Integrated streamlined hydrogenation gun capable of real-time monitoring and flow regulation and control method

Abstract

The application provides an integrated streamlined hydrogen filling gun capable of real-time monitoring and flow regulation and a control method, relates to the field of high-pressure hydrogen filling of a hydrogen storage system of a hydrogen fuel cell vehicle, and comprises a main valve body, a stop valve, a first filter, a redundant one-way valve, a flow regulating valve, a second filter, a temperature sensor, a pressure sensor and a flow sensor. The temperature sensor is used for monitoring the temperature T in the valve body in real time. When T < T1, the pressure sensor is started to monitor the real-time pressure. When T1 <= T < T2, cooling is started until T < T1. When the real-time pressure P < P1, the flow sensor is started to monitor the pre-filling flow. When the pre-filling flow Q is in a first flow threshold range, hydrogen is filled at a first flow. When P1 <= P < P2, hydrogen is filled at a second flow. When P2 <= P < P3, hydrogen is filled at a third flow. When P = P3, the stop valve is closed to stop hydrogen filling. The hydrogen filling gun adopts a streamlined valve body, has high integration, can adapt to filling requirements of multiple pressure grades, and is safe and efficient.

Description

Technical Field

[0001] This invention relates to the field of high-pressure hydrogen refueling in hydrogen storage systems for hydrogen fuel cell vehicles, specifically to an integrated streamlined hydrogen refueling gun and control method capable of real-time monitoring and flow regulation. Background Technology

[0002] Hydrogen, a highly permeable and diffusive, flammable and explosive colorless gas, possesses extremely small molecular size and very low density, placing stringent requirements on sealing and material compatibility. In high-pressure rapid hydrogen refueling systems, the hydrogen refueling nozzle connects upstream to the hydrogen storage system or hydrogen dispenser at the refueling station and downstream to the on-board hydrogen storage system, serving as the core hub for regulating refueling pressure and flow. Therefore, in the field of high-pressure hydrogen refueling for hydrogen fuel cell vehicle storage systems, rapid refueling technology is a key support for improving the user refueling experience and overcoming the core bottlenecks in the commercialization of hydrogen fuel cell vehicles. It was developed to address extreme challenges such as high pressure, high speed, zero leakage, overcharge prevention, wide temperature range, standardized communication, and compact integration. Its core technology lies in the optimized design of the flow channel, the high integration of functions, the adaptability of materials to extreme operating conditions, and the seamless coordination of the intelligent refueling control system.

[0003] Users expect hydrogen refueling time to be comparable to the 3-5 minutes required for refueling a traditional gasoline vehicle. However, rapid refueling implies extremely high instantaneous mass flow rates, typically ranging from 1.5 kg / min to 5 kg / min or higher. High flow rates generate a significant Joule-Thomson effect, causing a rapid increase in hydrogen temperature, potentially exceeding the safe temperature limits of the onboard hydrogen storage tank, posing a safety risk. Simultaneously, the high-speed airflow causes significant erosion, vibration, and noise issues for valves and pipelines.

[0004] In terms of pressure management and safety, the pressure of hydrogen refueling station storage cylinders is typically much higher than the pressure of empty cylinders on vehicles, requiring precise control of the refueling pressure curve. Overcharging must be prevented to ensure absolute safety. Pressure and temperature need to be monitored in real time during refueling, with feedback control implemented. Instantaneous and reliable shut-off is required upon completion of refueling or in emergencies. High-pressure hydrogen places extremely high demands on valve sealing, material strength, and fatigue life. Any leakage could potentially cause a fire or explosion. Traditional valves struggle to guarantee zero leakage under rapid opening and closing and high pressure differentials.

[0005] In terms of temperature management, rapid refueling leads to temperature rise issues. Strategies are needed to manage this temperature rise, such as pre-cooling hydrogen, controlling the refueling rate, or a combination of both. Combination valves need to integrate temperature sensors and be able to adjust flow rates in conjunction with the refueling control system. Simultaneously, the valve materials and seals themselves need to withstand alternating extremely low and extremely high temperature shocks.

[0006] In terms of space constraints and integration, the internal space of a hydrogen refueling unit is limited, requiring a compact design. Integrating multiple functions such as connection, on / off, one-way, filtration, pressure measurement, temperature measurement, and communication into a single valve block is an inevitable trend. Integrating multiple functional components within a confined space while ensuring their respective performance, reliability, and ease of maintenance presents significant design challenges. Optimization of flow path design is necessary to reduce pressure drop and dead volume.

[0007] However, early or traditional high-pressure hydrogen refueling solutions for hydrogen fuel cell vehicles have several shortcomings, mainly in the following aspects:

[0008] First, multiple independent valves are used, connecting gate valves, check valves, safety valves, and pressure / temperature sensors via pipelines. This results in large size, numerous leakage points, large pressure drop, slow response, high cost, and complex installation and maintenance.

[0009] Second, early filling valves may have only focused on connection and on / off, lacking the ability to monitor temperature and pressure, communicate, or adjust and match flow in real time.

[0010] Third, under extreme conditions of rapid opening and closing, high pressure differential, high flow rate, and large temperature difference, the sealing life and operational reliability of traditional valves are difficult to guarantee. Furthermore, it is difficult to integrate the real-time data acquisition and flow control required to achieve the complex filling strategies stipulated in standard protocols.

[0011] Fourth, the filling process is qualitatively controlled rather than quantitatively optimized: valve switching relies on a preset fixed pressure threshold and cannot dynamically adjust parameters based on real-time temperature and pressure data, resulting in low filling efficiency or excessive safety redundancy;

[0012] Fifth, insufficient collaborative execution capability: The action of a single valve lacks linkage logic with the precooling unit and check valve. When dealing with temperature exceeding the limit or pressure change, it can only trigger passive protection such as emergency stop or lockout, interrupting the filling process.

[0013] While existing research has proposed multi-objective optimization models combining precooling energy consumption, refueling time, and hydrogen filling rate, and employs improved particle algorithms to generate pressure switching coefficients and precooling temperature parameters, the optimization results are difficult to directly map onto the real-time control of the combined valve system. For example, the response delay of traditional solenoid valves cannot match the millisecond-level scenario mitigation requirements of Monte Carlo simulations, and the discrete actions of flow control valves cannot achieve a continuous and smooth transition in refueling rate. Therefore, there is an urgent need for a hydrogen refueling gun control method that integrates valve collaborative scheduling, dynamic parameter feedback, and rapid execution response to overcome the industry challenge of balancing safety and efficiency. Summary of the Invention

