current, and then by comparing the operation deviation index threshold and the operation deviation index, it is determined whether to give an operation parameter warning to the fuel cell system to be tested.

[0156] Step 305: Perform a preset fault handling operation on the fuel cell system to be tested according to the fault level and the determination result of the operation parameter warning.

[0157] In this embodiment, based on the recognition results of the fault level and the fault type, determine the current corresponding state jump fault level, equipment fault level, sensor fault level, electrical fault level, anode side fault level, cathode side fault level or cooling circuit fault level of the fuel cell system to be tested. Among them, different levels correspond to different fault handling operations. For example, for accessory equipment, various sub-faults of the accessory equipment are divided into faults that can be recovered by load reduction, faults that cannot be solved by load reduction and require shutdown processing, and faults that may cause irreversible losses or dangers to the system if continued to operate and need to be stopped immediately, namely first-level, second-level, and third-level faults.

[0158] For this, select the highest fault level from the state jump fault level, equipment fault level, sensor fault level, electrical fault level, anode side fault level, cathode side fault level or cooling circuit fault level, and perform the fault handling operation corresponding to the highest fault level. For example, if the state jump fault level is the first level and the equipment fault level is the second level, then perform the fault handling operation corresponding to the second level, that is, shut down the fuel cell system to be tested.

[0159] Further, for the fault situation, the fault code corresponding to the fault level and the fault type can also be obtained and output from the fault database, and the fault code is input into the fault recording module for storage to facilitate troubleshooting. For the warning information, upload it to the background to prompt relevant personnel to conduct troubleshooting.

[0160] A fault diagnosis and handling method for a fuel cell system disclosed in this embodiment classifies in detail the possible faults in the fuel cell system, including equipment faults, sensor faults, communication faults, and operating parameter faults, etc. This framework-based classification method can cover various faults that may occur during the operation of the fuel cell system, avoid missing potential problems, and improve the accuracy of fault diagnosis and system safety. Secondly, by establishing a predefined fault library, the fault types are associated with the fault levels, enabling the system to quickly identify the fault types during real-time monitoring, output the corresponding fault levels and fault codes, which is convenient for subsequent fault diagnosis and cause analysis, and provides a basis for the accurate diagnosis and handling of faults. Among them, an online fault diagnosis process based on dynamic thresholds is also provided, that is, a quantitative evaluation is carried out based on the deviation degree between the real-time value of the operating parameter and the normal operation statistical value to identify atypical faults, such as the steady-state error caused by actuator jamming or the problem of non-converging feedback values, and maintenance and adjustment are carried out in advance to avoid long-term impact on the system durability. Distinguish minor deviations from major faults, improve the operating stability, and reduce the efficiency loss caused by false shutdowns. Further, by collecting the normal operating parameters of the fuel cell system at different current points, calculating their mean and variance, the deviation threshold is dynamically set. During the operation of the system, the deviation degree of the monitored parameters is real-time monitored. When the deviation value exceeds the dynamic threshold but does not reach the hard constraint, a warning is triggered to indicate a potential abnormality; when the operating parameter exceeds the hard constraint, protection measures such as load reduction or shutdown are taken. Compared with the traditional diagnosis method with fixed thresholds, the dynamic threshold can more sensitively capture the abnormal changes during operation, while avoiding false alarms and false shutdowns, and improving the system safety and operating efficiency.

[0161] The specific embodiments described above further elaborate on the purpose, technical solutions, and beneficial effects of the present invention. It should be understood that the above are only specific embodiments of the present invention and are not used to limit the protection scope of the present invention. It is particularly pointed out that for those skilled in the art, any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A fault diagnosis and processing method for a fuel cell system, characterized in that: include: Real-time acquisition of the output current of the fuel cell system to be tested, the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell; Obtaining a fault type and a fault level of the fuel cell system to be tested according to the output current, the state data, the fault diagnosis data, the operation data, the operation parameter data and a pre-built fault database; When it is determined that there is no fuel cell operation fault in the fuel cell system to be tested, an operation deviation index is obtained based on the operation parameter data, so as to determine whether to perform a fuel cell operation warning for the fuel cell system to be tested according to the operation deviation index and an operation deviation index threshold corresponding to the output current; A preset fault processing operation is performed on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level and the fault type.

