Three-in-one integrated air valve device for fuel cell system and control method

Abstract

The invention relates to a three-in-one integrated air valve device for a fuel cell system and a control method. The valve comprises a valve body and an air compressor side air inlet formed in the valve body. The electric pile side air outlet is connected with the air compressor side air inlet to form a pile inlet air path; the stack side air inlet is used for being connected with an air outlet of a fuel cell stack; the tail exhaust side air outlet is connected with the electric pile side air inlet to form a pile outlet air path; the reactor inlet shut-off valve structure is arranged on the reactor inlet air path and comprises a reactor inlet shut-off valve cavity and a reactor inlet shut-off valve plate rotationally connected into the reactor inlet shut-off valve cavity; the pile-out shut-off valve structure is arranged on the pile-out air path and comprises a pile-out shut-off valve cavity and a pile-out shut-off valve plate rotationally connected to the interior of the pile-out shut-off valve cavity; a driving module; the bypass comprises a bypass channel, and the two ends of the bypass channel are connected with the reactor inlet shut-off valve cavity and the reactor outlet shut-off valve cavity respectively. According to the invention, the compactness of the system is obviously improved.

Description

Technical Field

[0001] The present invention relates to the technical field of fuel cell systems, and in particular to a three-in-one integrated air valve device and a control method for a fuel cell system. Background Art

[0002] A fuel cell system is a power generation device that uses hydrogen as fuel, generating electricity through an electrochemical reaction between hydrogen and oxygen. The power density of a fuel cell is a key performance metric and directly impacts the application and market penetration of fuel cell systems. However, due to the numerous complex functional components and piping systems integrated within a fuel cell system, further reductions in overall size and weight are difficult, hindering improvements in system power density.

[0003] A fuel cell system typically includes an air flow subsystem, a hydrogen flow subsystem, and a cooling flow subsystem. The air flow subsystem is typically equipped with an inlet shutoff valve, an outlet shutoff valve, and a bypass valve. The inlet shutoff valve is located at the air inlet of the fuel cell stack, while the outlet shutoff valve is located at the air outlet of the stack. When the fuel cell system is shut down, both the inlet and outlet shutoff valves are closed to prevent air from entering the stack, thereby preventing degradation or corrosion of the membrane electrode, which could affect the stack's durability.

[0004] In addition, during the startup or shutdown of the fuel cell system, the stack needs to be purged. During this operation, the bypass valve in the air path is opened to allow air from the intake channel to flow directly into the exhaust channel, thereby diluting the discharged purge gas and reducing the hydrogen concentration in it to ensure system safety.

[0005] However, existing fuel cell air circuit subsystems typically utilize independently configured inlet and outlet shutoff valves and bypass valves for air shutoff and bypass control. These valves are mostly poppet valves or butterfly valves, interconnected by pipelines, and each valve is equipped with an independent drive module, which typically includes components such as a controller, valve position sensor, motor, and transmission gear set. Due to the independent layout of each valve, the overall piping layout of the air circuit subsystem is relatively complex, the number of components is large, the system is large in size and weight, and the manufacturing and maintenance costs are also increased. This makes it difficult to meet the technical requirements of fuel cell systems for high power density, miniaturization, and lightweight.

[0006] Therefore, in order to further improve the power density of the fuel cell system, reduce the system volume and weight, and reduce manufacturing and operation and maintenance costs, it is of great technical significance to carry out integrated design of valves and their connecting pipes in the air path system. Summary of the Invention

[0007] To this end, the present invention provides a three-in-one integrated air valve device and control method for a fuel cell system. This three-in-one integrated air valve device integrates the stack shutoff valve structure, the stack exit shutoff valve structure, and the bypass valve structure within a single valve body, using a unified drive module to achieve synchronous and linked control of these three valves. This integrated design effectively simplifies the drive structure and pipeline connection layout, significantly improving the overall compactness of the system, significantly reducing the volume and weight of the air path subsystem, and reducing manufacturing and installation costs, thereby better meeting the technical requirements of fuel cell systems for high power density, miniaturization, and lightweighting.

[0008] To solve the above technical problems, the present invention provides a three-in-one integrated air valve device for a fuel cell system, comprising a valve body and: An air inlet on the air compressor side, used to connect to the air outlet part on the air compressor side of the fuel cell system; The stack side air outlet is connected to the air inlet of the air compressor to form an air path into the stack, and the stack side air outlet is used to be connected to the air inlet of the fuel cell stack; The air inlet on the fuel cell stack side is used to connect to the air outlet of the fuel cell stack; The tail exhaust side air outlet is connected to the stack side air inlet to form an out-of-stack air path, and the tail exhaust side air outlet is used to be connected to the tail exhaust side exhaust part of the fuel cell system; a stack entry shutoff valve structure, disposed in the stack entry air path, comprising a stack entry shutoff valve cavity and a stack entry shutoff valve plate rotatably connected to the stack entry shutoff valve cavity; a stack-out shut-off valve structure, arranged in the stack-out air path, comprising a stack-out shut-off valve cavity and a stack-out shut-off valve plate rotatably connected to the stack-out shut-off valve cavity; A driving module, configured to drive the valve plate of the stack entry shut-off valve and the valve plate of the stack exit shut-off valve to rotate synchronously; A bypass passage, comprising a bypass channel, both ends of which are connected to the inlet shut-off valve cavity and the outlet shut-off valve cavity respectively; The inlet and outlet at both ends of the bypass channel are respectively located on the lower surface of the inlet shut-off valve cavity and the lower surface of the outlet shut-off valve cavity, and are respectively connected to the air inlet on the air compressor side and the air outlet on the tail exhaust side. When the valve plate of the inlet shut-off valve and the valve plate of the outlet shut-off valve are rotated to different positions, the inlet air path, the outlet air path and the bypass path are controlled to be on and off.

