Hydrogen pressure reducer structure integrated with proportional valve for hydrogen fuel cell vehicle and method

Abstract

The invention relates to the field of hydrogen energy automobiles, and discloses a hydrogen pressure reducer structure and method for a hydrogen fuel cell vehicle integrated with a proportional valve, the hydrogen pressure reducer structure comprises a hydrogen pressure reducer and the proportional valve, and a pressure reducer valve body and a proportional valve body are provided with a bolt fixing platform; a gas input interface and a gas output interface between the two valve bodies are designed in a concave-convex mode and sealed through rubber rings, and meanwhile an exhaust interface is reserved at the gas inlet end of the proportional valve body. The method can adapt to variable working condition operation of the fuel cell stack.

Description

Technical Field

[0001] This invention relates to the field of hydrogen fuel cell vehicles, specifically to a hydrogen pressure regulator structure and method for hydrogen fuel cell vehicles with an integrated proportional valve. Background Technology

[0002] With the increasing global pursuit of environmental protection and sustainable energy, hydrogen fuel cell vehicles, as a highly efficient and clean new energy vehicle, have achieved remarkable development in recent years. Hydrogen fuel cell vehicles power the vehicle by directly converting the chemical energy of hydrogen and oxygen into electrical energy, with emissions consisting only of water, achieving near-zero pollution. This unique advantage makes hydrogen fuel cell vehicles one of the important development directions in the future transportation sector.

[0003] Among the key components of hydrogen fuel cell vehicles, the on-board hydrogen system plays a crucial role in ensuring the efficient and stable operation of the fuel cell system. The hydrogen pressure regulator and proportional control valve are core components for controlling hydrogen flow and pressure. In traditional on-board hydrogen systems, when the hydrogen fuel cell stack needs to operate under varying conditions (variable power), a proportional control valve is typically added at the rear end of the hydrogen pressure regulator pipeline and the front end of the fuel cell stack. This separate design makes the control piping extremely complex, increasing not only the system's construction cost and maintenance difficulty but also reducing the overall system's integration and reliability. More seriously, the complex piping connections significantly increase the risk of hydrogen leakage, posing a potential threat to vehicle safety.

[0004] This invention addresses the shortcomings of traditional technical solutions. By innovatively integrating the proportional control valve and the pressure reducer body into a single structure, it aims to provide a novel and cost-effective integrated pressure reducer solution. This solution not only effectively simplifies the control piping of the on-board hydrogen system and reduces system costs, but also significantly improves system integration and reliability, reduces the risk of hydrogen leakage, and thus provides strong support for the safe and efficient operation of hydrogen fuel cell vehicles. Summary of the Invention

[0005] The present invention aims to provide a hydrogen pressure regulator structure and method for hydrogen fuel cell vehicles with integrated proportional valve, so as to solve the problems of low integration and poor reliability of existing hydrogen pressure regulator structures.

[0006] To solve the above problems, the present invention adopts the following technical solution: Option 1: A hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve, comprising a hydrogen pressure regulator and a proportional valve, wherein a bolt fixing platform is designed between the pressure regulator body and the proportional valve body; the bolt fixing platform includes two symmetrical bolts set between the pressure regulator body and the proportional valve body and a positioning pin set between the two valve bodies; the gas input and output interfaces between the two valve bodies adopt a cylindrical concave-convex design and are sealed with sealing rings, while the gas inlet end of the proportional valve body is provided with an exhaust interface; both the pressure regulator body and the proportional valve body are made of high-strength stainless steel with a burst pressure greater than 200MPa.

[0007] Beneficial effects: This invention facilitates the installation and fixation of the two valve bodies via a bolt-fixing platform, providing a carrier for integrating the hydrogen pressure regulator and proportional valve. The concave-convex design combined with a rubber ring seal effectively prevents gas leakage, ensuring the system's airtightness. The exhaust port design can be used to discharge abnormal gases, ensuring the safe and stable operation of the system. The two-point symmetrical bolt fixing and locating pin design ensures the accuracy and stability of the two valve body installation, preventing valve body displacement or loosening during vehicle operation and ensuring reliable system operation.

[0008] Preferably, the pressure reducer is equipped with a safety unloading valve and a pressure sensor at the output end.