2. A method for fault diagnosis and treatment of a fuel cell system according to claim 1, characterized in that: The real-time acquisition of the output current of the fuel cell system to be tested and the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell include: Acquire the current state of the fuel cell controller in real time; wherein the current state includes standby, cold start, start, operation and shutdown; Timing the current state to obtain a response time length of time that the fuel cell controller stays in the current state; The current state and the response time are used as state data of the fuel cell controller.

3. A method for fault diagnosis and treatment of a fuel cell system according to claim 1, characterized in that: The real-time acquisition of the output current of the fuel cell system to be tested and the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell include: Determine a plurality of accessory devices with controllers in the fuel cell system to be tested, and use a controller corresponding to each of the accessory devices as a sub-controller of the fuel cell system to be tested; Real-time acquisition of fault information obtained by each sub-controller after performing fault diagnosis on its corresponding accessory device and the heartbeat signal of the sub-controller itself; The fault information and the heartbeat signal are used as fault diagnosis data of each sub-controller.

4. A method for fault diagnosis and treatment of a fuel cell system according to claim 1, characterized in that: The real-time acquisition of the output current of the fuel cell system to be tested and the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell include: Acquire the measurement value of each sensor in real time, and use the measurement value as the operation data of the sensor; The electrical operation data, anode side operation data, cathode side operation data and cooling circuit operation data of the fuel cell are acquired in real time; wherein the electrical operation data include the output current, output voltage and insulation detection value of the fuel cell; the anode side operation data include the front stage hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack and the pressure difference entering and leaving the stack; the cathode side operation data include the air flow of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack and the air temperature leaving the stack; the cooling circuit operation data include the water temperature entering the stack, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack and the air-water pressure difference of the stack when the stack is dissipating heat.

5. A method for fault diagnosis and treatment of a fuel cell system according to claim 1, characterized in that: The obtaining the fault type and fault level of the fuel cell system to be tested according to the output current, the state data, the fault diagnosis data, the operation data, the operation parameter data and a pre-built fault database includes: Acquire multiple fault types from the fault database; wherein the multiple fault types include state jump fault, device fault, sensor fault and fuel cell operation fault; Acquire multiple fault thresholds corresponding to each fault type from the fault database; wherein the fault thresholds include a state jump fault threshold corresponding to a state jump fault, an equipment fault threshold corresponding to an equipment fault, a sensor fault threshold corresponding to a sensor fault, and an operation fault threshold corresponding to a fuel cell operation fault; Acquire the fault level corresponding to each fault threshold from the fault database; The fault current corresponding to each of the operating fault thresholds is obtained from the fault database.

6. A method for fault diagnosis and treatment of a fuel cell system according to any one of claims 1 to 5, characterized in that: The obtaining the fault type and fault level of the fuel cell system to be tested according to the output current, the state data, the fault diagnosis data, the operation data, the operation parameter data and a pre-built fault database includes: Acquire a first comparison result of the state data and each state transition fault threshold; Obtaining a second comparison result of the fault diagnosis data and each device fault threshold; obtaining a third comparison result of the operating data of the sensor and a fault threshold of each sensor; Selecting a plurality of first operation fault thresholds from a plurality of operation fault thresholds based on a matching result between the fault current and the output current of the fuel cell system to be tested; obtaining a fourth comparison result of the operating parameter data and each of the first operating fault thresholds; According to the first comparison result, the second comparison result, the third comparison result and the fourth comparison result, determining whether the fuel cell system to be tested has a state jump fault, a device fault, a sensor fault or a fuel cell operation fault; When it is determined that the fuel cell system to be tested has a state jump fault, a device fault, a sensor fault or a fuel cell operation fault, the highest fault level is selected from the fault levels corresponding to the state jump fault threshold currently being compared, the fault level corresponding to the device fault threshold, the fault level corresponding to the sensor fault threshold and the fault level corresponding to the first operation fault threshold as the fault level of the fuel cell system to be tested.