[0009] In one embodiment of the present invention, the valve plate of the stack entry shut-off valve and the valve plate of the stack exit shut-off valve both include a front valve plate and a rear valve plate that are connected; Wherein, the front valve plates of the stack entry shut-off valve plates and the stack exit shut-off valve plates respectively form butterfly valves with the corresponding stack entry shut-off valve cavities and the stack exit shut-off valve cavities; the front valve plates of the stack entry shut-off valve plates and the stack exit shut-off valve plates can respectively seal with the corresponding stack entry shut-off valve cavities and the stack exit shut-off valve cavities to correspondingly shut off the stack entry air path and the stack exit air path; The rear valve plates of the stack entry shut-off valve plate and the stack exit shut-off valve plate can respectively seal with end surfaces of the bypass channel to shut off the bypass channel.

[0010] In one embodiment of the present invention, butterfly valve seals are provided on the side walls of the stack entry shut-off valve cavity and the stack exit shut-off valve cavity to form a sealing structure with the front valve plate.

[0011] In one embodiment of the present invention, the front valve plate is made of a metal substrate and is provided with a self-lubricating layer or a wear-resistant coating on the surface, and the butterfly valve seal matched therewith is made of a sealing rubber vulcanized with a hard skeleton; Alternatively, the front valve plate adopts a metal frame, and a layer of sealing rubber is vulcanized on its sealing surface to form a front valve plate sealing ring, and the butterfly valve seal adopts a sealing bushing made of metal material, and a sealing protrusion structure is provided on its sealing contact surface.

[0012] In one embodiment of the present invention, a rear valve plate sealing gasket made of sealing rubber is provided on the sealing side of the rear valve plate, and a flange is provided on both end surfaces of the bypass channel, which can be pressed against the rear valve plate sealing gasket to form a sealing structure; Alternatively, the surface of the sealing side of the rear valve plate is provided with a wear-resistant layer or a self-lubricating coating, and the end face of the bypass channel is provided with a bypass sealing ring, which is made of rubber and vulcanized to form a sealing structure with the rear valve plate.

[0013] In one embodiment of the present invention, the driving module includes a driving motor, a transmission gear set and a valve stem; The valve stem is connected to the valve plate of the stack entry shut-off valve and the valve plate of the stack exit shut-off valve respectively; The driving end of the driving motor is connected to the input end of the transmission gear set, and one end of the valve stem extends out of the valve body and is connected to the output end of the transmission gear set; the driving motor drives the transmission gear set and transmits the rotational power to the valve stem, so that the valve stem drives the valve plate of the inlet shut-off valve and the valve plate of the outlet shut-off valve to rotate synchronously.

[0014] In one embodiment of the present invention, a valve stem sealing ring and a valve stem bearing are provided between the valve stem and the valve body, and the valve stem bearing includes a rolling bearing and a sliding bearing; the valve stem sealing ring is installed between the valve stem bearing and the valve cavity of the valve body.

[0015] In one embodiment of the present invention, a torsion spring is installed between the gear connected to the valve stem in the transmission gear set and the valve body, and the extended ends at the upper and lower ends of the torsion spring are respectively inserted into the valve body and the gear, and the torsion spring can provide force for the valve stem to rotate and reset.

[0016] In one embodiment of the present invention, the three-in-one integrated air valve device has three position states: When in the first position, the front valve plates of the stack entry shut-off valve plate and the stack exit shut-off valve plate rotate to the sealing position, respectively forming a seal with the corresponding stack entry shut-off valve cavity and the stack exit shut-off valve cavity, thereby closing the stack entry shut-off valve structure and the stack exit shut-off valve structure; the rear valve plates of the stack entry shut-off valve plate and the stack exit shut-off valve plate are at a 90-degree angle relative to the end face of the bypass channel, and no seal is formed with the end face of the bypass channel. At this time, the stack entry air path and the stack exit air path are disconnected, the bypass channel is connected, and the bypass path is connected; When in the second position, the front valve plates of the stack entry shut-off valve plate and the stack exit shut-off valve plate are separated from the sealing position, and the rear valve plates of the stack entry shut-off valve plate and the stack exit shut-off valve plate are also separated from the end surface of the bypass channel, and no seal is formed. At this time, the stack entry air path and the stack exit air path are connected, and the bypass channel is connected; When in the third position, the front valve plates of the inlet shut-off valve plate and the outlet shut-off valve plate are separated from the sealing position and are 90 degrees relative to the sealing end faces of the corresponding inlet shut-off valve cavity and the outlet shut-off valve cavity; the rear valve plates of the inlet shut-off valve plate and the outlet shut-off valve plate are in contact with the end face of the bypass channel to form a seal. At this time, the inlet air path and the outlet air path are connected, the bypass channel is closed, and the bypass path is disconnected.

[0017] The present invention also provides a control method based on the three-in-one integrated air valve device for a fuel cell system, wherein the fuel cell system includes a fuel cell stack, an air compressor side air outlet portion, and a tail exhaust side exhaust portion, wherein the air compressor side air inlet is connected to the air outlet of the air compressor side air outlet portion or the gas outlet of the intercooler; the tail exhaust side air outlet is connected to the air inlet of the tail exhaust side exhaust portion; the stack side air outlet is connected to the air inlet of the fuel cell stack; and the stack side air inlet is connected to the air outlet of the fuel cell stack; The control method includes: When the fuel cell system is in a shutdown state, the three-in-one integrated air valve device is in a first position state; When the fuel cell system is started and enters the stack purge step, the air compressor runs at the set purge speed, the three-in-one integrated air valve device is maintained in the first position, and compressed air enters the three-in-one integrated air valve device through the air inlet on the air compressor side, and reaches the tail exhaust side air outlet through the bypass channel, where it mixes with the purge gas exhausted from the fuel cell stack to dilute the hydrogen concentration in the exhaust gas; In response to the completion of the purge, the fuel cell system enters a normal operating state, and the three-in-one integrated air valve device switches to a third position, at which time the bypass path is disconnected, and the stack air path and the stack air path are connected; During the operation of the fuel cell system, the operating conditions are monitored in real time through the air pressure and flow sensors in the fuel cell system. If surge of the air compressor is detected, the air compressor speed and air flow are increased, and the three-in-one integrated air valve device is controlled to switch to the second position, opening the bypass channel and directing excess air flow from the bypass channel to the exhaust part on the tail exhaust side to suppress surge. When the fuel cell system is ready to shut down and re-enter the stack purge step, the air compressor operates at the set purge speed, and the three-in-one integrated air valve device switches to the third position; After the purge process is completed, the air compressor continues to operate at the purge speed, and the three-in-one integrated air valve device switches back to the first position until the oxygen in the fuel cell stack is exhausted and the fuel cell system shuts down.

