Hydrogen production system

Abstract

This application discloses a hydrogen production system, belonging to the field of water electrolysis hydrogen production technology. The hydrogen production system includes a hydrogen power source and an electrolyzer, connected to the electrolyzer via a copper busbar; a status monitoring module coupled to the copper busbar and configured to monitor the current and temperature of the copper busbar; a cooling system thermally coupled to the copper busbar and configured to cool the copper busbar; and a controller connected to both the status monitoring module and the cooling system. The controller is configured to determine the predicted temperature of the copper busbar within a set time period based on a temperature prediction algorithm and parameters monitored by the status monitoring module. If the predicted temperature of the copper busbar is greater than or equal to a temperature threshold, the controller activates the cooling system. By predicting the temperature trend of the copper busbar within a future time period based on the current flowing through it and the copper busbar temperature, the cooling system is proactively activated before the actual surface temperature of the copper busbar exceeds the threshold. This early intervention prevents the copper busbar from continuously operating at extreme high temperatures, reducing its heat load and mitigating the risk of aging.

Description

Technical Field

[0001] This application belongs to the field of water electrolysis for hydrogen production technology, and particularly relates to a hydrogen production system. Background Technology

[0002] In current large-scale water electrolysis hydrogen production systems, the AC and DC side copper busbars are continuously under high heat load due to carrying thousands of amperes of rated current. Traditional temperature control systems can only respond passively after the temperature exceeds the limit, resulting in delayed fault handling and accelerated thermal aging and wear of the copper busbar materials. Summary of the Invention

[0003] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes a hydrogen production system that actively activates a cooling system before the actual surface temperature of the copper busbar exceeds a threshold. By intervening in advance, the system prevents the copper busbar from continuously operating at extreme high temperatures, reducing its heat load and thus extending the aging risk of the copper busbar.

[0004] In a first aspect, this application provides a hydrogen production system, the hydrogen production system comprising: Hydrogen power supply and electrolyzer, with the hydrogen power supply and electrolyzer connected by a copper busbar; A status monitoring module, coupled to the copper busbar, is configured to monitor the current and temperature of the copper busbar; A cooling system, thermally coupled to the copper busbar, is configured to cool the copper busbar. The controller is connected to the status monitoring module and the cooling system respectively. The controller is configured to determine the predicted temperature of the copper busbar within a set time period based on the temperature prediction algorithm and the parameters monitored by the status monitoring module. When the predicted temperature of the copper busbar is greater than or equal to the temperature threshold, the controller controls the cooling system to start.

[0005] According to one embodiment of this application, the status monitoring module includes: A current monitoring device is installed at the current measurement node of the copper busbar; Temperature monitoring device is installed on the surface of the copper busbar.

[0006] According to one embodiment of this application, the current monitoring device includes a Rogowski coil and / or a Hall effect current sensor; The Rogowski coil is mounted on a copper busbar, and the Hall effect current sensor is electrically connected to the current measurement node of the copper busbar.

[0007] According to one embodiment of this application, the temperature monitoring device includes a temperature probe and an infrared thermal imager; The temperature probe is placed on the surface of the copper busbar, and the infrared thermal imager is positioned facing the surface of the copper busbar.

[0008] According to one embodiment of this application, the controller is electrically connected to the hydrogen production power supply, and the controller is further configured to control the reduction of the output power of the hydrogen production power supply when the predicted temperature of the copper busbar is greater than or equal to a temperature threshold.

[0009] According to one embodiment of this application, the condition monitoring module further includes a deformation monitoring device for monitoring the deformation of the copper busbar. The controller is connected to the deformation monitoring device and is further configured to determine the cooling intensity level based on the predicted temperature of the copper busbar and / or the deformation of the copper busbar, and control the cooling system to operate at a level corresponding to the cooling intensity level.

[0010] According to one embodiment of this application, the deformation monitoring device is disposed at at least one of the bolted connection of the copper busbar, the fixing point of the supporting insulator, and the right-angle bend.

[0011] According to one embodiment of this application, the deformation monitoring device includes a fiber Bragg grating sensor and / or a distributed sensing fiber; The fiber Bragg grating sensor is installed at at least one of the following locations: the bolt connection of the copper busbar, the fixing point of the supporting insulator, and the right-angle bend. The distributed sensing fiber is laid along the length of the copper busbar.

[0012] According to one embodiment of this application, the cooling system includes a fan, and the controller is further configured to control the fan to operate at a first speed when the predicted temperature of the copper busbar is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar is greater than or equal to a first deformation threshold; and to control the fan to operate at a second speed when the predicted temperature of the copper busbar is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar is greater than or equal to a second deformation threshold, wherein the second speed is greater than the first speed, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

[0013] According to one embodiment of this application, the cooling system further includes a liquid cooling system, and the controller is further configured to control the fan to stop working and start the liquid cooling system when the predicted temperature of the copper busbar is greater than or equal to a third temperature threshold and / or the deformation of the copper busbar is greater than or equal to a third deformation threshold. The third temperature threshold is greater than a first temperature threshold and the third deformation threshold is greater than a second deformation threshold.