[0014] To address the shortcomings of existing technologies, this invention aims to provide an integrated streamlined hydrogen refueling nozzle and control method capable of real-time monitoring and flow regulation. This integrated streamlined hydrogen refueling nozzle integrates the refueling connector, shut-off valve, check valve, filter, pressure sensor, temperature sensor, communication module, and flow regulating valve into a compact valve block, significantly reducing the combined valve size. It eliminates redundant piping and interfaces of traditional distributed valve assemblies, reducing volume by over 40%. The internal flow channels of the hydrogen refueling nozzle are meticulously designed to minimize pressure drop, avoid dead zones, and optimize flow conditions to reduce turbulence and temperature rise, while ensuring strength and sealing. Integrated sensors within the valve body provide real-time data, interacting with the hydrogen refueling machine's main control system via the communication module to achieve closed-loop control, adjusting pre-cooling temperature and controlling the refueling rate to ensure the fastest possible refueling within a safe range. The shut-off valve is designed for rapid opening and closing, achieving millisecond-level operation, and employs redundant sealing to ensure zero leakage even after millions of cycles. The control method employs a graded triggering system based on the hydrogen storage tank pressure, implementing three levels of flow regulation: when both temperature and pressure are below the safety threshold, a rapid first-flow refueling is initiated; when the pressure approaches the target value, it automatically switches to a second-flow refueling and then a third-flow fine-matching refueling. For temperature safety, if the maximum safety threshold is exceeded, refueling is immediately cut off; if the temperature is near the critical value, a cooling program is immediately initiated. Through multi-valve collaborative control and multi-sensor linkage, combined with real-time feedback from the pressure reducing valve outlet pressure, the system can dynamically and accurately match and optimize the refueling rate, achieving adaptive flow regulation. This method significantly improves refueling efficiency while effectively preventing the risk of combustion and explosion, ensuring the safety and accuracy of the high-pressure hydrogen refueling process.

[0015] In a first aspect, the present invention provides an integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation, comprising a main valve body, a shut-off valve, a first filter, a redundant check valve, a flow regulating valve, a second filter, a temperature sensor, a pressure sensor, a flow sensor, a hydrogen inlet, a hydrogen outlet, a first channel, a second channel, and a third channel; the shut-off valve and the redundant check valve are disposed at the inlet of the main valve body, the first filter is integrated inside the redundant check valve, and the flow regulating valve and the second filter are disposed at the outlet of the main valve body in the first channel of the main valve body; the redundant check valve and the flow regulating valve are both embedded inside the main valve body, the hydrogen inlet is disposed at the inlet of the shut-off valve, and the hydrogen outlet is disposed at the outlet of the second filter;

[0016] The shut-off valve, redundant check valve, main valve body, flow regulating valve, and second filter are all sealed together to form a valve body structure with a streamlined first flow channel;

[0017] The hydrogen refueling gun achieves adaptive regulation of hydrogen refueling at multiple pressure levels through a three-level coordinated control mechanism of temperature, pressure and flow. Based on the real-time monitoring value P of the pressure sensor, the refueling process is divided into three levels of flow control. When P < P1, pre-filling flow monitoring is started and refueling is carried out at the first flow rate Q1. When P1 ≤ P < P2, refueling is carried out at the second flow rate Q2. When P2 ≤ P < P3, it switches to the third flow rate Q3. When P = P3, it automatically stops.

[0018] First, the temperature sensor monitors the temperature T inside the first flow channel of the main valve body in real time:

[0019] ;

[0020] A pressure sensor monitors the pressure, and a piecewise optimized control function is used to control the flow rate and valve. (Flow control) The control function is shown below:

[0021] ;

[0022] The control function of the shut-off valve is shown below:

[0023] ;

[0024] when When =1, the shut-off valve remains open. When the value is 0, the shut-off valve is closed. Here, T1 is the first temperature threshold, T2 is the second temperature threshold, P1 is the first pressure threshold, P2 is the second pressure threshold, and P3 is the third pressure threshold. Represents AND, ∇Tth is the heating rate threshold, V is the prefill flow rate, and P1 <P2<P3。

[0025] Preferably, the traffic switching conditions are as follows:

[0026] ;

[0027] Where t is time, This represents actual traffic changes. This represents real-time temperature changes.

[0028] Preferably, the second channel is located in the middle of the main valve body and forms a vertical orifice with the inner surface of the first channel. The temperature sensor, pressure sensor and flow sensor are integrated in the second channel. The third channel is parallel to the first channel and perpendicular to the second channel. A fourth flow channel for cooling medium is also provided on the side wall of the main valve body.

[0029] Preferably, the shut-off valve constitutes the first section of the valve body structure, the redundant check valve constitutes the second section of the valve body structure, the flow regulating valve constitutes the third section of the valve body structure, and the second filter constitutes the fourth section of the valve body structure.

[0030] Preferably, the shut-off valve includes both manual and electric control, and the redundant check valve is composed of two check valves connected in series to form a redundant structure. The first filter is used to filter metal particles, moisture, or pipeline impurities in hydrogen, and the second filter is used to filter metal debris, abrasion particles of sealing material, or fine impurities that penetrate the first filter.

[0031] Preferably, during the hydrogen refueling process, the pressure sensor feeds back the pressure signal to the controller in real time based on the hydrogen pressure of the hydrogen storage tank of the hydrogen fuel cell vehicle. The controller sends a flow regulation signal to the flow regulating valve based on the pressure signal. After receiving the flow regulation signal, the flow regulating valve drives the valve core to move, changing the flow cross-sectional area to perform real-time flow regulation.

[0032] Preferably, the relationship between P1, P2 and P3 is: P1=0.71P3, P2=0.93P3, P3=rated pressure.

[0033] Preferably, the optimal parameters are obtained by optimizing the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate through an optimization objective function. The optimization objective function is as follows:

[0034] ;

[0035] Where ω1−ω6 are the weighting coefficients of the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate, respectively, and F is the objective function value.

[0036] Secondly, the present invention provides a control method for an integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation, comprising the following steps:

[0037] S1. Temperature sensor monitors the temperature T inside the first flow channel of the main valve body in real time:

[0038] ;

[0039] S2. A pressure sensor monitors pressure and uses a piecewise optimized control function to control flow and valves. Flow control. The control function is shown below:

[0040] ;

[0041] The control function of the shut-off valve is shown below:

[0042] ;

[0043] when When =1, the shut-off valve remains open. When =0, the shut-off valve is closed;

[0044] S3. During the refueling process, the flow rate is switched. The flow rate switching control function is as follows:

[0045] ;

[0046] Where ∇Tth is the heating rate threshold, This represents actual traffic changes. This represents real-time temperature changes.

[0047] Preferably, the optimal parameters are obtained by optimizing the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate through an optimization objective function. The optimization objective function is as follows:

[0048] ;

[0049] Where ω1−ω6 are the weighting coefficients of the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate, respectively, and F is the objective function value;

[0050] The optimal parameters are as follows: first temperature threshold T1 is 70℃, second temperature threshold T2 is 80℃, first pressure threshold P1 is 50MPa, second pressure threshold P2 is 65MPa, third pressure threshold P3 is 70MPa, and the heating rate ∇T th It is 0.3℃ / s.