[0018] The above technical solution of the present invention has the following advantages over the prior art: The three-in-one integrated air valve device and control method for a fuel cell system described in the present invention integrates the stack shut-off valve structure, the stack shut-off valve structure and the bypass valve into an air valve device within a single valve body, and adopts a set of drive modules to realize the synchronous linkage of the above three valves, effectively simplifying the drive structure and the connection pipeline layout, thereby significantly improving the compactness of the system, reducing the overall volume and weight, and reducing manufacturing and installation costs.

[0019] The present invention achieves flexible switching and joint control of the inlet and outlet air paths, as well as the bypass path, through three position states: The first position closes the inlet and outlet air paths and opens the bypass path to meet system purge and hydrogen dilution requirements. The second position simultaneously connects all three paths, and the airflow distribution can be adjusted by adjusting the position of the inlet and outlet shutoff valve plates to adapt to different operating conditions, particularly useful for suppressing air compressor surge. The third position closes the bypass path and opens the inlet and outlet air paths, ensuring sufficient air flow for the normal operation of the fuel cell stack. This meets the diverse needs of the fuel cell system at different operating stages.

[0020] The stack entry and exit shutoff valve structures of the present invention are both butterfly valves, comprising a valve chamber, a front valve plate, a rear valve plate, a butterfly valve seal, a rear valve plate gasket, a valve stem, and other components. The valve chambers of the stack entry and exit shutoff valves are interconnected via a bypass channel. The front valve plate and the rear valve plate are connected to the valve stem back to back by bolts. The front valve plate and the butterfly valve seal can form a seal. The front valve plate can be flexibly selected to be a metal base material with a self-lubricating or wear-resistant coating, and the butterfly valve seal is a hard skeleton vulcanized sealing rubber, or the front valve plate adopts a metal skeleton, and the sealing rubber is vulcanized on the sealing surface, and the butterfly valve seal is changed to a metal sealing bushing with a sealing protrusion; the rear valve plate is provided with a rear valve plate sealing gasket, which cooperates with the flange on the end face of the bypass channel of the valve body to form a seal. A sealing gasket made of sealing rubber can be flexibly selected and bonded to the surface of the sealing side of the rear valve plate, or a wear-resistant or self-lubricating coating can be set on the rear valve plate, and a rubber sealing ring is vulcanized on the end face of the bypass channel to form a seal with the rear valve plate.

[0021] The present invention provides a sealing ring and a bearing between the valve stem and the valve body. The sealing ring is installed between the bearing and the valve cavity of the valve body to prevent gas from leaking from the valve cavity of the valve body. At the same time, it can prevent water in the gas from entering the bearing and between the bearing and the valve stem from the valve cavity and freezing at low temperatures to cause jamming.

[0022] The present invention provides a torsion spring in the drive module. When the drive motor fails or the power is cut off, the spring can automatically reset the valve plate of the stack shut-off valve and the stack exit shut-off valve to the first position (bypass open, stack entry and exit closed), ensuring that the system can still be safely purged or isolated under abnormal circumstances, preventing hydrogen leakage and system failure, and improving the safety and stability of the fuel cell system.

[0023] During the startup, purging, normal operation, operating condition change, and shutdown of the fuel cell system, the present invention controls the integrated air valve device to switch between three position states according to the control strategy and fuel cell operating parameters, and adjusts the position in the second position state to achieve shut-off control and bypass control of the air in and out of the fuel cell stack. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to make the contents of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments of the present invention in conjunction with the accompanying drawings.

[0025] Figure 1 It is a schematic diagram of the fuel cell air path system of the present invention.

[0026] Figure 2 It is a schematic diagram of the integrated air valve device and air passage of the present invention.

[0027] Figure 3 It is a top view of the integrated air valve device of the present invention.

[0028] Figure 4 yes Figure 3 Cross-sectional view along the AA direction.

[0029] Figure 5 yes Figure 4 Cross-sectional view along direction BB.

[0030] Figure 6 It is a schematic diagram of one side of the connection between the valve plates of the stack entry shut-off valve and the valve plates of the stack exit shut-off valve, the valve stem and the drive module of the present invention.

[0031] Figure 7 This is a schematic diagram of the other side of the connection between the valve plates of the stack entry shut-off valve and the valve plates of the stack exit shut-off valve, the valve stem and the drive module of the present invention.

[0032] Figure 8 This is a schematic diagram of the installation of the valve torsion spring of the present invention (for Figure 3 Cross-sectional view along CC direction).

[0033] Figure 9 It is a schematic diagram of the three-in-one integrated air valve device of the present invention when it is in the first position.

[0034] Figure 10 It is a schematic diagram of the three-in-one integrated air valve device of the present invention when it is in the second position.

[0035] Figure 11 It is a schematic diagram of the three-in-one integrated air valve device of the present invention when it is in the third position.

