Multifunctional integrated hydrogenation system based on direct-drive compression module and hydrogenation machine

Abstract

The invention relates to a multifunctional integrated hydrogenation system based on a direct-driven compression module and a hydrogenation machine. A first electric valve and a first pressure release valve are arranged on a filling pipeline for connecting a hydrogen source and the direct-driven compression module; a hydrogen source enters the first heat exchange channel for primary precooling and then enters the direct-driven compressor for primary compression; the hydrogen subjected to primary compression enters the direct-driven compressor to be subjected to secondary compression after being subjected to secondary cooling through a second heat exchange channel; after secondary compression, the air enters a third heat exchange channel to be cooled for the third time, and then enters an output pipeline connected with the output end and the direct-drive compression module; temperature and pressure sensors are arranged on a pipeline between the direct-driven compressor and an inlet of the heat exchanger b1 and a pipeline between the direct-driven compressor and an inlet of the heat exchanger c1; the electric control module controls the opening and closing degree of the first electric valve and / or controls the first pressure release valve to release pressure according to the received hydrogen temperature and pressure intensity sent by the temperature sensor and the pressure sensor. According to the invention, high efficiency, compactness and intellectualization of the hydrogenation machine are realized.

Description

Technical Field

[0001] This invention relates to the field of hydrogen energy equipment technology, specifically to a multifunctional integrated hydrogen refueling system and hydrogen refueling machine based on a direct-drive compression module. Background Technology

[0002] Traditional hydrogen refueling machines employ a split-type architecture, with core components such as the compressor, precooling system, and heat exchanger configured independently. This results in redundant system transmission links, limited energy efficiency, and large equipment size with high maintenance complexity. Their reciprocating compressors rely on crank-connecting rod mechanisms for transmission, leading to low mechanical efficiency and sluggish dynamic response, making them unsuitable for the wide dynamic demands of fuel cell refueling. Furthermore, the high temperatures generated during hydrogen compression require cooling through redundant systems (such as multi-stage water cooling), resulting in low waste heat recovery rates and further exacerbating energy waste and equipment footprint.

[0003] With the large-scale development of hydrogen energy infrastructure, industry standards (such as SAE J2601 and GB / T 31138-2022) have put forward comprehensive requirements for hydrogen refueling machines, including low energy consumption, high compactness, and high metering accuracy. Hydrogen energy storage and transportation technology is evolving towards higher pressure and larger capacity. The trend of high-pressure storage and transportation has put forward new directions for the improvement of on-site hydrogen pressurization and refueling systems: the system needs to have the ability to adapt to a wider range of inlet pressure and be able to operate efficiently and stably under high inlet pressure conditions, making full use of the pressure potential energy of on-board hydrogen to achieve energy saving and consumption reduction. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a multifunctional integrated hydrogen refueling system and hydrogen refueling machine based on a direct-drive compression module. By integrating a direct-drive compressor and a high-efficiency integrated heat exchanger, it solves the problems of low efficiency, large size, and poor energy efficiency in existing hydrogen refueling machine technologies, thereby achieving high efficiency, compactness, and intelligence in the hydrogen refueling machine.

[0005] This invention provides the following technical solution: A multifunctional integrated hydrogen refueling system based on a direct-drive compression module includes an electronic control module and a direct-drive compression module disposed between a hydrogen source and an output end. The direct-drive compression module includes a heat exchanger and a direct-drive compressor. A first electric valve and a first pressure relief valve are installed on the refueling pipeline connecting the hydrogen source and the direct-drive compression module. The heat exchanger has three heat exchange channels. Hydrogen from the hydrogen source enters the first heat exchange channel through the refueling pipeline from the inlet a1 of the heat exchanger for initial pre-cooling, and then flows out from the outlet a2 of the heat exchanger into the direct-drive compressor for primary compression. The hydrogen after primary compression enters the second heat exchange channel from the inlet b1 of the heat exchanger. After secondary cooling in the heat exchange channel, the hydrogen flows out from the outlet of heat exchanger b2 and enters the direct-drive compressor for secondary compression. After secondary compression, the hydrogen enters the inlet of heat exchanger c1 and undergoes tertiary cooling in the third heat exchange channel. After tertiary cooling, the hydrogen flows out from the outlet of heat exchanger c2 and enters the output pipeline connecting the output end to the direct-drive compression module. Temperature and pressure sensors are installed on the pipelines between the direct-drive compressor and the inlet of heat exchanger b1, and between the direct-drive compressor and the inlet of heat exchanger c1. The electronic control module controls the opening degree of the first electric valve and / or controls the first pressure relief valve to release pressure based on the hydrogen temperature and pressure received from the temperature and pressure sensors.