[0051] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0052] This invention provides an integrated streamlined hydrogen refueling nozzle capable of real-time monitoring and flow control. Its core advantage lies in its optimized streamlined topology design. Following the gas flow direction, this streamlined nozzle highly integrates and linearly connects key components such as the main valve body, shut-off valve, first filter, redundant check valve, flow regulating valve, second filter, temperature sensor, pressure sensor, and flow sensor along the hydrogen flow path. This topology significantly reduces flow path bends and resistance, ensuring smooth gas flow, achieving low turbulence and low pressure drop, while greatly improving structural compactness. The first filter at the inlet effectively intercepts impurities to protect downstream precision components; the series connection of the redundant check valve and flow regulating valve ensures controllable flow direction and precise flow regulation; the second filter before the outlet further refines the hydrogen purification; and the temperature, pressure, and flow sensors are strategically embedded in key locations, enabling real-time in-situ monitoring of core parameters during the refueling process. The streamlined topology not only optimizes fluid performance, enabling efficient and stable fluid flow, but also supports real-time acquisition of sensor data and execution of flow control, forming the foundation for integrated functionality. The integrated streamlined hydrogen refueling nozzle eliminates redundant piping and interfaces of traditional distributed valve groups, reducing volume by more than 40% and directly addressing the pain point of limited internal space in hydrogen refueling machines.

[0053] (2) The hydrogen inlet and outlet channels of the combined valve of the present invention adopt a streamlined design to minimize pressure drop, avoid dead zones, and optimize flow state to reduce turbulence and temperature rise, while ensuring strength and sealing. Based on computational fluid dynamics and stress field co-simulation, the inlet and outlet channels are reconstructed into a continuous and smooth three-dimensional curved surface with variable curvature. This eliminates the eddy current energy consumption caused by traditional right-angle bends and sudden contraction / expansion structures, minimizes the resistance to high-speed hydrogen flow, and significantly improves filling efficiency; the curvature radius dynamically adapts to the flow velocity distribution, completely eliminates dead zones, avoids impurity deposition and hydrogen retention, and eliminates the safety risks caused by the slow release of hydrogen in dead zones from the root; the streamlined profile maintains the stability of the laminar boundary layer, reduces turbulent kinetic energy to 1 / 5 of the traditional design, effectively suppresses the temperature rise caused by the Joule-Thomson effect caused by vortex friction, and simultaneously alleviates material thermal fatigue; strength-sealing synergistic enhancement: while reducing the thickness of the channel wall, the internal reinforcing rib layout is optimized through stress-guided algorithm. By integrating fluid mechanics, structural mechanics, and materials science to achieve extreme depths, this invention sets a new benchmark for high-pressure, ultra-high-speed hydrogen refueling: "low resistance, low temperature, and zero retention." The combined valve body is made of hydrogen-embrittlement-resistant stainless steel, while key seals utilize high-performance polymer composite materials, ensuring high-pressure sealing, low-temperature toughness, wear resistance, and long service life. The valve body is made of hydrogen-embrittlement-resistant stainless steel, employing ultra-low carbon content, grain boundary purification treatment, and stress homogenization processes to completely block lattice distortion and crack propagation caused by hydrogen atom penetration. Simultaneously, the shut-off valve of this invention is designed for rapid opening and closing, achieving millisecond-level operation, and utilizes redundant seals to ensure zero leakage even after millions of cycles.

[0054] (3) The integrated sensor of this invention provides real-time data, interacts with the main control system of the hydrogen dispenser, realizes closed-loop control, adjusts the pre-cooling temperature, controls the dispensing rate, and ensures the fastest dispensing within a safe range. The integrated high-precision temperature sensor, pressure sensor, and flow sensor collect data at millisecond-level frequency, and construct a closed-loop control network with the main control system of the hydrogen dispenser through the built-in communication module. Multiple valves in the integrated control combination valve system are linked in real time with multiple sensors for pressure, temperature, etc., to form a closed-loop control system. Through the coordinated action between valves and the comprehensive analysis of sensor data, precise management of the complex dispensing process is achieved.

[0055] (4) The control method of the present invention is based on a graded trigger control strategy of hydrogen storage tank pressure. This control method abandons single flow control and divides the filling process into different stages and triggers corresponding control actions according to the real-time pressure change of the hydrogen storage tank, so as to realize a more intelligent and safer filling process. Through the three-level coordinated control mechanism of temperature-pressure-flow, adaptive regulation of hydrogen filling at multiple pressure levels is realized. Based on the real-time monitoring value P of the pressure sensor, the filling process is divided into three levels of precise regulation. When P < P1, pre-filling flow monitoring is started and filling is carried out with the first flow. When the temperature and pressure of the hydrogen storage tank are both lower than the safety threshold, it is started to achieve efficient filling. When P1 ≤ P < P2, filling is carried out with the second flow to avoid pressure overshoot. When P2 ≤ P < P3, it switches to the third flow for fine matching filling to ensure that the pressure accurately reaches the set value. When P = P3, it is automatically cut off, directly realizing the safe adaptation of multiple pressure levels. At the same time, temperature safety dual threshold emergency control is adopted. When the temperature exceeds the maximum safety threshold, filling is stopped immediately to eliminate the risk of combustion and explosion. When the temperature is close to but has not yet exceeded the critical safety value, cooling intervention is started immediately. This control method significantly improves the efficiency of high-pressure hydrogen refueling. Through high flow rate and staged adjustment in the early stage, as well as strict monitoring of temperature and pressure safety thresholds and a rapid response mechanism, it can effectively prevent the risk of combustion and explosion, and ultimately ensure the safety and accuracy of the entire high-pressure hydrogen refueling process. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the integrated streamlined hydrogen refueling gun layout that enables real-time monitoring and flow control according to the present invention.

[0057] Figure 2 This is a schematic diagram of the transverse front cross-sectional structure of the integrated streamlined hydrogen refueling gun of the present invention, which enables real-time monitoring and flow control.

[0058] Figure 3 This is a schematic diagram of the transverse back cross-sectional structure of the integrated streamlined hydrogen refueling gun of the present invention, which enables real-time monitoring and flow control.

[0059] Figure 4 This is a schematic diagram of the valve body of the shut-off valve of the present invention;

[0060] Figure 5 This is a schematic diagram of the combined valve body integrating the redundant one-way valve and the first filter of the present invention;

[0061] Figure 6 This is a schematic diagram of the sensor carrier module of the present invention installed on the combined valve body;

[0062] Figure 7 This is a schematic diagram of the flow sensor of the present invention installed on the sensor carrier module;

[0063] Figure 8 This is a schematic diagram of the valve body of the flow regulating valve of the present invention;

[0064] Figure 9 This is a schematic diagram of the structure of the second-stage filter of the present invention;

[0065] Figure 10 This is a schematic flowchart of a hydrogen refueling gun control method according to an embodiment of the present invention;

[0066] Figure 11 This is a schematic diagram of the integrated streamlined hydrogen refueling gun control method of the present invention, which enables real-time monitoring and flow regulation.