[0009] Beneficial effects: The safety unloading valve can automatically relieve pressure when the system pressure is too high, preventing the system from being damaged due to overpressure; the pressure sensor can monitor the pressure in real time and provide feedback data, which facilitates the system to accurately control and regulate the pressure.

[0010] Preferably, the pressure reducer has a maximum flow rate of 8 g / s.

[0011] Beneficial effects: A clearly defined maximum flow rate can meet the hydrogen flow requirements of specific hydrogen fuel cell vehicles under different operating conditions, ensuring that the system can operate stably under various circumstances.

[0012] Preferably, the pressure reducer adopts a two-stage pressure reduction design.

[0013] Beneficial effects: The two-stage pressure reduction design allows high-pressure hydrogen to be reduced to a suitable pressure more smoothly, improving the stability and accuracy of the pressure reduction process and better adapting to the hydrogen pressure requirements of fuel cell stacks.

[0014] Preferably, the proportional valve controls the opening range to be 0%-95%, corresponding to a flow rate range of 0%-100%.

[0015] Beneficial effects: A wider control range of opening and flow rate allows for flexible and precise adjustment of hydrogen flow rate to meet the precise hydrogen flow requirements of the hydrogen fuel cell stack under different operating conditions, thereby improving the operating efficiency of the fuel cell stack.

[0016] Preferably, the inner diameter of the cylindrical concave-convex interface for gas input and output between the two valve bodies is Ф6.0±0.1mm; the sealing ring is an "O" type rubber sealing ring with a cross-sectional dimension of Ф2.0±0.05mm and an outer diameter of Ф16.0±0.1mm.

[0017] Beneficial effects: Through the specific design of the cylindrical concave-convex interface between the two valve bodies and the sealing ring, not only can the existing hydrogen pressure regulator valve body and the existing proportional valve body be effectively integrated, but also many problems caused by integration, such as flow channel and pressure field, structural modularity and rigidity matching, and dynamic sealing, are overcome, so that the existing hydrogen pressure regulator can be integrated with the proportional valve to form a new hydrogen pressure regulator structure.

[0018] Option 2: A method for controlling a hydrogen pressure regulator in a hydrogen fuel cell vehicle with an integrated proportional valve, comprising the following steps: Step 1: Power on the vehicle. The on-board hydrogen system controller performs a self-test of the hydrogen supply system, including the hydrogen pressure regulator and proportional valve. If the self-test is normal, the hydrogen supply system will start. Step 2: The on-board hydrogen system controller opens the proportional valve integrated into the hydrogen pressure regulator based on the received hydrogen demand information. Step 3: Based on the hydrogen demand information and the output pressure of the pressure reducer, the on-board hydrogen system controller dynamically adjusts the proportional valve to ensure that the hydrogen flow rate meets the dynamic requirements of the fuel cell stack.

[0019] Preferably, during operation, if the on-board hydrogen system controller detects an abnormal outlet pressure of the pressure reducer, it will close the cylinder valve solenoid valve and the proportional valve solenoid valve, thus cutting off the hydrogen supply to the hydrogen supply system.

[0020] Preferably, during operation, if the on-board hydrogen system controller detects an abnormal increase in the outlet pressure of the pressure reducer, the safety unloading valve on the hydrogen pressure reducer will automatically open, and the gas will be depressurized from the pipeline after the safety unloading valve.

[0021] Working principle of the invention: High-pressure hydrogen enters the hydrogen pressure regulator through the high-pressure gas inlet. First, it passes through a safety unloading valve. When the system pressure abnormally rises above a set value, the safety unloading valve automatically opens to release pressure and protect the system. Next, the hydrogen undergoes two stages of pressure reduction within the pressure regulator, lowering its pressure to a range suitable for the fuel cell stack's operation. Pressure sensors monitor the hydrogen pressure at the pressure regulator's output in real time and feed the pressure signal back to the onboard hydrogen system controller.

[0022] Meanwhile, the on-board hydrogen system controller receives power demand signals from the fuel cell stack and related signals from the vehicle controller. Based on these signals, the controller adjusts the opening of the proportional valve by controlling the solenoid valve. When the opening of the proportional valve changes, the hydrogen flow rate changes accordingly. The low-pressure hydrogen, regulated by the proportional valve, is output from the low-pressure gas outlet and enters the fuel cell stack, thereby precisely meeting the fuel cell stack's hydrogen flow and pressure requirements under different operating conditions.