[0006] Furthermore, the heat exchanger uses two coolants to cool the three heat exchange channels; one coolant provides heat exchange only for the third heat exchange channel, while the other coolant provides heat exchange for the first and second cooling channels and the direct-drive compressor.

[0007] Furthermore, the upstream section of the output pipeline is provided with a second pressure relief valve and a second electric valve in sequence; the second pressure relief valve and the first pressure relief valve form a redundant isolation structure, and the second electric valve and the first electric valve form a redundant pressure relief structure.

[0008] Furthermore, a first pressure sensor is also provided on the filling pipeline; the first pressure sensor, the first electric valve, and the first pressure relief valve are sequentially arranged between the hydrogen source and the heat exchanger; the first pressure sensor is used to monitor the hydrogen pressure added from the hydrogen source, and the electronic control module is also used to control the opening degree of the first and second electric valves and / or control the first and second pressure relief valves to release pressure according to the pressure value received from the first pressure sensor.

[0009] Furthermore, a protection branch is provided downstream of the output pipeline; a second pressure sensor and a third electric valve are sequentially installed on the protection branch, with the third electric valve located at the end of the protection branch; the second pressure sensor is used to monitor the pressure of the hydrogen output at the output end, and the electronic control module is also used to control the opening and closing degree of the first and second electric valves and / or control the first and second pressure relief valves to release pressure based on the pressure value received from the second pressure sensor.

[0010] Furthermore, it also includes a first isolation valve, a second isolation valve, and a third isolation valve; the first isolation valve is located on the filling pipeline, upstream of the first pressure sensor; the second isolation valve is located on the output pipeline, between the protection branch and the second electric valve; and the third isolation valve is located on the protection branch, between the third electric valve and the second pressure sensor; the first isolation valve, the second isolation valve, and the third isolation valve are all used for maintenance isolation, and the multi-functional integrated hydrogen dispenser is kept fully open during operation.

[0011] Furthermore, the filling pipeline is also equipped with a mass flow meter with a built-in flow equalization plate, and the mass flow meter is located between the first electric valve and the first pressure relief valve.

[0012] Furthermore, it also includes a first filter and a second filter. The first filter is disposed on the filling pipeline, between the first pressure sensor and the first electric valve, and the second filter is disposed on the output pipeline, between the second pressure relief valve and the second electric valve. Both the first filter and the second filter are provided with a two-stage filtration structure, wherein the impurity particles that can be filtered by the upstream first-stage filtration structure are larger than the impurity particles that can be filtered by the downstream second-stage filtration structure.

[0013] A multi-functional integrated hydrogen refueling machine based on a direct-drive compression module, based on the aforementioned multi-functional integrated hydrogen refueling system based on a direct-drive compression module, comprises a process valve group module consisting of a first isolation valve, a first electric valve, a first pressure relief valve, and a first pressure sensor on the refueling pipeline, and a second isolation valve, a second electric valve, a second pressure relief valve, a third electric valve, a second pressure sensor, and a third isolation valve on the output pipeline. The valve group module is located inside a first housing, the direct-drive compression module is located inside a second housing, and the electronic control module is located inside a third housing. The first housing, the second housing, and the third housing are sequentially mounted on a base, which is used to house the connecting lines and pipelines between the valve group module, the direct-drive compression module, and the electronic control module.

[0014] Furthermore, there is one or more direct-drive compression modules, and one or more direct-drive compression modules are respectively disposed inside one or more second housings; all direct-drive compression modules are connected in parallel.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. The heat exchanger of this invention features a three-channel system with a three-stage cooling process, precisely matching the cooling requirements of the first and second stages of hydrogen compression. Combined with real-time data feedback from two temperature and pressure sensors, the electronic control module can dynamically adjust the first electric valve and the first pressure relief valve, intelligently and promptly responding to abnormal hydrogen temperature and pressure during compression, avoiding the risk of overheating and overpressure, and ensuring stable system operation. Furthermore, the direct-drive compression module integrates a direct-drive compressor and heat exchanger, solving the problems of low efficiency, large size, and poor energy efficiency in existing hydrogen refueling technologies, achieving a more efficient and compact hydrogen refueling machine.

[0016] 2. This invention adopts a differentiated cooling design with two coolants, which allows the hydrogen after the second stage of compression to receive independent cooling protection and ensure that the output hydrogen temperature meets the standard. At the same time, the other coolant takes into account the cooling needs of the first two heat exchange channels and the direct-drive compressor, realizing efficient reuse of cooling resources. There is no need to configure a separate cooling system for the compressor, which reduces the number of pipelines and cooling components, and reduces system complexity and failure rate.