[0036] Figure 12 yes Figure 9 A partial enlarged schematic diagram of point C in the middle.

[0037] Figure 13 yes Figure 11 A local enlarged schematic diagram of point D in the middle.

[0038] Figure 14 It is a schematic diagram of another sealing structure between the rear valve plate and the end face of the bypass channel.

[0039] Figure 15 yes Figure 14 A partial enlarged schematic diagram of point E in the middle.

[0040] Figure 16 It is a schematic diagram of another sealing structure between the front valve plate and the butterfly valve seal.

[0041] Figure 17 yes Figure 16 A partial enlarged schematic diagram of point F in the middle.

[0042] Description of the accompanying drawings: 100, stack air inlet; 200, stack air outlet; 300, bypass; 400, air outlet on the air compressor side; 500, exhaust on the tail exhaust side; 600, fuel cell stack; 1. Valve body; 1-1, stack side air outlet; 1-2, stack side air inlet; 1-3, bypass channel; 1-4, compressor side air inlet; 1-5, tail exhaust side air outlet; 1-6, stack inlet shut-off valve cavity; 1-7, stack outlet shut-off valve cavity; 2. Drive module; 2-1. Drive motor; 2-2. Transmission gear set; 2-3. Cover plate; 3. Lower cover plate; 4. Butterfly valve seal; 5. Valve stem; 6a. Inlet shut-off valve plate; 6b. Outlet shut-off valve plate; 6. Front valve plate; 7. Rear valve plate; 8. Rear valve plate sealing gasket; 9. Lower cover plate sealing ring; 10. Valve stem sealing ring; 11. Valve stem bearing; 12. Torsion spring; 13. Bypass sealing ring; 14. Sealing bushing; 15. Front valve plate sealing ring. DETAILED DESCRIPTION

[0043] The present invention will be further described below with reference to the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it. However, the embodiments are not intended to limit the present invention.

[0044] In the present invention, if directions (up, down, left, right, front and back) are described, it is only for the convenience of describing the technical solution of the present invention, and does not indicate or imply that the technical features referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it cannot be understood as a limitation of the present invention.

[0045] In the present invention, "several" means one or more, "multiple" means more than two, "greater than," "less than," "exceeds," etc. are understood to exclude the number itself; "above," "below," "within," etc. are understood to include the number itself. In the description of the present invention, the use of "first" or "second" is solely for the purpose of distinguishing technical features and is not to be construed as indicating or implying relative importance, implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0046] In the present invention, unless otherwise expressly defined, terms such as "disposed," "installed," and "connected" should be interpreted broadly. For example, they may refer to direct connection or indirect connection through an intermediate medium; fixed connection or detachable connection or integral molding; mechanical connection or electrical connection or mutual communication; and internal connection between two components or interaction between two components. Those skilled in the art can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0047] Reference Figure 1 、 Figure 2 、 Figure 5 As shown, a three-in-one integrated air valve device for a fuel cell system of the present invention includes a valve body 1 and: The air compressor side air inlet 1-4 is used to connect to the air compressor side air outlet portion 400 of the fuel cell system; the air compressor side air inlet 1-4 is connected to the air outlet of the air compressor in the air compressor side air outlet portion 400 or the gas outlet of the intercooler. The air compressed by the air compressor is cooled by the intercooler and then enters the valve body 1 through the air compressor side air inlet 1-4; The stack-side air outlet 1-1 is connected to the air compressor-side air inlet 1-4 to form an air inlet path 100. The stack-side air outlet 1-1 is used to connect to the air inlet of the fuel cell stack 600. Compressed air leaves the valve body 1 through the stack-side air outlet 1-1 and enters the fuel cell stack 600 through the pipeline. The stack-side air inlet 1-2 is used to be connected to the air outlet of the fuel cell stack 600; the residual air from the reaction in the stack is discharged from the fuel cell stack 600 through the air outlet of the fuel cell stack 600 and enters the valve body 1 through the stack-side air inlet 1-2; The tail-side air outlet 1-5 is connected to the stack-side air inlet 1-2 to form an out-of-stack air path 200. The tail-side air outlet 1-5 is used to be connected to the tail-side exhaust portion 500 of the fuel cell system; the remaining air leaves the valve body 1 through the tail-side air outlet 1-5 and enters the tail-side exhaust portion 500 of the fuel cell system; The stack entry shutoff valve structure is provided on the stack entry air path 100 and includes a stack entry shutoff valve cavity 1-6 and a stack entry shutoff valve plate 6a rotatably connected to the stack entry shutoff valve cavity 1-6; The stack-out shut-off valve structure is provided on the stack-out air path 200 and includes a stack-out shut-off valve cavity 1-7 and a stack-out shut-off valve plate 6b rotatably connected to the stack-out shut-off valve cavity 1-7; A driving module 2 is used to drive the valve plate 6a of the stack entry shut-off valve and the valve plate 6b of the stack exit shut-off valve to rotate synchronously; The bypass passage 300 includes a bypass passage 1-3, both ends of which are connected to the stack entry shutoff valve cavity 1-6 and the stack exit shutoff valve cavity 1-7 respectively; Among them, the inlet and outlet at both ends of the bypass channel 1-3 are respectively located on the lower surface of the stack entry shut-off valve cavity 1-6 and the lower surface of the stack exit shut-off valve cavity 1-7, and are respectively connected to the air inlet 1-4 on the air compressor side and the air outlet 1-5 on the tail exhaust side. When the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b are rotated to different positions, the stack entry air path 100, the stack exit air path 200 and the bypass path 300 are controlled to be on and off.