[0067] Some of the attached labels in the figure are as follows:

[0068] 1-Main valve body; 101-Main valve body inlet; 102-Main valve body outlet; 12-Sensor end cap; 13-Carrier module cap; 14-Sensor carrier module; 15-Sensor sealing ring; 2-Stop valve; 201-Stop valve inlet; 202-Stop valve outlet; 21-Stop valve body; 22-Valve stem; 23-Valve cover; 24-End cap; 25-Guide sleeve; 3-Redundant check valve; 31-First-stage filter valve core; 32-First-stage filter plug; 33-First plug sealing ring; 34-Check valve body sealing ring; 35-Check valve core; 36-Check valve body; 37-Check valve spring; 38 - Mounting seat; 39 - Washer; 310 - Retaining ring; 311 - Pressure cap; 4 - Flow regulating valve; 41 - Regulating valve inlet; 42 - Valve core assembly mounting hole; 43 - Flow regulating hole; 44 - Regulating valve outlet; 5 - Second filter; 51 - Second stage filter valve core; 52 - Second stage filter element plug; 53 - Second plug sealing ring; 54 - Second stage filter valve body; 55 - Second stage filter valve body sealing ring; 6 - Temperature sensor; 7 - Pressure sensor; 8 - Flow sensor; 81 - Flow probe; 82 - Locking bolt; 83 - Mounting pressure plate; 84 - Flow sensor; 85 - Flow sensor sealing ring. Detailed Implementation

[0069] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0070] In a first aspect, the present invention provides an integrated streamlined hydrogen refueling nozzle capable of real-time monitoring and flow rate control, such as... Figure 1 , Figure 2 and Figure 3 As shown, it includes: a main valve body 1, a shut-off valve 2, a redundant check valve 3 integrating a first filter, a flow regulating valve 4, a second filter 5, a temperature sensor 6, a pressure sensor 7, a flow sensor 8, a hydrogen inlet a, a hydrogen outlet b, a sensor interface c, a first channel A, a second channel B, a third channel C, and a fourth channel D. Based on the flow direction of hydrogen within the valve body structure, the valve body structure is specifically divided into four sections: the first section is sealed and embedded with the shut-off valve 2; the second section is sealed and embedded with an integrated valve body combining the redundant check valve 3 and the first filter; the third section is sealed and embedded with the flow regulating valve 4; and the fourth section is sealed and embedded with the second filter 5.

[0071] like Figure 6 As shown, the main valve body 1 includes an air inlet 101, an air outlet 102, and a valve body 11. A third channel C is provided on the valve body 11 to accommodate the sensor. A sensor end cap 12, a support module cap 13, a sensor support module 14, and a sensor sealing ring 15 are located at the third channel C. The main valve body 1 adopts a streamlined flow channel design, the core advantage of which is significantly optimized fluid dynamics performance, simultaneously improving filling efficiency and system safety. Specifically, the smooth and continuous curved surface transition eliminates the concentrated stress caused by right-angle turns and abrupt changes in cross-section, suppresses turbulent vortices, and minimizes the flow resistance of 70MPa high-pressure hydrogen, avoiding the decrease in refueling rate and increase in energy consumption due to kinetic energy loss. Specifically, by suppressing gas throttling expansion and turbulent frictional heat generation, it effectively alleviates the "Joule-Thomson effect" of hydrogen, preventing local temperature surges that exceed limits and trigger safety interlock shutdowns, ensuring refueling continuity. Specifically, the streamlined profile smoothly guides high-speed hydrogen, weakening pressure fluctuations and impacts, reducing the risk of pipeline vibration and fatigue damage to sealing structures, and extending valve life. Specifically, the flow channel without dead corners reduces the probability of particulate matter deposition, and in conjunction with filters, reduces the risk of secondary contamination, ensuring the reliability of precision components such as check valves.

[0072] As the filling pressure of the hydrogen storage tank in a hydrogen energy vehicle continues to rise to prevent hydrogen leakage during filling and improve the filling accuracy of the hydrogen filling gun, the hydrogen filling gun can adopt a three-stage flow control mode. The three-stage flow controls are the first flow rate, the second flow rate, and the third flow rate with gradually decreasing flow rates. Through a three-stage collaborative control mechanism of temperature-pressure-flow, the hydrogen filling gun achieves adaptive regulation for hydrogen filling at multiple pressure levels. Based on the real-time monitoring value P of the pressure sensor, the filling process is divided into three-stage flow control. When P < P1, pre-fill flow monitoring is started and filling is carried out at the first flow rate Q1. When P1 ≤ P < P2, filling is carried out at the second flow rate Q2. When P2 ≤ P < P3, it is switched to the third flow rate Q3. When P = P3, it automatically stops, directly achieving safe adaptation at multiple pressure levels. In a specific embodiment, the first flow rate is a fast filling mode of 40 - 60 g / s. The second flow rate is a medium flow rate filling mode of 20 - 30 g / s, and the third flow rate is a small flow rate fine matching mode of 10 - 20 g / s.

[0073] The temperature sensor continuously monitors the temperature T in the first flow channel of the main valve body. When T < T1, the pressure sensor starts real-time pressure monitoring of the first flow channel of the main valve body. When T1 ≤ T < T2, cooling is started until T < T1. When T2 ≤ T, shutdown protection is started.

[0074] After entering pressure monitoring, when the real-time pressure P < P1, the flow sensor starts pre-fill flow monitoring of the first flow channel of the main valve body. When the pre-fill flow rate Q is within the first flow rate threshold range, the stop valve is opened and filling is carried out at the first flow rate. When P1 ≤ P < P2, filling is carried out at the second flow rate. When P2 ≤ P < P3, filling is carried out at the third flow rate. When P = P3, the stop valve is closed to stop hydrogen filling.

[0075] The entire control process is temperature safety monitoring → pressure zoning → dynamic flow regulation

[0076] The state transition function is as follows:

[0077] ;

[0078] The temperature-pressure combined safety envelope is:

[0079] ;

[0080] Exceeding the limit immediately triggers:

[0081] ;

[0082] The entire control process is as follows. First, the temperature sensor continuously monitors the temperature T in the first flow channel of the main valve body:

[0083] ;

[0084] The pressure sensor monitors the pressure and uses a piecewise optimization control function to control the flow rate and the valve. The control function for the flow rate control is as follows:

[0085] ;

[0086] The control function for the globe valve is as follows:

[0087] ;

[0088] When = 1, the globe valve is kept open. When = 0, the globe valve is closed. Here, T1 is the first temperature threshold, T2 is the second temperature threshold, P1 is the first pressure threshold, P2 is the second pressure threshold, P3 is the third pressure threshold, represents AND, ∇Tth is the heating rate threshold, V is the pre-fill flow rate, and P1 < P2 < P3. In specific applications, the constraint conditions for each parameter are as follows:

[0089] T1 > ambient temperature, T2 = T1 + 10°C, P ∈ [0, P3], P1 = 0.71P3, P2 = 0.93P3, P3 = rated pressure, ∇Tth ∝ Q1, V ∈ [0.8Vnom, 1.2Vnom].