[0017] 3. This invention constructs a dual-redundancy safety defense line, significantly improving the system's fault tolerance. The second pressure relief valve in the output pipeline and the first pressure relief valve in the filling pipeline, as well as the second electric valve and the first electric valve, each form a redundant structure, breaking the safety limitations of a single valve or pressure relief component. Even if one valve or pressure relief valve fails, the other can promptly take over, avoiding safety hazards such as gas leakage and pipeline overpressure during filling, significantly enhancing the system's reliability in high-pressure hydrogen filling scenarios.

[0018] 4. This invention achieves precise pressure control throughout the entire hydrogen refueling process. The first pressure sensor on the refueling pipeline can monitor the hydrogen pressure at the source in advance, while the second pressure sensor on the output pipeline protection branch can monitor the terminal output pressure in real time. Both data are fed back to the electronic control module. Based on this, the electronic control module coordinates and regulates relevant valves and pressure relief valves, preventing abnormal gas source pressure from affecting the compression process and preventing excessive terminal output pressure from damaging the hydrogen refueling equipment, thus forming a full-link pressure protection system from source to end.

[0019] 5. The three isolation valves of this invention can isolate key pipelines during system maintenance without purging the entire pipeline of hydrogen, reducing maintenance difficulty and losses. The first and second filters with a two-stage filtration structure can filter impurities of different particle sizes step by step, preventing impurities from entering the direct-drive compressor or filling equipment and causing component wear. At the same time, the differential pressure sensor can provide early warning of filter replacement, ensuring the purity of input and output hydrogen and further extending the service life of the system's core components. The pre-positioned mass flow meter with a built-in flow equalization plate solves the metering inaccuracy problem caused by pipeline resonance and pressure surges in traditional designs, ensuring accurate hydrogen metering under high-pressure conditions. 6. The modular layout of this invention allows all high-pressure pipelines to be built-in, and the standardized direct-drive compression modules connected in parallel can be added or removed as needed to flexibly match different refueling flow requirements, reducing the land occupation and equipment upgrade costs of hydrogen refueling stations. Attached Figure Description

[0020] Figure 1 This is a flowchart of the workflow of the present invention.

[0021] Figure 2 This is a schematic diagram of the overall structure of the present invention.

[0022] Figure 3 This is a schematic diagram of the overall structure of the present invention, which includes two or more direct-drive compression modules.

[0023] Figure 4 This is a schematic diagram of the internal structure of the present invention.

[0024] Figure 5 This is a schematic diagram of the internal structure of the present invention, which includes two or more direct-drive compression modules (the internal structure of some compression modules is not shown).

[0025] Wherein: 1-First isolation valve, 2-First filter, 3-First electric valve, 4-Mass flow meter, 5-First pressure relief valve, 6-Heat exchanger, 7-Direct drive compressor, 8-Second pressure relief valve, 9-Second filter, 10-Second electric valve, 11-Check valve, 12-Second isolation valve, 13-Third isolation valve, 14-Third electric valve, 15-Break-off valve assembly, 16-Hydrogen refueling nozzle, 17-First pressure sensor, 18-First pressure gauge, 19-Second pressure gauge, 20-Second temperature sensor, 21-Third pressure sensor, 22-First temperature sensor, 23-Fourth pressure sensor, 24-Third temperature sensor, 25-Second pressure sensor, 26-Third pressure gauge, 27-Cooling water inlet A, 28-Cooling water inlet B, 29-Cooling water outlet B, 30-Cooling water outlet A; 100-Process valve assembly module, 200-Direct drive compressor module, 300-Electrical control module. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0027] Example 1 This embodiment provides a multifunctional integrated hydrogen refueling system based on a direct-drive compression module, such as... Figure 1As shown, the multifunctional integrated hydrogen refueling system includes an electronic control module 300 and a direct-drive compression module 200. The direct-drive compression module 200 is located between the hydrogen source and the output end. The connection pipeline between the hydrogen source and the direct-drive compression module 200 is a refueling pipeline, which is equipped with a first electric valve 3 and a first pressure relief valve 5. The connection pipeline between the direct-drive compression module 200 and the output end is an output pipeline. The direct-drive compression module 200 includes a heat exchanger 6 and a direct-drive compressor 7.

[0028] Hydrogen sources can typically be transported to the multi-functional integrated hydrogen refueling unit by a long-tube trailer or supplied by an on-site hydrogen production unit. Hydrogen is then introduced into the multi-functional integrated hydrogen refueling unit via the refueling pipeline inlet (hydrogen inlet). In some embodiments, a safety blocking structure is provided at the hydrogen inlet, such as a quick-connect coupling with a double-sealed flange structure for auxiliary sealing; a pneumatic shut-off valve and a pull-off valve may also be configured.