[0048] Through this arrangement, the air valve assembly integrates the inlet and outlet shutoff valve structures, the outlet shutoff valve structure, and the bypass valve within a single valve body 1. A single drive module 2 is used to synchronize the three valves, effectively simplifying the drive structure and connecting piping layout. This significantly improves the system's compactness, reduces overall volume and weight, and lowers manufacturing and installation costs. It should be noted that the inlet air path 100 and the outlet air path 200 have identical structures and can therefore be interchanged depending on actual installation and usage.

[0049] In one embodiment, referring to Figure 5 As shown, the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b both include a front valve plate 6 and a rear valve plate 7 connected to each other; The front valve plates 6 of the stack entry shut-off valve plates 6a and the stack exit shut-off valve plates 6b respectively form butterfly valves with the corresponding stack entry shut-off valve cavities 1-6 and the stack exit shut-off valve cavities 1-7. The front valve plates 6 of the stack entry shut-off valve plates 6a and the stack exit shut-off valve plates 6b can respectively seal with the corresponding stack entry shut-off valve cavities 1-6 and the stack exit shut-off valve cavities 1-7 to correspondingly shut off the stack entry air path 100 and the stack exit air path 200. The rear valve plates 7 of the stack entry shut-off valve plates 6 a and the stack exit shut-off valve plates 6 b can respectively seal against the end faces of the bypass passage 1 - 3 to shut off the bypass passage 300 .

[0050] In one embodiment, referring to Figure 4 As shown, a lower cover plate 3 is installed at the bottom end of the valve body 1, and the bypass channel 1-3 is formed between the lower cover plate 3 and the valve body 1; a lower cover plate sealing ring 9 is provided between the lower cover plate 3 and the valve body 1.

[0051] In one embodiment, butterfly valve seals 4 are provided on the side walls of the stack entry shut-off valve cavity 1 - 6 and the stack exit shut-off valve cavity 1 - 7 to form a sealing structure with the front valve plate 6 .

[0052] In one embodiment, the front valve plate 6 is made of a metal base material (such as stainless steel or aluminum alloy) and is provided with a self-lubricating layer or a wear-resistant coating on the surface. The butterfly valve seal 4 matched therewith is made of a sealing rubber vulcanized with a hard skeleton; Or, refer to Figure 16 、 Figure 17 As shown, the front valve plate 6 utilizes a metal frame (e.g., stainless steel or aluminum alloy), with a layer of sealing rubber vulcanized on its sealing surface (using a vulcanization process that permanently bonds the rubber to the metal under high temperature and pressure), forming a front valve plate sealing ring 15. The butterfly valve seal 4 utilizes a metal sealing bushing 14 with a sealing protrusion structure on its sealing contact surface. This sealing protrusion creates a localized high contact pressure when in contact with the front valve plate sealing ring 15, significantly improving sealing performance and preventing air leakage while also reducing friction and wear areas and extending service life.

[0053] By adopting a butterfly valve seal 4 with a metal base front valve plate 6 plus a self-lubricating layer or a wear-resistant coating and a hard skeleton vulcanized sealing rubber, or adopting a structure in which a vulcanized rubber sealing ring of the front valve plate 6 is matched with a metal sealing bushing 14, the wear resistance, corrosion resistance and sealing reliability of the valve are greatly improved, ensuring stable air tightness under long-term operation, and reducing maintenance frequency and system failure rate.

[0054] In one embodiment, referring to Figure 14 、 Figure 15 As shown, the surface of the sealing side of the rear valve plate 7 is provided with a rear valve plate sealing gasket 8 made of sealing rubber, and the two end surfaces of the bypass channel 1-3 are provided with a circle of flanges, which can be pressed against the rear valve plate sealing gasket 8 to form a sealing structure; Alternatively, the surface of the sealing side of the rear valve plate 7 is provided with a wear-resistant layer or a self-lubricating coating, and the end face of the bypass channel 1-3 is provided with a bypass sealing ring 13, and the bypass sealing ring 13 is made of rubber and vulcanized to form a sealing structure with the rear valve plate 7.

[0055] By providing a rubber sealing gasket or a wear-resistant coating on the rear valve plate 7 and forming a vulcanized rubber sealing ring on the end face of the bypass channel 1-3, the bypass channel 1-3 maintains a good end face sealing effect during the opening and closing process, effectively preventing leakage and pressure loss, and ensuring the sealing reliability and system safety when the bypass channel 300 is switched.

[0056] In one embodiment, referring to Figure 6 As shown, the driving module 2 includes a driving motor 2-1, a transmission gear set 2-2 and a valve stem 5; a cover plate 2-3 covering the driving module 2 is installed on the valve body 1; The valve stem 5 is connected to the stack inlet shut-off valve plate 6a and the stack outlet shut-off valve plate 6b respectively; The driving end of the driving motor 2-1 is connected to the input end of the transmission gear set 2-2, and one end of the valve stem 5 extends out of the valve body 1 and is connected to the output end of the transmission gear set 2-2; the driving motor 2-1 drives the transmission gear set 2-2 and transmits the rotational power to the valve stem 5, so that the valve stem 5 drives the valve plate 6a of the stack shut-off valve and the valve plate 6b of the stack discharge shut-off valve to rotate synchronously.

[0057] In addition, the drive module 2 also includes a controller, a motor position sensor, a drive motor 2-1, and other components. The controller controls the motor's rotation based on commands from the fuel cell system, and the transmission gear set 2-2 is driven by the drive motor 2-1. By using a single drive module 2 to drive the synchronous movement of two butterfly valves (the inlet shut-off valve and the outlet shut-off valve), the inlet and outlet channels and bypass channels 1-3 are controlled together. This eliminates the need for multiple independent drive devices, reduces the number of motors, sensors, and transmission mechanisms, and significantly reduces overall size, weight, and cost. It should be noted that the drive module 2 can also employ other drive methods (such as motor-worm gear drive, pneumatic actuator drive, etc.), as long as they can achieve the aforementioned functions.