[0090] Among them, the flow rate switching conditions are as follows:

[0091] ;

[0092] Among them, t is the time, is the actual flow rate change, is the real-time temperature change.

[0093] Such as Figure 4As shown, the shut-off valve 2 includes a shut-off valve inlet 201, a shut-off valve outlet 202, a shut-off valve body 21, a valve stem 22, a valve cover 23, an end cap 24, and a guide sleeve 25. The shut-off valve inlet 201 and the shut-off valve outlet 202 are respectively located on both sides of the shut-off valve body 21 and are respectively connected to the valve stem 21. The guide sleeve 25 is sleeved on the outside of the valve stem 21. The valve cover 23 is provided on the outer end of the valve stem 21, and the end cap 24 is provided on the valve cover 23. The shut-off valve 2 is used to control the start and stop of hydrogen refueling. The shut-off valve 2 is sealed and nested in the first section of the first channel A of the combined valve body 1. The shut-off valve 2 has two control methods, including manual control and electric control, both of which can achieve the control of the start and stop of hydrogen refueling. When a hydrogen fuel cell vehicle needs to be refueled with hydrogen, the hydrogen outlet b of the quick refueling combination valve is connected to the hydrogen refueling nozzle of the hydrogen fuel cell vehicle. With the connection secure, the shut-off valve 2 opens, and hydrogen refueling begins into the hydrogen storage tank of the hydrogen fuel cell vehicle. When the hydrogen pressure in the hydrogen storage tank of the hydrogen fuel cell vehicle is close to the preset pressure value, the pressure sensor 8 feeds back the pressure signal to the controller. The quick refueling combination valve automatically stops refueling when the hydrogen pressure in the hydrogen storage tank of the hydrogen fuel cell vehicle equals the preset pressure value, thus completing the hydrogen refueling process.

[0094] like Figure 5 As shown, the redundant one-way valve 3 and the first filter are integrated into a combined valve body. The integrated combined valve body of the redundant one-way valve 3 and the first filter includes a first-stage filter valve core 31, a first-stage filter plug 32, a first plug sealing ring 33, a one-way valve body sealing ring 34, a one-way valve core 35, a one-way valve body 36, a one-way valve spring 37, a fixing seat 38, a gasket 39, a retaining ring 310, and a gland 311. The one-way valve and the first-stage filter valve are topologically optimized into a small combined valve, which is sealed and nested in the second section of the front end of the first channel A of the combined valve body 1. The redundant one-way valve assembly, through filtration protection and redundant locking mechanisms, constructs a dual safety barrier against impurity damage and backflow failure in the high-pressure, high-speed, and high-risk hydrogen refueling environment. The filter at the front of the redundant check valve 3 can efficiently intercept metal particles, moisture, or pipeline impurities in hydrogen, preventing foreign objects from wearing down downstream precision valve components and ensuring long-term stable operation of the refueling system. In other embodiments, the check valve at the rear of the redundant check valve 3 can be composed of multiple check valves connected in series to form a redundant design. When one check valve is stuck due to impurities or fails to seal, the other can still absolutely block the backflow of high-pressure hydrogen, avoiding major risks such as refueling interruption, backfire explosion, or uncontrolled pressure in the storage tank. The integrated valve body of the redundant check valve 3 and the first filter, through compact integration, reduces pipeline leakage points and provides millisecond-level backflow protection for high-speed refueling conditions, making it a key module for ensuring the safety and efficiency of hydrogen refueling.

[0095] like Figure 8As shown, the flow regulating valve 4 includes a regulating valve inlet 41, a valve core assembly mounting hole 42, a flow regulating hole 43, and a regulating valve outlet 44. The flow regulating valve 4 is sealed and nested in the third section of the first channel A of the combined valve body 1. During the hydrogen refueling process, the pressure sensor feeds back the pressure signal to the controller in real time according to the hydrogen pressure of the hydrogen storage tank of the hydrogen fuel cell vehicle. The controller then transmits the signal to the flow regulating valve 4. After receiving the feedback control signal, the flow regulating valve 4 drives the valve core to move, changing the flow cross-sectional area to achieve the purpose of real-time flow regulation.

[0096] The shut-off valve, as the basic flow control unit, is responsible for opening and closing the fluid flow. The flow regulating valve further refines and controls the flow rate. The pre-cooling unit, as the final execution unit, is responsible for achieving specific cooling objectives. Furthermore, this layer integrates redundant check valves, forming a double-insurance mechanism to prevent backflow. This dual protection effectively prevents unexpected reverse flow of fluid under any operating condition, significantly improving the system's safety and reliability.

[0097] like Figure 9 As shown, the second filter 5 includes a second-stage filter valve core 51, a second-stage filter element plug 52, a second plug sealing ring 53, a second-stage filter valve body 54, and a second-stage filter valve body sealing ring 55. The second filter 5 is nested in the fourth section of the first channel A of the combined valve body 1. As the last barrier before hydrogen enters the hydrogen storage tank of a hydrogen fuel cell vehicle, the second filter eliminates micron-level risks through ultra-fine filtration, and is the core line of defense to ensure the long-term sealing, metering accuracy, and operational safety of the high-pressure hydrogen storage system. It captures metal debris, abrasion particles of sealing materials, or extremely fine impurities that may be generated by the operation of upstream valves or penetrate the pre-filter with sub-micron-level filtration precision, preventing contaminants from entering the hydrogen storage container; it prevents hard particles from scratching the sealing surface of the hydrogen storage tank or damaging the sensors inside the tank, avoiding hydrogen leakage or metering inaccuracies due to sealing failure; under the extreme conditions of high-speed and ultra-high-pressure refueling, it maintains stable filtration performance through a sintered metal filter element that is resistant to high-pressure impact, preventing sudden impurities from blocking the pipeline or causing valve jamming, and ensuring the continuous and safe refueling process. In the specific hydrogenation process, the primary coarse filter first undertakes the basic protection task, efficiently intercepting particulate impurities in the fluid, reducing the load on subsequent processing and protecting critical equipment. Then, the secondary fine filter performs high-precision purification, responsible for filtering out fine particulate matter, ensuring that the purity of the final output fluid meets stringent standards. These two stages of filters work closely together to construct a tiered barrier against contaminants of different particle sizes. This significantly improves system reliability and the lifespan of critical components, while also effectively reducing energy consumption and maintenance frequency through optimized filtration processes. It is a key link in ensuring the quality of the final output and the economy of the system.