[0029] The direct-drive compressor 7 (direct-motor driven compressor) fundamentally eliminates the mechanical vibration sources and radial wear inherent in the crank and connecting rod components of traditional compressor modules, ensuring lifespan and adaptability to high-frequency, high-pressure environments. The direct-drive compressor 7 can provide single-stage and two-stage hydrogen compression functions.

[0030] The heat exchanger 6 has three heat exchange channels: a first heat exchange channel, a second heat exchange channel, and a third heat exchange channel. The first heat exchange channel corresponds to inlet a1 and outlet a2 of the heat exchanger 6; the second heat exchange channel corresponds to inlet b1 and outlet b2; and the third heat exchange channel corresponds to inlet c1 and outlet c2. The first heat exchange channel is used for pre-cooling hydrogen from the hydrogen source; the second heat exchange channel is used for cooling hydrogen after the first stage of compression; and the third heat exchange channel is used for cooling hydrogen after the second stage of compression.

[0031] Hydrogen source hydrogen enters the first heat exchange channel through the a1 inlet of the self-heating exchanger 6 in the filling pipeline. After initial pre-cooling, the hydrogen flows out through the a2 outlet of the self-heating exchanger 6 and enters the direct-drive compressor 7 for primary compression. After primary compression, the hydrogen enters the second heat exchange channel through the b1 inlet of the self-heating exchanger 6 for secondary cooling. After secondary compression, the hydrogen flows out through the b2 outlet of the self-heating exchanger 6 and enters the direct-drive compressor 7 for secondary compression. After secondary compression, the hydrogen enters the third heat exchange channel through the c1 inlet of the self-heating exchanger 6 for tertiary cooling. After secondary compression, the hydrogen enters the output pipeline through the c2 outlet of the self-heating exchanger 6 and is then added to the equipment that needs hydrogen refueling. The output end is generally the hydrogen refueling gun 16.

[0032] A first temperature sensor 22 and a fourth pressure sensor 23 are installed on the connecting pipe between the direct-drive compressor 7 and the b1 inlet of the heat exchanger 6. The first temperature sensor 22 is used to measure the temperature of the hydrogen gas after the first stage of compression, and the fourth pressure sensor 23 is used to measure the pressure of the hydrogen gas after the first stage of compression. A second temperature sensor 20 and a third pressure sensor 21 are installed on the connecting pipe between the direct-drive compressor 7 and the c1 inlet of the heat exchanger 6. The second temperature sensor 20 is used to measure the temperature of the hydrogen gas after the second stage of compression, and the third pressure sensor 21 is used to measure the pressure of the hydrogen gas after the second stage of compression.

[0033] The electronic control module 300 receives temperature and pressure signals from the first temperature sensor 22, the fourth pressure sensor 23, the second temperature sensor 20, and the third pressure sensor 21. Based on the temperature and pressure values ​​of the hydrogen after primary and secondary compression, and according to a preset dynamic response mechanism, the electronic control module 300 controls the opening degree of the first electric valve 3 and / or controls the pressure relief valve 5. Controlling the opening degree of the first electric valve 3 includes controlling the degree of opening or directly closing it, thereby achieving the purpose of adjusting the flow rate or directly cutting off the refueling.

[0034] The dynamic response mechanism includes preset threshold values ​​for hydrogen temperature and pressure after primary and secondary compression. The electronic control module 300 can also compare the received temperature and pressure values ​​with the threshold values. If either the temperature or pressure value of the hydrogen after primary or secondary compression exceeds the threshold, the electronic control module 300 can control the first electric valve 3 to achieve injection isolation and / or control the first pressure relief valve 5 to release pressure. That is, the electronic control module 300 can control the first electric valve 3 alone to achieve emergency cut-off, or control the first pressure relief valve 5 alone to release overpressure gas in the pipeline, or both achieve emergency cut-off through the first electric valve 3 and release overpressure gas in the pipeline through the first pressure relief valve 5.

[0035] In this embodiment, the heat exchanger 6 is a microchannel heat exchanger, which uses two coolants to cool the three heat exchange channels; one coolant provides heat exchange only for the third heat exchange channel, while the other coolant provides heat exchange for the first and second cooling channels and the direct-drive compressor. The cylinder block of the direct-drive compressor 7 adopts a water jacket structure to facilitate heat exchange of the coolant.

[0036] Specifically, another coolant enters from the microchannel heat exchanger cooling water inlet A27 to pre-cool the hydrogen entering the first heat exchange channel from inlet a1, and to provide a second cooling for the first-stage compressed hydrogen entering the second heat exchange channel from inlet b1. Afterward, this coolant cools the direct-drive compressor 7 cylinder body via its outer side, and then flows out from the cooling water outlet A30 located on the direct-drive compressor 7 cylinder body. Another coolant enters from the microchannel heat exchanger cooling water inlet B28 to provide a third cooling for the second-stage compressed hydrogen entering the third heat exchange channel from inlet c1, and then flows out from the microchannel heat exchanger cooling water outlet B29. This ensures that the second-stage compressed hydrogen can be cooled independently to guarantee the temperature of the hydrogen finally entering the output pipeline.