[0058] Specifically, refer to Figure 7 As shown, the front valve plate 6 and the rear valve plate 7 corresponding to the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b are connected back to back to the valve stem 5 by bolts (or welding). The structures of the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b are consistent and are distributed axially (in an array) along the valve stem 5.

[0059] Specifically, refer to Figure 8 As shown, a stem seal ring 10 and a stem bearing 11 are provided between the valve stem 5 and the valve body 1. The stem bearing 11 may include a rolling bearing, a sliding bearing, or other bearing device capable of achieving the same function. The stem seal ring 10 is installed between the stem bearing 11 and the valve cavity of the valve body 1. This prevents gas from leaking from the valve cavity of the valve body 1 and also prevents water in the gas from entering the stem bearing 11 and between the stem bearing 11 and the valve stem 5 from freezing at low temperatures, causing sticking.

[0060] In one embodiment, referring to Figure 8As shown, a torsion spring 12 is installed between the gear connected to the valve stem 5 in the transmission gear set 2-2 and the valve body 1. The upper and lower extensions of the torsion spring 12 are respectively inserted into the valve body 1 and the gear. The torsion spring 12 provides the force to rotate and reset the valve stem 5. When the transmission gear set 2-2 drives the valve stem 5 away from the preset reset angle, the torsion spring 12 twists, accumulating more elastic potential energy. When the system is powered off, the elastic potential energy of the torsion spring 12 is released, and the torsion spring 12 twists in the opposite direction, thereby driving the valve stem 5 to rotate back to the preset reset angle.

[0061] It is understood that torsion spring 12 constantly applies a rotational reset force to valve stem 5. When the system loses power, torsion spring 12 drives valve stem 5 to rotate, which in turn drives the two front valve plates 6 to rotate, achieving automatic reset. The provision of torsion spring 12 in drive module 2 automatically resets inlet and outlet shutoff valve plates 6a and 6b to their first position (bypass open, inlet and outlet closed) when drive motor 2-1 fails or loses power. This ensures that the system can still be safely purged or isolated under abnormal circumstances, preventing hydrogen leakage and system failure, and improving the safety and stability of the fuel cell system.

[0062] It should be noted that, referring to Figures 9 to 11 As shown, the three-in-one integrated air valve device has three position states: When in the first position, which is also the default position, the front valve plates 6 of the inlet shut-off valve plate 6a and the outlet shut-off valve plate 6b rotate to the sealing position, forming a seal with the corresponding inlet shut-off valve cavity 1-6 and the outlet shut-off valve cavity 1-7, respectively, thereby closing the inlet shut-off valve structure and the outlet shut-off valve structure; the rear valve plates 7 of the inlet shut-off valve plate 6a and the outlet shut-off valve plate 6b are at a 90-degree angle relative to the end face of the bypass channel 1-3, and do not form a seal with the end face of the bypass channel 1-3. At this time, the inlet air path 100 and the outlet air path 200 are disconnected, the bypass channel 1-3 is connected, and the bypass path 300 is connected.

[0063] When in the second position, the front valve plates 6 of the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b are separated from the sealing position, and the rear valve plates 7 of the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b are also separated from the end face of the bypass channel 1-3, and no seal is formed. At this time, the stack entry air path 100 and the stack exit air path 200 are connected, and the bypass channel 300 is connected; in the second position, the stack entry shut-off valve plate 6a and the stack exit shut-off valve plate 6b can swing at a certain angle according to working conditions to adjust the distribution of air flow in the stack entry air path 100, the stack exit air path 200 and the bypass channel 300 respectively, but the front valve plate 6 and the rear valve plate 7 will not contact the butterfly valve sealing ring, the end face of the bypass channel 1-3, etc.

[0064] When in the third position, the front valve plates 6 of the inlet shut-off valve plate 6a and the outlet shut-off valve plate 6b are separated from the sealing position and are 90 degrees relative to the sealing end faces of the corresponding inlet shut-off valve cavity 1-6 and the outlet shut-off valve cavity 1-7; the rear valve plates 7 of the inlet shut-off valve plate 6a and the outlet shut-off valve plate 6b are in contact with the end face of the bypass channel 1-3 to form a seal. At this time, the inlet air path 100 and the outlet air path 200 are connected, the bypass channel 1-3 is closed, and the bypass channel 300 is disconnected.

[0065] This embodiment also provides a control method for the three-in-one integrated air valve device for a fuel cell system based on the above-mentioned method. The fuel cell system includes a fuel cell stack 600, an air compressor side air outlet portion 400, and a tail exhaust side exhaust portion 500. The air compressor side air inlet 1-4 is connected to the air outlet of the air compressor side air outlet portion 400 or the gas outlet of the intercooler; the tail exhaust side air outlet 1-5 is connected to the air inlet of the tail exhaust side exhaust portion 500, the stack side air outlet 1-1 is connected to the air inlet of the fuel cell stack 600, and the stack side air inlet 1-2 is connected to the air outlet of the fuel cell stack 600. In addition, refer to Figure 1 As shown, the air compressor side outlet portion 400 further includes an air filter, and a flow sensor is provided between the air filter and the air compressor; a temperature sensor, a pressure sensor, and a flow sensor are provided on the pipe at the air inlet of the fuel cell stack 600, and a temperature sensor and a pressure sensor are provided on the pipe at the air outlet of the fuel cell stack 600; The control method includes: When the fuel cell system is in shutdown state, due to the action of the torsion spring 12, the three-in-one integrated air valve device is in a default position, that is, in a first position state; When the fuel cell system is started and enters the stack purge step, the air compressor operates at the set purge speed, the three-in-one integrated air valve device is maintained in the first position, and compressed air enters the three-in-one integrated air valve device through the air inlet 1-4 on the air compressor side, and reaches the tail exhaust side air outlet 1-5 through the bypass channel 1-3, and mixes with the purge gas exhausted from the fuel cell stack 600 to dilute the hydrogen concentration in the exhaust gas; In response to the completion of the purge, the fuel cell system enters a normal operating state, and the three-in-one integrated air valve device switches to the third position, at which time the bypass path 300 is disconnected, and the stack air path 100 and the stack air path 200 are connected; During the operation of the fuel cell system, the operating conditions are monitored in real time by the air pressure and flow sensors in the fuel cell system. If surge of the air compressor is detected, the air compressor speed and air flow are increased, and the three-in-one integrated air valve device is controlled to switch to the second position, opening the bypass channels 1-3, directly diverting the excess air flow and directing the excess air flow from the bypass channel 300 into the tail exhaust portion 500. The three-in-one integrated air valve device and the air compressor work together to suppress surge. When the fuel cell system is ready to shut down and re-enter the stack purge step, the air compressor operates at the set purge speed, and the three-in-one integrated air valve device switches to the third position; After the purge process is completed, the air compressor continues to operate at the purge speed, and the three-in-one integrated air valve device switches back to the first position until the oxygen in the fuel cell stack 600 is exhausted and the fuel cell system shuts down.