[0098] Temperature sensor 6, pressure sensor 7, and flow sensor 8 work in real-time in a high-pressure hydrogen rapid refueling combination valve to construct a core control closed loop for the refueling process through coordinated monitoring and data linkage. Pressure sensor 7 monitors the pressure difference and absolute pressure value between the refueling port and the storage tank in real time. Its synergistic function is to provide a pressure differential reference for flow control, triggering pressure equalization logic; and to urgently cut off refueling in case of overpressure to prevent overcharging of the storage tank. During hydrogen refueling, temperature sensor 6 monitors the temperature rise of the hydrogen fluid, focusing on the throttle valve, nozzle, and valve body surface temperature. Its synergistic function is to dynamically compensate for hydrogen density changes caused by the Joule-Thomson effect, correcting flow metering; and to activate cooling or speed reduction protection in case of overtemperature to prevent hydrogen embrittlement failure of materials. When an over-limit temperature is detected, the system will trigger the highest level of response without delay: immediately executing a safety emergency stop to block potential thermal runaway risks, and simultaneously activating a pre-cooling regulation program, achieving rapid cooling and process control through a two-pronged approach. If a sudden pressure change is detected, the system automatically activates the valve lockout mode, forcibly locking critical valves to form a physical isolation barrier, effectively curbing abnormal pressure transmission or media leakage. These two intelligent response designs ensure that the system can automatically trigger and accurately respond to abnormal core parameters, providing reliable dual protection for equipment and personnel safety and minimizing the risk of accidents.

[0099] like Figure 7 As shown, the flow sensor includes a flow probe 81, a locking bolt 82, a fixed pressure plate 83, a flow sensor 84, and a flow sensor sealing ring 85. The flow sensor 84 accurately measures the instantaneous injection flow rate and accumulates the total hydrogen injection volume. Its synergistic function is to receive pressure / temperature data, enabling real-time adjustment of valve opening to achieve flow-PID control; and to monitor abnormal flow changes, such as leaks or blockages, triggering an emergency stop via the safety valve.

[0100] The combined valve body 1 adopts a streamlined flow channel design, which is optimized for fluid dynamics performance, effectively improving filling efficiency and system safety. Specifically, the streamlined flow channel design eliminates stress concentration caused by right-angle turns and abrupt changes in cross-section, reduces flow resistance, suppresses turbulent vortices, inhibits gas throttling expansion and turbulent frictional heat generation, reduces pipeline vibration risk and fatigue damage to the sealing structure, and extends valve life. Specifically, one end of the combined valve body 1 is a high-pressure hydrogen inlet, and the other end is a high-pressure hydrogen outlet. The hydrogen inlet is sealed with a shut-off valve 2. The advantage is that in an unsafe environment or if internal components malfunction, the shut-off valve can be automatically or manually activated to cut off the hydrogen supply, ensuring the safety of the hydrogen filling process. The first front port of the shut-off valve 2 is the high-pressure hydrogen inlet, connected to the high-pressure hydrogen delivery pipe of the hydrogen filling machine. The second rear port is connected to the first front port of the combined valve, which integrates the first filter and the redundant check valve. The advantage of the redundant check valve is that it reduces one hydrogen inlet / outlet, improving the sealing performance of the combined valve body 1. The first filter and redundant check valve are integrated into a combined valve whose second rear port connects to three major sensors: temperature sensor 6, pressure sensor 7, and flow sensor 8. These three sensors are integrated and installed in the second channel B, located in the middle of the combined valve body 1. The outer orifice of the second channel B is used to insert the three sensors. The second channel B is perpendicular to the first channel A, forming an inner orifice. High-pressure hydrogen gas flows into the second channel B through the first channel A, allowing the three sensors to collect pressure, temperature, and flow data. The pressure, temperature, and flow data collected by the three sensors are input to the controller. The controller analyzes the data and then inputs the signal to the flow regulating valve 4. The flow regulating valve 5 matches the digital flow rate output by the controller in real time. After precise flow regulation, the flow regulating valve 4 delivers hydrogen to the second filter 5. The second filter 5 further refines the hydrogen before it reaches the high-pressure hydrogen outlet of the combined valve body 1, ultimately ensuring the precise and safe delivery of hydrogen to the on-board hydrogen storage system. The fourth channel D is used to introduce cooling medium to cool the inside of the valve body; the cooling medium is supplied externally by a cooling unit.

[0101] Secondly, the present invention provides a control method for an integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation, such as... Figure 10 and Figure 11 As shown, it includes the following steps:

[0102] S1. Temperature sensor monitors the temperature T inside the first flow channel of the main valve body in real time:

[0103] ;

[0104] S2. A pressure sensor monitors pressure and uses a piecewise optimized control function to control flow and valves. Flow control. The control function is shown below:

[0105] ;

[0106] The control function of the shut-off valve is shown below:

[0107] ;

[0108] when When =1, the shut-off valve remains open. When =0, the shut-off valve is closed;

[0109] S3. During the refueling process, the flow rate is switched. The flow rate switching control function is as follows:

[0110] ;

[0111] Where ∇Tth is the heating rate threshold, This represents actual traffic changes. This represents real-time temperature changes.

[0112] Wherein, T1 is the first temperature threshold, T2 is the second temperature threshold, P1 is the first pressure threshold, P2 is the second pressure threshold, and P3 is the third pressure threshold.

[0113] In specific application embodiments, the above parameters can also be optimized by optimizing the objective function, which is as follows:

[0114] .

[0115] Where ω1−ω6 are the weighting coefficients for the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate, respectively, and F is the objective function value. Based on the determined objective function value and the weights of different thresholds, the values ​​of different thresholds can be solved. In practical applications, an improved simulated annealing algorithm can also be used for iterative solutions.

[0116] In one specific embodiment, such as Figure 10 As shown, the first temperature threshold T1 is 70℃, the second temperature threshold T2 is 80℃, the first pressure threshold P1 is 50MPa, the second pressure threshold P2 is 65MPa, the third pressure threshold P3 is 70MPa, and the heating rate ∇T th The value is 0.3℃ / s. It should be emphasized that this value and the attached... Figure 10The values ​​and diagrams shown are for a specific embodiment only. The specific pressure values ​​are determined according to different rated pressures and can be optimized according to actual conditions. Generally, the following conditions should be met: T1 > ambient temperature, T2 = T1 + 10℃, P ∈ [0, P3], P1 = 0.71P3, P2 = 0.93P3, P3 = rated pressure, ∇Tth ∝ Q1, V ∈ [0.8Vnom, 1.2Vnom].

[0117] The working process of this application will be further described below with reference to a specific embodiment. The rated power of the hydrogen refueling gun in this embodiment is 70 MPa, and the specific working process is as follows:

[0118] The shut-off valve, as the basic flow control unit, is responsible for opening and closing the fluid flow. The flow regulating valve further refines and controls the flow rate. The pre-cooling unit, as the final execution unit, is responsible for achieving specific cooling objectives. Furthermore, this layer integrates redundant check valves, forming a double-insurance mechanism to prevent backflow. This dual protection effectively prevents unexpected reverse flow of fluid under any operating condition, significantly improving the system's safety and reliability.