[0037] The heat exchanger 6 is used for cooling the hydrogen source, the hydrogen after primary and secondary compression, and the compression cylinder, forming a three-stage coupled heat exchange architecture. The hydrogen after primary and secondary compression is detected by the first temperature sensor 22 and the second temperature sensor 20, which can quickly identify the heat exchanger 6 heat exchange system faults.

[0038] Not only can the refueling pipeline achieve dynamic response, but the output pipeline can also be equipped with multiple safety linkages and dynamic responses. In this embodiment, the upstream section of the output pipeline is sequentially equipped with a second pressure relief valve 8, a second electric valve 10, a one-way valve 11, and a third temperature sensor 24; the second pressure relief valve 8 and the first pressure relief valve 5 form a redundant isolation structure, and the second electric valve 10 and the first electric valve 3 form a redundant pressure relief structure. The redundant isolation structure and the redundant pressure relief structure constitute a dual redundancy structure. That is, the electronic control module 300 can simultaneously control the opening and closing degree of the first electric valve 3 and the second electric valve 10 to achieve flow regulation or directly close them to achieve refueling cutoff, and can also simultaneously control the first pressure relief valve 5 and the second pressure relief valve 8 to relieve pressure; the dual redundancy structure can further enhance the stability and safety of the multi-functional integrated hydrogen refueling system.

[0039] The third temperature sensor 24 is used to monitor the hydrogen temperature in the output pipeline and send the temperature signal to the electronic control module 300. When the electronic control module 300 detects that the temperature exceeds the preset threshold, it controls the first electric valve 3 and the second electric valve 10 to realize the filling isolation and / or controls the first pressure relief valve 5 and the second pressure relief valve 8 to release pressure.

[0040] A protection branch is also provided downstream of the output pipeline; a second pressure sensor 25, a third pressure gauge 26, and a third electric valve 14 are sequentially installed on the protection branch. The third electric valve 14 is a solenoid valve and is located at the end of the protection branch. The second pressure sensor 25 is used to monitor the pressure of the hydrogen output at the output end. The electronic control module 300 is also used to receive the pressure value sent by the second pressure sensor 25 and control the opening and closing degrees of the first electric valve 3 and the second electric valve 10 and / or control the first pressure relief valve 5 and the second pressure relief valve 8. A breakaway valve assembly 15 can be installed at the connection between the end of the output pipeline and the hydrogen refueling gun 16 for physical isolation and protection between the output pipeline and the hydrogen refueling gun 16.

[0041] As an improvement, the filling pipeline is also equipped with a first pressure sensor 17, a first pressure gauge 18, and a second pressure gauge 19; the first pressure sensor 17, the first pressure gauge 18, the first electric valve 3, the first pressure relief valve 5, and the second pressure gauge 19 are sequentially arranged between the hydrogen source and the heat exchanger 6. The first pressure sensor 17 is used to monitor the hydrogen pressure being filled from the hydrogen source, and the electronic control module 300 is also used to receive the pressure value sent by the first pressure sensor 17, control the opening and closing degree of the first electric valve 3 and the second electric valve 10, and / or control the first pressure relief valve 5 and the second pressure relief valve 8.

[0042] In this embodiment, the electronic control module 300 adopts a PLC, and the first electric valve 3 and the second electric valve 10 are both pneumatic needle valves. The pneumatic needle valve 3 is controlled by the central PLC system. When the pressure of the first pressure sensor 17 exceeds the limit / under the limit, the ambient hydrogen concentration exceeds the standard, the temperature and pressure of the key point exceed the limit, or the emergency stop button is triggered, the first electric valve 3 and the second electric valve 10 are controlled to cut off the gas path.

[0043] As an improvement, the multi-functional integrated hydrogen refueling system also includes a first isolation valve 1, a second isolation valve 12, and a third isolation valve 13, all of which are used for maintenance isolation. During operation of the multi-functional integrated hydrogen refueling unit, all three remain fully open. In this embodiment, the first isolation valve 1, the second isolation valve 12, and the third isolation valve 13 are all needle valves. The first isolation valve 1 is located on the refueling pipeline, upstream of the first pressure sensor 17; the second isolation valve 12 is located on the output pipeline, between the protection branch and the second electric valve 10; and the third isolation valve 13 is located on the protection branch, between the third electric valve 14 and the second pressure sensor 25.