[0023] If abnormal gas accumulation occurs at the gas inlet of the proportional valve body, it can be discharged through the exhaust port to maintain a stable gas environment within the system.

[0024] Advantages of this invention: Novel structural design: It provides an innovative hydrogen pressure reducer structure that adapts to the variable operating conditions (variable power) of fuel cell stacks, breaking the limitations of traditional split design and providing new ideas and directions for the optimization of on-board hydrogen systems in hydrogen fuel cell vehicles.

[0025] Economical and efficient: The integrated design avoids the increased costs associated with adding an additional proportional control valve, including equipment procurement costs, installation costs, and maintenance costs due to complex piping, thus improving the system's economic efficiency.

[0026] Ensuring efficient operation of the fuel cell stack: It can maximize the accuracy of hydrogen flow and pressure requirements during variable operating conditions of the fuel cell stack, improve the operating efficiency of the fuel cell stack, and thus enhance the overall performance of the hydrogen fuel cell vehicle.

[0027] High integration and modularity: The product design is simpler, with a higher degree of integration and modularity, reducing the number of system components and connecting pipelines, reducing system complexity, improving system reliability and stability, and also facilitating later maintenance and repair. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the hydrogen pressure regulator for hydrogen fuel cell vehicles with integrated proportional valve in this invention.

[0029] Figure 2 This is a schematic diagram of the hydrogen flow control process of the hydrogen pressure regulator structure for hydrogen fuel cell vehicles with integrated proportional valve in this invention.

[0030] The reference numerals in the accompanying drawings are as follows: 1-High-pressure gas inlet, 2-Safety unloading valve, 3-Hydrogen pressure reducer, 4-Pressure sensor, 5-Fixing bolt, 6-Positioning pin, 7-Sealing boss, 8-Sealing ring, 9-Solenoid valve, 10-Exhaust port, 11-Proportional valve, 12-Low-pressure gas outlet, 13-On-board hydrogen system controller. Detailed Implementation

[0031] The following detailed description illustrates the specific implementation method: The basic features of this invention are as follows: Figure 1 As shown: This invention patent discloses a structural design for a hydrogen pressure regulator for a hydrogen fuel cell vehicle with an integrated proportional valve. It includes a high-pressure gas inlet 1, a safety unloading valve 2, a hydrogen pressure regulator 3, a pressure sensor 4, fixing bolts 5, locating pins 6, a sealing boss 7, a sealing ring 8, a solenoid valve 9, an exhaust port 10, a proportional valve 11, a low-pressure gas outlet 12, and an on-board hydrogen system controller 13. The high-pressure gas inlet 1, safety unloading valve 2, and pressure sensor 4 are designed on the hydrogen pressure regulator 3. The solenoid valve 9, exhaust port 10, and low-pressure gas outlet 12 are designed on the proportional valve 11. The hydrogen pressure regulator 3 is assembled with the proportional valve 11 via fixing bolts 5, locating pins 6, sealing bosses 7, and sealing rings 8. The on-board hydrogen system controller 13 is responsible for data storage, processing, and valve actuation. It receives relevant signals (such as the power demand signal of the fuel cell stack, the pressure signal of the pressure sensor 4, and relevant signals of the vehicle controller) and controls the opening of the proportional valve 11 through the solenoid valve 9, thereby precisely controlling the flow of hydrogen to meet the operating requirements of hydrogen fuel cell new energy vehicles under various working conditions.

[0032] The hydrogen flow control process of the hydrogen pressure regulator structure for hydrogen fuel cell vehicles with integrated proportional valve in this invention is as follows: Figure 2 As shown, firstly, the vehicle is powered on, and the on-board hydrogen system controller performs a self-test of the hydrogen supply system (including the hydrogen pressure regulator and proportional valve). If the self-test is normal, the electronic valves such as the cylinder valve and solenoid valve of the hydrogen supply system are activated to prepare for hydrogen supply. Except for the hydrogen pressure regulator structure for hydrogen fuel cell vehicles with the integrated proportional valve of this invention, the other connecting components, connecting pipes, valves, etc., in the hydrogen supply system described in this paper all adopt existing technology products. That is, the hydrogen pressure regulator structure of this invention can be adapted to existing hydrogen supply systems and can directly replace the hydrogen pressure regulator and proportional valve in existing hydrogen supply systems for use.