[0066] During the startup, purging, normal operation, operating condition change, and shutdown of the fuel cell system, the integrated air valve device is controlled to switch between three position states and adjust its position in the second position state according to the control strategy and fuel cell operating parameters, thereby realizing shut-off control and bypass control of the air in and out of the fuel cell stack.

[0067] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A three-in-one integrated air valve device for a fuel cell system, characterized in that: It comprises a valve body (1) and: An air compressor side air inlet (1-4) for connecting to an air compressor side air outlet portion (400) of a fuel cell system; The stack-side air outlet (1-1) is connected to the air compressor-side air inlet (1-4) to form an air inlet path (100), and the stack-side air outlet (1-1) is used to be connected to the air inlet of the fuel cell stack (600); The stack side air inlet (1-2) is used to be connected to the air outlet of the fuel cell stack (600); A tail-side air outlet (1-5) is connected to the stack-side air inlet (1-2) to form an out-of-stack air path (200); the tail-side air outlet (1-5) is used to be connected to a tail-side exhaust portion (500) of the fuel cell system; A stack entry shutoff valve structure is provided on the stack entry air path (100), comprising a stack entry shutoff valve cavity (1-6) and a stack entry shutoff valve plate (6a) rotatably connected to the stack entry shutoff valve cavity (1-6); A stack-out shutoff valve structure is provided on the stack-out air path (200), comprising a stack-out shutoff valve cavity (1-7) and a stack-out shutoff valve plate (6b) rotatably connected to the stack-out shutoff valve cavity (1-7); A driving module (2) for driving the valve plate (6a) of the stack entry shut-off valve and the valve plate (6b) of the stack exit shut-off valve to rotate synchronously; A bypass passage (300) comprises a bypass channel (1-3), wherein both ends of the bypass channel (1-3) are respectively connected to the stack entry shutoff valve cavity (1-6) and the stack exit shutoff valve cavity (1-7); The inlet and outlet at both ends of the bypass channel (1-3) are respectively located on the lower surface of the stack entry shut-off valve cavity (1-6) and the lower surface of the stack exit shut-off valve cavity (1-7), and are respectively connected to the air inlet (1-4) on the air compressor side and the air outlet (1-5) on the tail exhaust side. When the stack entry shut-off valve plate (6a) and the stack exit shut-off valve plate (6b) are rotated to different positions, the stack entry air path (100), the stack exit air path (200) and the bypass channel (300) are controlled to be on and off.

2. The three-in-one integrated air valve device for a fuel cell system according to claim 1, characterized in that: The stack entry shut-off valve plate (6a) and the stack exit shut-off valve plate (6b) both comprise a front valve plate (6) and a rear valve plate (7) that are connected; Wherein, the front valve plates (6) of the stack entry shut-off valve plates (6a) and the stack exit shut-off valve plates (6b) respectively form butterfly valves with the corresponding stack entry shut-off valve cavities (1-6) and the stack exit shut-off valve cavities (1-7); the front valve plates (6) of the stack entry shut-off valve plates (6a) and the stack exit shut-off valve plates (6b) can respectively seal and cooperate with the corresponding stack entry shut-off valve cavities (1-6) and the stack exit shut-off valve cavities (1-7) to correspondingly shut off the stack entry air path (100) and the stack exit air path (200); The rear valve plate (7) of the stack entry shut-off valve plate (6a) and the stack exit shut-off valve plate (6b) can respectively seal with the end faces of the bypass channel (1-3) to shut off the bypass channel (300).

3. The three-in-one integrated air valve device for a fuel cell system according to claim 2, characterized in that: Butterfly valve seals (4) are provided on the side walls of the stack entry shut-off valve cavity (1-6) and the stack exit shut-off valve cavity (1-7) to form a sealing structure with the front valve plate (6).

4. The three-in-one integrated air valve device for a fuel cell system according to claim 3, characterized in that: The front valve plate (6) is made of a metal base material and is provided with a self-lubricating layer or a wear-resistant coating on the surface, and the butterfly valve seal (4) matched therewith is made of a sealing rubber formed by vulcanization of a hard skeleton; Alternatively, the front valve plate (6) adopts a metal frame, and a layer of sealing rubber is vulcanized on its sealing surface to form a front valve plate sealing ring (15), and the butterfly valve seal (4) adopts a sealing bushing (14) made of metal material, and a sealing protrusion structure is provided on its sealing contact surface.