[0044] As an improvement, this multifunctional integrated hydrogen refueling system also includes a metering anti-fluctuation structure, which adopts a pre-metering design. Specifically, the multifunctional integrated hydrogen refueling system installs the mass flow meter 4 upstream of the system, breaking with traditional designs by placing it on the refueling line instead of the output line. This completely solves the metering inaccuracy problems caused by pipeline resonance and pressure surges in traditional solutions, maintaining metering accuracy even under high-pressure conditions. The porous flow equalization plate built into the mass flow meter 4 effectively eliminates fluid eddies and homogenizes the flow velocity distribution, thus providing a stable and reliable flow field environment for the flow meter 4, ensuring the accuracy and anti-interference capability of the measurement data.

[0045] As an improvement, the multifunctional integrated hydrogen refueling system also includes a first filter 2 and a second filter 9. The first filter 2 is disposed on the refueling line between the first pressure sensor 17 and the first electric valve 3, and the second filter 9 is disposed on the output line between the second pressure relief valve 8 and the second electric valve 10.

[0046] Both the first filter 2 and the second filter 9 are equipped with a two-stage filtration structure. The upstream first-stage filtration structure can filter impurity particles larger than the downstream second-stage filtration structure. In other words, the upstream first-stage filtration structure in the first filter 2 is used to filter larger contaminant particles, while the downstream second-stage filtration structure filters smaller contaminant particles, ensuring that impurities are filtered out as completely as possible and guaranteeing the purity of the hydrogen input to the direct-drive compression module 200. Similarly, the second filter 9 performs fine filtration of the hydrogen in the output pipeline, ensuring the purity of the hydrogen dispensed by the hydrogen refueling gun 16.

[0047] Furthermore, differential pressure sensors can be added to both the first filter 2 and the second filter 9. The dynamic response mechanism also includes setting a resistance threshold, which triggers an alarm to prompt the replacement of the filter elements of the first filter 2 and the second filter 9 when the threshold is exceeded.

[0048] In some embodiments, a flow meter can also be installed at the hydrogen outlet of the direct-drive compressor 7. The electronic control module 300 integrates a PID control algorithm to adjust the opening and closing of the first electric valve 3 and the second electric valve 10 according to the flow rate changes detected by the flow meter, the refueling demand identified through communication, and a preset dynamic response mechanism, thereby achieving adaptive adjustment. The dynamic response and adaptive adjustment of this system can achieve compensated adjustment of the hydrogen output at the output end, achieving precise flow control and pressure adaptation without relying on an external independent flow regulating valve. This simplifies the system structure and improves the intelligence and reliability of the control.

[0049] As an improvement, a hydrogen storage tank pressure sensor can be installed at the connection between the hydrogen source and the filling pipeline. The direct-drive compressor 7 is equipped with a voltage sensor and a current sensor. The electronic control module 300 controls the opening and closing of the first electric valve 3 and the second electric valve 10 according to the hydrogen storage tank pressure value sent by the hydrogen storage tank pressure sensor to match the system flow requirements. The electronic control module 300 dynamically adjusts and matches the compression ratio and cooling strategy of the direct-drive compression module 200 according to the voltage and current values ​​of the direct-drive compressor 7 sent by the voltage sensor and the current sensor. As an improvement, the dynamic response mechanism of the multifunctional integrated hydrogen refueling system can also include dual temperature thresholds, such as setting two temperature thresholds in the dynamic response mechanism: a first-level temperature warning and a second-level temperature shutdown. The electronic control module 300 receives the temperature values ​​sent by the second temperature sensor 20, the first temperature sensor 22, and the third temperature sensor 24, compares them with the dual temperature thresholds, and controls the system to issue a warning or shutdown feedback according to the preset dynamic response mechanism.

[0050] Furthermore, the electronic control module 300 can also control the operating mode of the direct drive compression module 200 based on a preset dynamic response mechanism. For example, it can preset the three operating modes of the direct drive compression module 200: "pressure equalization - direct charging - standby" based on the hydrogen source pressure difference.

[0051] The direct-drive compression module 200's pressure equalization mode refers to the direct-drive compressor 7 not requiring compressor operation; refueling can be achieved solely through the gas source pressure difference. In this mode, the microchannel heat exchanger's operating mode is adjusted, activating only the basic cooling system of the microchannel heat exchanger (e.g., only activating the coolant for hydrogen pre-cooling, without activating the coolant for hydrogen cooling after secondary compression), maintaining only the minimum cooling flow rate. The direct-drive compression module 200's direct-charge mode refers to the direct-drive compressor 7 starting, with the direct-drive compressor 7 and the microchannel heat exchanger operating in tandem to ensure the refueling hydrogen temperature remains within safe standards. The direct-drive compression module 200's standby mode occurs when the system has been inactive for more than 5 minutes; in this mode, the electronic control module 300 reduces the microchannel heat exchanger's cooling power to the minimum baseline.