[0119] During the flow filling process, the primary coarse filter first undertakes the basic protection task, effectively intercepting particulate impurities in the fluid, reducing the load on subsequent processing and protecting critical equipment. Then, the secondary fine filter performs high-precision purification, responsible for filtering out fine particulate matter, ensuring that the purity of the final output fluid meets stringent standards. These two stages of filters work closely together to construct a tiered barrier against contaminants of different particle sizes. This significantly improves system reliability and the lifespan of critical components, while also effectively reducing energy consumption and maintenance frequency through optimized filtration processes. It is a key link in ensuring the quality of the final output and the economy of the system.

[0120] Before initiating or maintaining the main rapid filling process, the system strictly executes a three-level monitoring and verification process in the following sequence, with each level serving as a prerequisite for the next: Level 1: Temperature Safety Monitoring. The intelligent control decision layer reads the cylinder temperature data from the temperature sensor. If the monitored cylinder temperature is less than 70°C, Level 1 monitoring passes, allowing entry into Level 2: Pressure Monitoring. If the cylinder temperature is ≥70°C, a safety interlock mechanism is triggered. For example, refueling initiation may be prohibited, or if refueling is already underway, cooling or emergency shut-off may be triggered, stopping subsequent processes. Level 2: Pressure Condition Monitoring. After passing Level 1 monitoring, the intelligent control decision layer reads the hydrogen storage tank pressure data from the pressure sensor. If the monitored hydrogen storage tank pressure is less than 50 MPa, Level 2 monitoring passes, allowing entry into Level 3: Flow Verification. If the pressure is ≥50 MPa, deceleration or fine filling mode may be triggered, or the system may determine whether the stop-filling conditions are met based on the target pressure, preventing entry into the main rapid filling mode. The third-level pipeline patency verification involves briefly opening the flow regulating valve to a predetermined small opening degree under the command of the intelligent control decision layer after passing the second-level monitoring. This allows hydrogen to enter the pipeline at a low pre-filling flow rate, and the intelligent control decision layer reads the data from the flow sensor. The system checks whether the instantaneous filling rate is stable within a preset range of 5-10 g / s. If the flow rate is within this range, the third-level monitoring passes, verifying pipeline patency and the absence of blockages or leaks, allowing the main rapid filling mode to be activated. If the flow rate is <5 g / s or >10 g / s, it may indicate a leak or excessive valve opening, indicating a potential fault. This triggers an alarm and prohibits entry into the main rapid filling mode, requiring troubleshooting.

[0121] Conditions for implementing and maintaining the main rapid filling mode: First, activation conditions: Only after successfully completing the above three-level monitoring (temperature <70℃, pressure <50MPa, pre-fill flow rate 5~10g / s) and without detecting any other faults will the intelligent control decision layer issue a command to the hardware collaborative execution layer. The flow regulating valve in the hardware collaborative execution layer adjusts to the corresponding opening degree according to the command. During the main rapid filling process, the system continuously monitors the temperature rise rate of the bottle. If the temperature rise rate is ≤0.3℃ / s, the main rapid filling mode of 40~60g / s is maintained; if the temperature rise rate is >0.3℃ / s, a safety interlock mechanism or control strategy adjustment is triggered. For example, the flow rate is immediately reduced to a deceleration mode or a fine mode, or a cooling program is initiated; in extreme cases, emergency shutdown is performed, exiting the main rapid filling mode.

[0122] When the first-level temperature sensor in the real-time monitoring and sensing layer detects an abnormal temperature in the hydrogen storage tank, the system executes a tiered emergency response according to the following logic: Level 1 Temperature Control: When the tank temperature is between 70℃ and 80℃: The intelligent control decision layer continuously monitors the tank temperature. If the temperature exceeds 70℃, a secondary temperature judgment procedure is immediately initiated. The system confirms whether the temperature is between 70℃ and 80℃. If the condition is met, a cooling procedure is immediately initiated, such as turning on the coolant circulation pump, increasing the cooling fan power, or triggering the hydrogen flow cooling device. During the cooling process, the temperature sensor provides real-time feedback of the tank temperature data. When the tank temperature drops to ≤70℃, the cooling procedure automatically stops, and the system is allowed to proceed to the next level of pressure signal monitoring. Level 2 Temperature Control: When the tank temperature exceeds 85℃, if the temperature sensor detects a temperature exceeding 85℃, the highest-level safety interlock is directly triggered. The intelligent control decision layer sends an emergency cut-off command to the hardware coordination execution layer. The flow regulating valve immediately closes, and the filling pipeline cut-off valve operates synchronously, forcibly terminating hydrogen filling. An audible and visual alarm is triggered, and a fault code is recorded. Manual intervention is required for troubleshooting before resetting.

[0123] The intelligent control decision layer dynamically switches between the following three filling modes based on real-time operating conditions, which must be activated when the cylinder temperature is <70℃. **High-flow-rate rapid filling mode:** After completing three-level safety monitoring (temperature <70℃, pressure <50MPa, pre-fill flow rate 5~10g / s without fault), the flow regulating valve is adjusted to the preset high-flow level, maintaining the filling rate at 40~60g / s. **Medium-flow-rate deceleration filling mode:** To prevent overshoot, during filling, when the pressure sensor detects the second condition (hydrogen storage tank pressure >50MPa <65MPa), the intelligent control decision layer immediately lowers the flow command, and the flow regulating valve switches to a medium opening, precisely controlling the filling rate within the range of 20~30g / s. This actively reduces the speed to suppress the pressure rise slope and avoid pressure overshoot. **Small-flow-rate fine-matching mode:** To achieve endpoint calibration. When the pressure sensor detects that the hydrogen storage tank pressure is ≥65MPa and approaching the transition stage of 70MPa, the system automatically switches to micro-adjustment mode, and the flow control valve adds hydrogen at a fine flow rate of <10g / s. When the pressure sensor detects the third operating condition with a pressure equal to 70MPa, the system determines that the adding is complete, closes all adding valves, saves the adding data, and switches the system to standby mode.

[0124] The three-stage flow actuator collaborative process: The shut-off valve is installed at the inlet of the main refueling pipeline, receiving control commands to control fluid flow. It opens during refueling startup and closes immediately upon emergency shut-off or completion of refueling. The flow regulating valve is installed downstream of the shut-off valve, adjacent to the refueling port, receiving commands from the intelligent decision-making layer to dynamically adjust its opening. In high-flow mode, the opening is ≥80%, outputting 40~60 g / s; in medium-flow mode, the opening is 40~50%, outputting 20~30 g / s; in low-flow mode, the opening is 5~15%, outputting <10 g / s. The precooling unit is installed at the end of the refueling pipeline or at the inlet of the hydrogen storage tank, executing the cooling procedure described in the claims. When the bottle temperature >70℃, it starts: the ethylene glycol circulation pump accelerates / increases the cooling fan power, running continuously until the bottle temperature ≤70℃, with real-time feedback from the temperature sensor. When starting high-flow refueling: the shut-off valve opens → the flow regulating valve opens to 80% → the precooling unit stands by; if cooling is triggered: the precooling unit starts → the flow regulating valve decreases to a low flow rate → the shut-off valve remains open. Redundant check valves are installed in series in the filling pipeline. Valve A is a spring-loaded type that opens by the forward pressure of the fluid and automatically locks in the reverse pressure differential. Valve B is a pressure differential driven type that is forcibly locked by controlling the air pressure when the system is shut down. When either check valve fails, the other valve can still independently block the reverse flow. A sealing test is automatically performed before each system startup.