[0033] The second step involves the on-board hydrogen system controller opening the proportional valve integrated into the pressure reducer based on the hydrogen demand information transmitted from the vehicle and the fuel cell stack.

[0034] The third step involves dynamically adjusting the proportional valve based on the hydrogen demand information and the output pressure of the pressure reducer to ensure that the hydrogen flow rate meets the dynamic requirements of the fuel cell stack (vehicle).

[0035] During operation, if the on-board hydrogen system controller of the hydrogen supply system detects an abnormal hydrogen concentration (greater than 1000 PPM), it will close the cylinder valve solenoid valve and the proportional valve solenoid valve, cutting off the gas supply.

[0036] During operation, if the on-board hydrogen system controller detects an abnormal outlet pressure from the pressure regulator, it will also close the cylinder valve solenoid valve and the proportional valve solenoid valve, cutting off the hydrogen supply. An abnormal outlet pressure refers to a pressure exceeding or falling below the set pressure by 10%. For example, an output pressure within the range of 1.5 ± 0.15 MPa is normal; anything outside this range is considered an abnormal outlet pressure.

[0037] During operation, if the on-board hydrogen system controller of the hydrogen supply system detects an abnormal increase in the outlet pressure of the pressure regulator, the safety unloading valve on the pressure regulator will automatically open, and the gas will be depressurized from the pipeline after the safety unloading valve. The hydrogen pressure regulator integrated in this invention is an existing structure. The new hydrogen pressure regulator structure that integrates the existing hydrogen pressure regulator and proportional valve is unique to this invention. However, the hydrogen pressure regulator used for integration is an existing product, and its safety unloading valve and other structures are also existing structures.

[0038] During operation, if the on-board hydrogen system controller of the hydrogen supply system receives an alarm for an abnormal situation from the fuel cell stack or the vehicle, it will close the cylinder valve solenoid valve and the proportional valve solenoid valve to cut off the hydrogen supply.

[0039] In this invention, the pressure regulator valve body and the proportional valve body are made of high-strength stainless steel with a burst pressure greater than 200MPa; the pressure regulator valve body and the proportional valve body can be made of low-nickel 316L stainless steel, which is not only corrosion resistant, but also effectively prevents hydrogen embrittlement, greatly improving the safety and reliability of the product, and its performance and service life are far superior to similar products.

[0040] The gas input and output interfaces between the two valve bodies adopt a cylindrical concave-convex design and are sealed with rubber sealing rings; the inner diameter of the cylindrical concave-convex interfaces between the two valve bodies is Ф6.0±0.1mm; the sealing ring is an "O" ring with a cross-sectional dimension of Ф2.0±0.05mm and an outer diameter (major diameter) of Ф16.0±0.1mm; the sealing ring is made of nitrile rubber with a hardness of HA90±5.

[0041] Compared to existing technologies, where hydrogen pressure regulators and proportional valves are typically designed as independent components, their working principles, performance requirements, and structural characteristics differ significantly. Simply assembling them can lead to a series of problems: 1. Pressure matching conflict The core function of the pressure reducer is to progressively reduce high-pressure hydrogen (e.g., 30 MPa) to the low pressure required by the fuel cell stack (typically 0.1-0.5 MPa). Its internal flow channels and valve designs must adapt to drastic pressure changes to ensure stable pressure reduction. Meanwhile, the proportional valve needs to precisely control the flow rate in the low-pressure range (responding to the power demands of the fuel cell stack), requiring extremely high inlet pressure stability. If simply integrated, even minor fluctuations in the pressure reducer's outlet pressure can directly interfere with the proportional valve's flow control accuracy, leading to unstable hydrogen supply to the fuel cell stack.