[0052] Example 2 This embodiment provides a multi-functional integrated hydrogen refueling machine based on a direct-drive compression module, based on the multi-functional integrated hydrogen refueling system based on a direct-drive compression module in Embodiment 1, such as... Figure 2 , 4As shown, the multifunctional integrated hydrogen refueling system includes a first isolation valve 1, a first filter 2, a first electric valve 3, a mass flow meter 4, a first pressure relief valve 5, a first pressure sensor 17, a first pressure gauge 18, and a second pressure gauge 19 on the refueling pipeline, and a second pressure relief valve 8, a second filter 9, a second electric valve 10, a one-way valve 11, a second isolation valve 12, a third isolation valve 13, a third electric valve 14, a second pressure sensor 25, and a third pressure gauge 26 on the output pipeline, which together constitute the process valve group module 100.

[0053] The process valve assembly module 100 is located inside a separate first housing, the direct drive compression module 200 is located inside a separate second housing, and the electrical control module 300 is located inside a separate third housing. The first housing, the second housing, and the third housing are sequentially mounted on a base, which is used to house the connecting lines and pipelines between the process valve assembly module 100, the direct drive compression module 200, and the electrical control module 300.

[0054] The first housing integrates the filling and output pipelines into a separate cabinet, while the second housing integrates the compression and cooling of the direct-drive compression module 200 into a separate cabinet, enabling all high-pressure pipelines to be built-in and zero external high-pressure pipelines to be installed.

[0055] Among them, the highly integrated cooling strategy of the direct-drive compression module 200 integrates hydrogen intake pre-cooling, compression cooling, and compressor cylinder cooling into one unit. The hydrogen cooling and compressor cylinder cooling share a cooling system, which greatly simplifies the equipment size and pipeline complexity, and reduces the cost of hydrogen refueling stations and the area of ​​land used.

[0056] In some embodiments, a cooling fan is provided at the top inside the second housing, a direct-drive compressor 7 is arranged in the middle, and a microchannel heat exchanger is integrated at the bottom. That is, the second housing, as a single cabinet structure, can realize the vertical integration layout of the direct-drive compression module 200 with the triple functions of "transmission-compression-cooling", which subverts the traditional distributed architecture and realizes the fundamental transformation of the equipment from fixed performance to upgradeable performance.

[0057] Furthermore, such as Figure 3 , 5 As shown, the multi-functional integrated hydrogen refueling device has one or more direct-drive compression modules 200, and one or more direct-drive compression modules 200 are respectively installed inside one or more second housings; all direct-drive compression modules 200 are connected in parallel.

[0058] The direct-drive compression module 200, as a standardized and expandable module, has unified external cabinet size constraints and interface standards, and is uniformly controlled by the electrical control module 300. In practice, it can achieve quick and safe connection with other direct-drive compression modules 200, process valve group modules 100, and electrical control modules 300 through standardized quick-connect connectors and foolproof design. The standardized expandable module aims to increase the refueling capacity per unit time by adding parallel identical direct-drive compression modules 200, adapting to higher frequency and higher flow rate refueling requirements.

[0059] The third housing contains an electrical control module 300, which can be implemented using a PLC control system. The electrical control module 300 can intelligently coordinate the work of each module based on a dynamic response mechanism. For example, the electrical control module 300 calculates and coordinates the operating phase of the direct-drive compressors 7 in each parallel direct-drive compressor module 200 based on the phase difference principle, so that the inherent periodic pipeline excitation force of two or more direct-drive compressors 7 cancels each other out before being transmitted through the frame, thereby suppressing the overall vibration response of the system from the source and significantly improving the stability and reliability of operation.

[0060] The multi-functional integrated hydrogen refueling machine provided in this embodiment innovatively reconstructs the core components of traditional split-type hydrogen refueling machines and compressors into deeply coupled modular units. Essentially, the multi-functional integrated hydrogen refueling machine is an integrated unit that combines direct-drive hydrogen compression, cooling, and hydrogen refueling functions. In terms of technical approach, energy efficiency optimization, system integration, and intelligent control, this invention revolutionizes the traditional separate design of compressors and hydrogen refueling machines, driving a leapfrog development of hydrogen refueling equipment towards high efficiency, compactness, and intelligence.