7. A method for fault diagnosis and treatment of a fuel cell system according to claim 6, characterized in that: The step of obtaining an operation deviation index based on the operation parameter data, and determining whether to perform a fuel cell operation warning for the fuel cell system to be tested according to the operation deviation index and an operation deviation index threshold corresponding to the output current, includes: When it is determined according to the fourth comparison result that the fuel cell system to be tested does not have the fuel cell operation fault, obtaining the sampling time of the operation parameter data, so as to obtain a plurality of historical operation parameter data based on a preset sampling step and the sampling time; Obtaining a plurality of the historical operating parameter data and a real-time mean value of the operating parameter and a real-time variance of the operating parameter corresponding to the operating parameter data; Obtaining the standard operating parameter real-time mean, standard operating parameter real-time variance and operating deviation index threshold corresponding to the output current from a preset operating parameter mean table, a preset operating parameter variance table and a preset operating deviation index threshold table; Obtaining the operation deviation index according to the real-time mean of the operation parameter, the real-time variance of the operation parameter, the real-time mean of the standard operation parameter, and the real-time variance of the standard operation parameter; A comparison result between the operation deviation index and the operation deviation index threshold is obtained to determine whether to perform a fuel cell operation warning for the fuel cell system to be tested according to the comparison result.

8. A method for fault diagnosis and treatment of a fuel cell system according to claim 7, characterized in that: The performing of a preset fault handling operation on the fuel cell system to be tested according to the determination result of the fuel cell operation early warning, the fault level and the fault type comprises: When it is determined that a fuel cell operation warning is to be performed on the fuel cell system to be tested, outputting warning information corresponding to the operation parameter data; A fault handling operation corresponding to the fault level is obtained from the fault database, and the fault handling operation is performed on the fuel cell system to be tested; wherein the fault handling operation includes load reduction, shutdown or emergency stop.

9. A fault diagnosis and processing system for a fuel cell system, characterized in that: It includes data acquisition module, fault diagnosis module, operation warning module and fault handling module; The data acquisition module is used to acquire in real time the output current of the fuel cell system to be tested, the status data of the fuel cell controller in the fuel cell system to be tested, the fault diagnosis data of each sub-controller, the operation data of the sensor and the operation parameter data of the fuel cell; The fault diagnosis module is used to obtain the fault type and fault level of the fuel cell system to be tested according to the output current, the state data, the fault diagnosis data, the operation data, the operation parameter data and a pre-built fault database; The operation warning module is used to obtain an operation deviation index based on the operation parameter data when it is determined that there is no fuel cell operation fault in the fuel cell system to be tested, so as to determine whether to perform a fuel cell operation warning for the fuel cell system to be tested according to the operation deviation index and the operation deviation index threshold corresponding to the output current; The fault processing module is used to perform a preset fault processing operation on the fuel cell system to be tested according to the determination result of the fuel cell operation warning, the fault level and the fault type.

10. A fault diagnosis and processing system for a fuel cell system according to claim 9, characterized in that: The data acquisition module includes a device unit, a state unit, a sensor unit and an operation unit; The state unit is used to obtain the current state of the fuel cell controller in real time; wherein the current state includes standby, cold start, start, operation and shutdown; the current state is timed to obtain the response time of the fuel cell controller staying in the current state; the current state and the response time are used as the state data of the fuel cell controller; The device unit is used to determine a number of accessory devices with controllers in the fuel cell system to be tested, and use the controller corresponding to each of the accessory devices as a sub-controller of the fuel cell system to be tested; obtain in real time the fault information obtained by each sub-controller after performing fault diagnosis on the accessory device corresponding to the sub-controller and the heartbeat signal of the sub-controller itself; and use the fault information and the heartbeat signal as fault diagnosis data of each sub-controller; The sensor unit is used to obtain the measurement value of each sensor in real time, and use the measurement value as the operation data of the sensor; The operation unit is used to obtain the electrical operation data, anode side operation data, cathode side operation data and cooling circuit operation data of the fuel cell in real time; wherein the electrical operation data include the output current, output voltage and insulation detection value of the fuel cell; the anode side operation data include the front hydrogen pressure of the stack, the hydrogen pressure entering the stack, the hydrogen pressure leaving the stack, the hydrogen-air pressure difference of the stack and the pressure difference between the inlet and outlet of the stack; the cathode side operation data include the air flow of the stack, the air pressure entering the stack, the air temperature at the outlet of the intercooler, the air temperature entering the stack and the air temperature leaving the stack; the cooling circuit operation data include the water temperature entering the stack, the water temperature leaving the stack, the water pressure entering the stack, the water pressure leaving the stack and the air-water pressure difference of the stack when the stack is dissipating heat.

Images