[0042] 2. Sealing and leakage risks Hydrogen is a highly flammable and explosive gas that is prone to leakage. The connection between the pressure regulator and the proportional valve must withstand the alternating effects of high pressure (pressure regulator side) and low pressure (proportional valve side), and the gas flow interface dimensions and shapes of the two are different. Simply using conventional flange or threaded connections cannot solve the dynamic sealing problem under different pressure levels, and the seal is easily damaged by vibration and temperature changes, leading to safety hazards.

[0043] 3. Insufficient structural compatibility Pressure regulators (especially two-stage pressure regulator designs) are typically large, containing elastic components such as springs and diaphragms, requiring sufficient space for pressure feedback regulation. Proportional valves, on the other hand, require the integration of electromagnetic drive components (such as solenoid valves) and precision valve cores, placing even higher demands on the precision of the installation space. The two types of valves differ significantly in their structural layout and weight distribution; simple integration would result in an excessively large overall size, assembly interference, or vibration transmission affecting the control accuracy of the proportional valve.

[0044] 4. Control logic disconnect The pressure reduction process of the pressure reducer relies on mechanical feedback (such as a diaphragm sensing the outlet pressure and adjusting the valve opening), while the proportional valve needs to dynamically adjust its opening via electrical signals (such as the PWM signal of the on-board hydrogen system controller). In the existing technology, the control of the two is independent. Simple integration cannot achieve the coordination of "pressure reduction stability" and "dynamic flow response". It is possible that the proportional valve will actuate before the pressure reducer is stable, resulting in uncontrolled hydrogen supply parameters.

[0045] This invention is not a simple assembly; rather, it resolves the aforementioned contradictions through targeted design. Its technical difficulty lies in: 1. Co-design of flow channels and pressure fields To prevent pressure fluctuations from affecting the proportional valve, this invention precisely designs the transition channel between the two (e.g., using a sealing boss 7 with a concave-convex fit). Pressure fluctuations are buffered through optimized channel shape (gradually expanding structure) while minimizing gas flow resistance. This requires balancing pressure reduction efficiency with flow control accuracy, rather than simply opening up the channel.

[0046] 2. Breakthrough in dynamic sealing technology To address the sealing challenges under alternating high and low pressure environments, this invention employs a "concave-convex design + rubber ring seal" (seal ring 8), along with a locating pin 6 to ensure assembly precision. This allows the connection to withstand high-pressure impacts from the pressure reducer side while maintaining low-pressure sealing on the proportional valve side. The selection of the rubber ring material (resistant to hydrogen embrittlement and high / low temperatures) and the compression design (to prevent overpressure deformation or insufficient sealing) are targeted technological innovations.

[0047] 3. Modular structure and rigidity matching This invention achieves a rigid connection between the two components through "two-point symmetrical bolt fixing" (fixing bolt 5) and locating pin 6, ensuring the stability of the overall structure under vehicle vibration conditions while preventing deformation of the pressure reducing diaphragm or proportional valve core due to excessive rigidity. Optimizing these structural parameters (bolt preload of 45±2 N.M, locating pin tolerance of ±0.05 mm) requires a combination of mechanical simulation and real-vehicle testing, making it far more challenging than designing individual components.

[0048] 4. Coordinated integration of control logic This invention achieves coordinated control of the pressure reducer and proportional valve through the on-board hydrogen system controller 13: the pressure sensor 4 provides real-time feedback on the pressure reducer outlet pressure, and the controller only drives the proportional valve 11 to operate after the pressure reducer has stabilized, while simultaneously expelling abnormal gas quickly through the exhaust port 10. This "pressure reduction-stabilization-flow regulation" timing control logic requires solving the matching problem of the response speeds of the two (e.g., the pressure reducer's mechanical response is slow vs. the proportional valve's electromagnetic response is fast), representing a cross-component system-level control innovation.

[0049] This invention breaks with the technological inertia of "independent design." In the prior art, pressure reducers and proportional valves have long been developed as independent components, with the industry generally believing that "separate design makes it easier to ensure their respective performance." However, this invention proposes an "integrated" approach, which is itself a breakthrough in traditional understanding. This breakthrough is not a simple "combination," but rather a creative breakthrough based on a deep understanding of the working mechanisms of both components, finding compatible solutions (such as flow channel buffering and rigid matching).