[0061] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A multifunctional integrated hydrogen refueling system based on a direct-drive compression module, characterized in that: It includes an electronic control module and a direct-drive compression module located between the hydrogen source and the output end. The direct-drive compression module includes a heat exchanger and a direct-drive compressor. The filling pipeline connecting the hydrogen source and the direct-drive compression module is equipped with a first electric valve and a first pressure relief valve; The heat exchanger has three heat exchange channels. Hydrogen source gas enters the first heat exchange channel through the filling pipeline from the inlet of heat exchanger a1. After initial pre-cooling, it flows out from the outlet of heat exchanger a2 and enters the direct-drive compressor for primary compression. After primary compression, the hydrogen gas enters the second heat exchange channel through the inlet of heat exchanger b1. After secondary cooling, it flows out from the outlet of heat exchanger b2 and enters the direct-drive compressor for secondary compression. After secondary compression, the hydrogen gas enters the third heat exchange channel through the inlet of heat exchanger c1. After tertiary cooling, it flows out from the outlet of heat exchanger c2 and enters the output pipeline connecting the output end to the direct-drive compression module. Temperature and pressure sensors are installed on the pipelines between the direct-drive compressor and the heat exchanger inlet b1, and between the direct-drive compressor and the heat exchanger inlet c1. The electronic control module controls the opening and closing degree of the first electric valve and / or controls the first pressure relief valve to release pressure based on the hydrogen temperature and pressure sent by the temperature and pressure sensors.

2. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 1, characterized in that: The heat exchanger uses two coolants to cool three heat exchange channels; One coolant path provides heat exchange only for the third heat exchange channel, while the other coolant path provides heat exchange for the first and second cooling channels and the direct-drive compressor.

3. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 1, characterized in that: The upstream section of the output pipeline is equipped with a second pressure relief valve and a second electric valve in sequence; the second pressure relief valve and the first pressure relief valve form a redundant isolation structure, and the second electric valve and the first electric valve form a redundant pressure relief structure.

4. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 3, characterized in that: The refueling pipeline is also equipped with a first pressure sensor; the first pressure sensor, the first electric valve, and the first pressure relief valve are sequentially arranged between the hydrogen source and the heat exchanger; The first pressure sensor is used to monitor the hydrogen pressure supplied from the hydrogen source. The electronic control module is also used to control the opening and closing degree of the first and second electric valves and / or control the first and second pressure relief valves to release pressure based on the pressure value received from the first pressure sensor.

5. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 4, characterized in that: A protection branch is also provided downstream of the output pipeline; a second pressure sensor and a third electric valve are installed in sequence on the protection branch, with the third electric valve located at the end of the protection branch; The second pressure sensor is used to monitor the pressure of the hydrogen gas output at the output end. The electronic control module is also used to control the opening and closing degree of the first and second electric valves and / or control the first and second pressure relief valves to release pressure based on the pressure value received from the second pressure sensor.

6. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 5, characterized in that: It also includes a first isolation valve, a second isolation valve, and a third isolation valve; the first isolation valve is located on the filling pipeline, upstream of the first pressure sensor; the second isolation valve is located on the output pipeline, between the protection branch and the second electric valve; and the third isolation valve is located on the protection branch, between the third electric valve and the second pressure sensor. The first isolation valve, the second isolation valve, and the third isolation valve are all used for maintenance isolation, and the multi-functional integrated hydrogen refueling machine is kept fully open during operation.

7. The multifunctional integrated hydrogenation system based on a direct-drive compression module according to any one of claims 3-6, characterized in that: The filling pipeline is also equipped with a mass flow meter with a built-in flow equalization plate, which is located between the first electric valve and the first pressure relief valve.

8. The multifunctional integrated hydrogen refueling system based on a direct-drive compression module according to claim 7, characterized in that: It also includes a first filter and a second filter. The first filter is disposed on the filling pipeline, between the first pressure sensor and the first electric valve, and the second filter is disposed on the output pipeline, between the second pressure relief valve and the second electric valve. Both the first and second filters are equipped with a two-stage filtration structure, wherein the first-stage filtration structure located upstream can filter impurity particles that are larger than those of the second-stage filtration structure located downstream.

9. A multi-functional integrated hydrogen refueling machine based on a direct-drive compression module, comprising the multi-functional integrated hydrogen refueling system based on a direct-drive compression module as described in any one of claims 6-8, characterized in that: The first isolation valve, the first electric valve, the first pressure relief valve, and the first pressure sensor installed on the filling pipeline, and the second isolation valve, the second electric valve, the second pressure relief valve, the third electric valve, the second pressure sensor, and the third isolation valve installed on the output pipeline together constitute the process valve group module; The valve assembly module is located inside the first housing, the direct drive compression module is located inside the second housing, and the electronic control module is located inside the third housing. The first housing, the second housing, and the third housing are sequentially mounted on the base, which is used to house the connecting lines and pipes between the valve group module, the direct drive compression module, and the electronic control module.

10. The multifunctional integrated hydrogen refueling machine based on a direct-drive compression module according to claim 9, characterized in that: There is one or more direct-drive compression modules, and one or more direct-drive compression modules are respectively installed inside one or more second housings; all direct-drive compression modules are connected in parallel.

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