[0125] A two-stage progressive filtration system ensures hydrogen purity and equipment safety. The primary coarse filter uses a 316L stainless steel sintered mesh filter element, installed at the hydrogen source inlet, to intercept large particles such as rust and pipeline debris, protecting downstream precision valves, especially flow control valves, from mechanical damage. A replacement alarm is triggered when the inlet-outlet pressure difference exceeds 0.5 MPa. The secondary fine filter uses a titanium alloy fiber composite filter membrane, installed between the flow control valve and the hydrogen storage tank, to filter out fine particles such as carbon powder and moisture condensates, ensuring a hydrogen purity of ≥99.999%. Replacement is mandatory when the pressure difference exceeds 0.3 MPa or the cumulative filling volume exceeds 10 tons.

[0126] The safety interlock mechanism, as a hard-wired protection layer independent of the main control system, is implemented through the following components: The safety instrumented system selects a programmable safety controller that meets the IEC61508 SIL2 level. The emergency action unit includes: a safety relay group to control valve emergency stop; an override start module for the pre-cooling unit; and an electromagnetically driven valve mechanical locking device. Direct-connected sensor channels select independent redundant signal lines for temperature sensors and a dedicated channel for pressure sensor transient monitoring. When any temperature sensor detects an over-limit signal: the safety instrumented system compares the temperature signals from the cylinder / pipeline / ambient environment. If any signal is >85℃ or both are >80℃, it is considered a valid over-limit. A dual response is executed simultaneously: a safety emergency stop sends a pulse signal to the safety relay, forcibly de-energizing the shut-off valve and flow control valve; pre-cooling activation uses override control to start the pre-cooling unit at maximum power. When the pressure transient monitoring channel detects an abnormal gradient, the safety instrumented system identifies the pressure change rate and eliminates sensor malfunction. After valve locking, sealing enhancement gel is automatically injected, triggering a negative pressure suction device to pump the isolation section of the pipeline to -0.5MPa to prevent media accumulation. This implementation method, through in-depth protection with no-delay electrical response and mechanical isolation, controls the accident containment time to within 100ms, which meets the mandatory requirements of NFPA hydrogen safety specifications for rapid shutdown, and also meets the sealing standards of ASME B31.12 for emergency isolation of high-pressure pipelines.

[0127] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A control method for an integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation, characterized in that: The integrated streamlined hydrogen refueling nozzle includes a main valve body, a shut-off valve, a first filter, a redundant check valve, a flow regulating valve, a second filter, a temperature sensor, a pressure sensor, a flow sensor, a hydrogen inlet, a hydrogen outlet, a first channel, a second channel, a third channel, and a fourth channel. The shut-off valve and the redundant check valve are located at the inlet of the main valve body. The first filter is integrated inside the redundant check valve. The flow regulating valve and the second filter are located at the outlet of the main valve body in the first channel. The redundant check valve and the flow regulating valve are both embedded inside the main valve body. The hydrogen inlet is located at the inlet of the shut-off valve, and the hydrogen outlet is located at the outlet of the second filter. The shut-off valve, the redundant check valve, the main valve body, the flow regulating valve, and the second filter are all sealed together to form a valve body structure with a streamlined first flow channel. The control method includes the following steps: S1. Temperature sensor monitors the temperature T inside the first flow channel of the main valve body in real time: ； S2. A pressure sensor monitors pressure and uses a piecewise optimized control function to control flow and valves. Flow control. The control function is shown below: ； The control function of the shut-off valve is shown below: ； When = 1, the globe valve remains open. When = 0, the globe valve is closed. Here, T1 is the first temperature threshold, T2 is the second temperature threshold, P1 is the first pressure threshold, P2 is the second pressure threshold, and P3 is the third pressure threshold. represents AND, is the heating rate threshold, V is the pre - filling flow rate, and P1 < P2 < P3; Q1 is the first flow rate, Q2 is the second flow rate, and Q3 is the third flow rate. S3. During the refueling process, the flow rate is switched. The flow rate switching control function is as follows: ； Where t is time, This represents actual traffic changes. For real-time temperature changes; The optimal parameters are obtained by optimizing the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate through the objective function. The objective function is as follows: ； in, These are the weighting coefficients for the first temperature threshold, the second temperature threshold, the first pressure threshold, the second pressure threshold, the third pressure threshold, and the heating rate, respectively, and F is the objective function value; The optimal parameters are as follows: first temperature threshold T1 is 70℃, second temperature threshold T2 is 80℃, first pressure threshold P1 is 50MPa, second pressure threshold P2 is 65MPa, third pressure threshold P3 is 70MPa, and heating rate... It is 0.3℃ / s.

2. The control method for the integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation according to claim 1, characterized in that: The second channel is located in the middle of the main valve body and forms a vertical orifice with the inner surface of the first channel. The temperature sensor, pressure sensor and flow sensor are integrated in the second channel. The third channel is parallel to the first channel and perpendicular to the second channel. The fourth channel is opened on the side wall of the main valve body and is used to introduce cooling medium.

3. The control method for the integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation according to claim 2, characterized in that: The shut-off valve constitutes the first section of the valve body structure, the redundant check valve integrated with the first filter constitutes the second section of the valve body structure, the flow regulating valve constitutes the third section of the valve body structure, and the second filter constitutes the fourth section of the valve body structure.

4. The control method for the integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation according to claim 3, characterized in that: The shut-off valve has two control modes: manual control and electric control. The first filter is used to filter out metal particles, moisture or pipeline impurities in hydrogen, and the second filter is used to filter out metal shavings, abrasion particles of sealing material or fine impurities that have penetrated the first filter.

5. The control method for the integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation according to claim 4, characterized in that: During hydrogen refueling, the pressure sensor feeds back the pressure signal to the controller in real time based on the pressure of hydrogen being added to the hydrogen storage tank of the hydrogen fuel cell vehicle. The controller sends a flow regulation signal to the flow regulating valve based on the pressure signal. After receiving the flow regulation signal, the flow regulating valve drives the valve core to move, changing the flow cross-sectional area to perform real-time flow regulation.

6. The control method for the integrated streamlined hydrogen refueling gun capable of real-time monitoring and flow regulation according to claim 5, characterized in that: The relationship between P1, P2 and P3 is: P1=0.71P3, P2=0.93P3, P3=rated pressure.

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