[0050] This invention solves the problem of synergistic optimization of "contradictory parameters". Integrated designs often contain multiple conflicting parameters (such as high-pressure sealing versus low-pressure control, and structural compactness versus flow resistance). This invention, through a combination of "convex and concave seals + locating pins + symmetrical fixing", simultaneously satisfies the requirements for sealing performance, rigidity, and assembly precision. This solution cannot be derived through conventional technical means and requires creative thinking.

[0051] This invention achieves a system gain of "functionality 1+1>2". In the prior art, the pipeline connection of independent components increases leakage points and pressure loss, while the integrated design of this invention not only reduces pipelines (improving safety), but also improves the hydrogen supply response speed through coordinated control (such as reducing gas lag caused by pipeline cavities). The system-level performance improvement brought about by this "structural integration + control coordination" exceeds the expected effect of simple combination and is non-obvious.

[0052] Example 1 The hydrogen pressure regulator structure for hydrogen fuel cell vehicles with integrated proportional valves is illustrated in this invention. Taking a certain model of hydrogen fuel cell vehicle as an example, its onboard hydrogen system adopts the hydrogen pressure regulator structure with integrated proportional valves of this invention. The maximum flow rate of the hydrogen pressure regulator is designed to be 8 g / s, which can meet the hydrogen flow requirements of this vehicle under high-power conditions such as high-speed driving and acceleration. The pressure regulator adopts a two-stage pressure reduction design. The first-stage pressure reduction reduces the high-pressure hydrogen from 35 MPa to 10 MPa, and the second-stage pressure reduction further reduces the pressure to 3 MPa to match the operating pressure range of the fuel cell stack.

[0053] The pressure regulator valve body and the proportional valve body are fixed together by two symmetrical bolts, and locating pins ensure accurate installation of the two valve bodies. The concave-convex design of the gas input and output interfaces between the two valve bodies, combined with rubber ring seals, has undergone rigorous airtightness testing. At a working pressure of 30MPa, the gas leakage rate is lower than the industry standard. .

[0054] The proportional valve controls the opening range of 0%-95%. In actual testing, when the opening is 0%, the hydrogen flow rate is 0; when the opening is 40%, the hydrogen flow rate is 40% of the rated flow rate; and when the opening is 95%, the hydrogen flow rate is close to 100% of the rated flow rate. It can accurately adjust the hydrogen flow rate according to the instructions of the on-board hydrogen system controller.

[0055] The safety unloading valve is set to a pressure of 32 MPa. When the system pressure rises to 32 MPa due to abnormal conditions, the safety unloading valve quickly opens to relieve pressure and ensure system safety. The pressure sensor has an accuracy of ±0.1%FS, accurately feeding back the hydrogen pressure at the pressure reducer output to the on-board hydrogen system controller in real time. Based on the pressure signal and other input signals, the controller precisely controls the opening of the proportional valve through the solenoid valve to achieve stable control of hydrogen flow and pressure.

[0056] Example 2 The hydrogen pressure regulator control method for hydrogen fuel cell vehicles with integrated proportional valves is described. During the actual operation of a hydrogen fuel cell vehicle, when the vehicle starts and accelerates, the power demand signal of the fuel cell stack increases rapidly. After receiving this signal change, the on-board hydrogen system controller quickly calculates and adjusts the opening of the proportional valve within 50ms, so that the hydrogen flow rate increases rapidly to meet the hydrogen demand for the increased power of the fuel cell stack, and the vehicle accelerates smoothly and quickly.

[0057] During vehicle operation, pressure sensors monitor the hydrogen pressure at the pressure reducer output in real time. When slight pressure fluctuations occur, the on-board hydrogen system controller fine-tunes the proportional valve opening based on the feedback signal from the pressure sensor. For example, when the pressure increases by 0.05 MPa, the controller reduces the proportional valve opening by 2%, allowing the hydrogen pressure to quickly stabilize and ensuring that the fuel cell stack operates efficiently under stable hydrogen pressure and flow conditions.

[0058] In the event of an emergency such as a collision, the vehicle controller sends a relevant signal to the on-board hydrogen system controller. The controller immediately controls the solenoid valve to close the proportional valve and simultaneously triggers the safety unloading valve to quickly discharge hydrogen from the system, ensuring the safety of the vehicle and its occupants.