5. The three-in-one integrated air valve device for a fuel cell system according to claim 2, characterized in that: The surface of the sealing side of the rear valve plate (7) is provided with a rear valve plate sealing gasket (8) made of sealing rubber, and the two end surfaces of the bypass channel (1-3) are provided with a circle of flanges that can be pressed together with the rear valve plate sealing gasket (8) to form a sealing structure; Alternatively, the surface of the sealing side of the rear valve plate (7) is provided with a wear-resistant layer or a self-lubricating coating, and the end surface of the bypass channel (1-3) is provided with a bypass sealing ring (13), and the bypass sealing ring (13) is made of rubber and vulcanized to form a sealing structure with the rear valve plate (7).

6. The three-in-one integrated air valve device for a fuel cell system according to claim 1, characterized in that: The driving module (2) comprises a driving motor (2-1), a transmission gear set (2-2) and a valve stem (5); The valve stem (5) is respectively connected to the stack entry shut-off valve plate (6a) and the stack exit shut-off valve plate (6b); The driving end of the driving motor (2-1) is connected to the input end of the transmission gear set (2-2); one end of the valve stem (5) extends out of the valve body (1) and is connected to the output end of the transmission gear set (2-2); the driving motor (2-1) drives the transmission gear set (2-2) and transmits the rotational power to the valve stem (5), so that the valve stem (5) drives the valve plate (6a) of the stack entry shut-off valve and the valve plate (6b) of the stack exit shut-off valve to rotate synchronously.

7. The three-in-one integrated air valve device for a fuel cell system according to claim 6, characterized in that: A valve stem sealing ring (10) and a valve stem bearing (11) are provided between the valve stem (5) and the valve body (1), and the valve stem bearing (11) includes a rolling bearing and a sliding bearing; the valve stem sealing ring (10) is installed between the valve stem bearing (11) and the valve cavity of the valve body (1).

8. The three-in-one integrated air valve device for a fuel cell system according to claim 6, characterized in that: A torsion spring (12) is installed between the gear connected to the valve stem (5) in the transmission gear set (2-2) and the valve body (1), and the extensions at the upper and lower ends of the torsion spring (12) are respectively inserted into the valve body (1) and the gear. The torsion spring (12) can provide a force for the valve stem (5) to rotate and reset.

9. The three-in-one integrated air valve device for a fuel cell system according to claim 1, characterized in that: The three-in-one integrated air valve device has three positions: When in the first position, the front valve plates (6) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) rotate to the sealing position, respectively forming a seal with the corresponding stack entry shutoff valve cavity (1-6) and the stack exit shutoff valve cavity (1-7), thereby closing the stack entry shutoff valve structure and the stack exit shutoff valve structure; the rear valve plates (7) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) form a 90-degree angle with respect to the end face of the bypass channel (1-3), and do not form a seal with the end face of the bypass channel (1-3); at this time, the stack entry air path (100) and the stack exit air path (200) are disconnected, the bypass channel (1-3) is open, and the bypass path (300) is open; When in the second position, the front valve plates (6) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) are separated from the sealing position, and the rear valve plates (7) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) are also separated from the end surface of the bypass channel (1-3), and no seal is formed. At this time, the stack entry air path (100) and the stack exit air path (200) are connected, and the bypass path (300) is connected; When in the third position, the front valve plates (6) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) are separated from the sealing position and are 90 degrees relative to the sealing end faces of the corresponding stack entry shutoff valve cavity (1-6) and the stack exit shutoff valve cavity (1-7); the rear valve plates (7) of the stack entry shutoff valve plate (6a) and the stack exit shutoff valve plate (6b) are in contact with the end face of the bypass channel (1-3) to form a seal. At this time, the stack entry air path (100) and the stack exit air path (200) are connected, the bypass channel (1-3) is closed, and the bypass path (300) is disconnected.

10. A control method for a three-in-one integrated air valve device for a fuel cell system based on any one of claims 1 to 9, characterized in that: The fuel cell system comprises a fuel cell stack (600), an air compressor side air outlet portion (400) and a tail exhaust side exhaust portion (500), wherein the air compressor side air inlet (1-4) is connected to the air outlet of the air compressor side air outlet portion (400) or the gas outlet of the intercooler; the tail exhaust side air outlet (1-5) is connected to the air inlet of the tail exhaust side exhaust portion (500); the stack side air outlet (1-1) is connected to the air inlet of the fuel cell stack (600); and the stack side air inlet (1-2) is connected to the air outlet of the fuel cell stack (600); The control method includes: When the fuel cell system is in a shutdown state, the three-in-one integrated air valve device is in a first position state; When the fuel cell system is started and enters the stack purge step, the air compressor operates at a set purge speed, the three-in-one integrated air valve device is maintained in the first position, and compressed air enters the three-in-one integrated air valve device through the air inlet (1-4) on the air compressor side, and reaches the tail exhaust side air outlet (1-5) through the bypass channel (1-3), and is mixed with the purge gas discharged from the fuel cell stack (600), thereby diluting the hydrogen concentration in the exhaust gas; In response to the completion of the purge, the fuel cell system enters a normal operating state, and the three-in-one integrated air valve device switches to a third position state, at which time the bypass path (300) is disconnected, and the stack air path (100) and the stack air path (200) are connected; During the operation of the fuel cell system, the operating conditions are monitored in real time by air pressure and flow sensors in the fuel cell system. If surge is detected in the air compressor, the air compressor speed is increased and the air flow is increased. At the same time, the three-in-one integrated air valve device is controlled to switch to the second position, the bypass channel (1-3) is opened, and excess air flow is directed from the bypass channel (300) into the tail exhaust portion (500) to suppress the surge phenomenon. When the fuel cell system is ready to shut down and re-enter the stack purge step, the air compressor operates at the set purge speed, and the three-in-one integrated air valve device switches to the third position; After the purge process is completed, the air compressor continues to operate at the purge speed, and the three-in-one integrated air valve device switches back to the first position state until the oxygen in the fuel cell stack (600) is exhausted and the fuel cell system shuts down.

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