[0059] Compared with the prior art, the present invention has the following advantages: Innovative Structural Design: Traditional technologies separate the hydrogen pressure regulator and proportional control valve, resulting in complex piping, high costs, and low reliability. This invention innovatively integrates both. This integrated structural design is not merely a simple combination of components, but rather fully considers factors such as gas flow characteristics, sealing requirements, and installation methods. Through unique valve body design, interface sealing design, and fixing method design, it achieves structural optimization and functional integration. No similar innovative design approach has been found in existing technologies.

[0060] Optimized Control Method: The control method of this invention is based on the comprehensive processing of multiple signals. Through real-time acquisition and analysis of power demand signals from the fuel cell stack, pressure sensor signals, and relevant signals from the vehicle controller via the onboard hydrogen system controller, the proportional valve opening is precisely controlled to achieve dynamic adjustment of hydrogen flow. This multi-signal fusion control strategy differs significantly from traditional single or few-signal control methods. It can more comprehensively and accurately adapt to the complex and changing operating conditions of vehicles, and has obvious advantages in improving system response speed and control accuracy. This is not something that those skilled in the art could easily conceive of based on existing technology.

[0061] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve, characterized in that, The device includes a hydrogen pressure regulator and a proportional valve. A bolt fixing platform is designed between the pressure regulator body and the proportional valve body. The bolt fixing platform includes two symmetrical bolts set between the pressure regulator body and the proportional valve body, and a locating pin set between the two valve bodies. The gas input and output interfaces between the two valve bodies adopt a cylindrical concave-convex design and are sealed with sealing rings. At the same time, an exhaust interface is reserved at the gas inlet end of the proportional valve body. Both the pressure regulator body and the proportional valve body are made of high-strength stainless steel with a burst pressure greater than 200MPa.

2. The hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 1, characterized in that, The pressure reducer is equipped with a safety unloading valve and a pressure sensor at the output end.

3. The hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 1, characterized in that, The pressure reducer has a maximum flow rate of 8 g / s.

4. The hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 1, characterized in that, The pressure reducer adopts a two-stage pressure reduction design.

5. The hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 1, characterized in that, The proportional valve controls the opening range of 0%-95%, corresponding to a flow rate range of 0%-100%.

6. The hydrogen pressure regulator structure for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 1, characterized in that, The inner diameter of the cylindrical concave-convex interface for gas input and output between the two valve bodies is Ф6.0±0.1mm; the sealing ring is an "O" type rubber sealing ring with a cross-sectional dimension of Ф2.0±0.05mm and an outer diameter of Ф16.0±0.1mm.

7. A method for controlling a hydrogen pressure regulator in a hydrogen fuel cell vehicle with an integrated proportional valve, characterized in that, The hydrogen pressure regulator structure for hydrogen fuel cell vehicles, applicable to the integrated proportional valve as described in claim 1, includes the following steps: Step 1: Power on the vehicle. The on-board hydrogen system controller performs a self-test of the hydrogen supply system, including the hydrogen pressure regulator and proportional valve. If the self-test is normal, the hydrogen supply system will start. Step 2: The on-board hydrogen system controller opens the proportional valve integrated into the hydrogen pressure regulator based on the received hydrogen demand information. Step 3: Based on the hydrogen demand information and the output pressure of the pressure reducer, the on-board hydrogen system controller dynamically adjusts the proportional valve to ensure that the hydrogen flow rate meets the dynamic requirements of the fuel cell stack.

8. The method for controlling a hydrogen pressure regulator for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 7, characterized in that, During operation, if the on-board hydrogen system controller detects an abnormal outlet pressure of the pressure reducer, it will close the cylinder valve solenoid valve and the proportional valve solenoid valve, thus cutting off the hydrogen supply to the hydrogen supply system.

9. A method for controlling a hydrogen pressure regulator for a hydrogen fuel cell vehicle with an integrated proportional valve according to claim 8, characterized in that, During operation, if the on-board hydrogen system controller detects an abnormal increase in the outlet pressure of the pressure regulator, the safety unloading valve on the hydrogen pressure regulator will automatically open, and the gas will be depressurized from the pipeline after the safety unloading valve.

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