[0014] According to one embodiment of this application, the cooling system further includes a liquid cooling system, and the controller is further configured to control the liquid cooling system to operate at a first flow rate when the predicted temperature of the copper busbar is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar is greater than or equal to a first deformation threshold; and to control the liquid cooling system to operate at a second flow rate when the predicted temperature of the copper busbar is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar is greater than or equal to a second deformation threshold, wherein the second flow rate is greater than the first flow rate, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

[0015] According to one embodiment of this application, the controller is further configured to generate a mechanical fault signal when the predicted temperature of the copper busbar is less than a first temperature threshold and the deformation value detected by the deformation monitoring device is greater than or equal to a third deformation threshold.

[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0017] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a structural block diagram of the hydrogen production system provided in the embodiments of this application; Figure 2 This is a schematic diagram of the long short-term memory neural network model provided in the embodiments of this application; Figure 3 This is a data transmission diagram of the copper busbar temperature control method for a hydrogen production system provided in an embodiment of this application.

[0018] Figure label: Controller 10, Long Short-Term Memory Neural Network Model 20, Input Layer 21, Hidden Layer 22, Output Layer 23, Cooling System 30, Hydrogen Power Supply 40, Electrolyzer 50, Monitoring Backend 60, Status Monitoring Module 70, Copper Busbar 80. Detailed Implementation

[0019] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0020] In the following description, a "circuit" refers to a conductive loop consisting of at least one element or sub-circuit connected by an electrical or electromagnetic link. When an element or circuit is said to be "coupled to" or "connected to" another element, or when an element / circuit is said to be "coupled at" or "connected at" two nodes, it can be directly coupled to or connected to the other element, or there may be intermediate elements. The connection between elements can be physical, logical, or a combination thereof. Conversely, when an element is said to be "directly coupled to" or "directly connected to" another element, it means that there are no intermediate elements between them.

[0021] In the description, the terms "first," "second," etc., are used to distinguish similar objects, not to describe a specific order or sequence. It should be understood that such numerical descriptors can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class, not limited in number; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0022] Furthermore, the use of terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicates that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0023] In current large-scale water electrolysis hydrogen production systems, the AC and DC side copper busbars are continuously under high heat load due to carrying thousands of amperes of rated current. Traditional temperature control systems can only respond passively after the temperature exceeds the limit, lacking the ability to predict temperature change trends, leading to delayed fault handling and exacerbating the thermal aging and wear of the copper busbar materials.

[0024] Figure 1 A structural block diagram of a hydrogen production system provided in an embodiment of this application is shown. (Refer to...) Figure 1 The hydrogen production system includes: a hydrogen production power source 40, an electrolyzer 50, a status monitoring module 70, a cooling system 30, and a controller 10. The hydrogen production power source 40 and the electrolyzer 50 are connected via a copper busbar 80; the status monitoring module 70 is coupled to the copper busbar 80 and configured to monitor the current and temperature of the copper busbar 80; the cooling system 30 is thermally coupled to the copper busbar 80 and configured to cool the copper busbar 80; the controller 10 is connected to both the status monitoring module 70 and the cooling system 30, and is configured to determine the predicted temperature of the copper busbar 80 within a set time period based on a temperature prediction algorithm and the parameters monitored by the status monitoring module 70. If the predicted temperature of the copper busbar 80 is greater than or equal to a temperature threshold, the controller activates the cooling system 30.

[0025] The hydrogen production power source 40 refers to the power supply device that provides DC power to the electrolyzer 50. It usually uses a rectifier or a dedicated electrolysis power supply to convert AC power into stable DC power required for electrolysis.

[0026] Electrolyzer 50 is a device for carrying out water electrolysis, which decomposes water into hydrogen and oxygen under the action of direct current.

[0027] Copper busbar 80 refers to a copper conductive busbar used for high current transmission. Due to its good conductivity and strong current carrying capacity, it is often used to connect power supplies to high-power electrical equipment such as electrolytic cells 50.

[0028] The condition monitoring module 70 typically includes a current sensor and a temperature sensor to collect the operating current and surface temperature of the copper busbar 80 in real time. In addition, the condition monitoring module 70 can also monitor the ambient temperature of the copper busbar 80.

[0029] The cooling system 30 may include an air-cooling device or a liquid-cooling circuit, or it may have both an air-cooling device and a liquid-cooling circuit. The cooling system 30 can exchange heat with the copper busbar 80 by controlling the flow of the cooling medium and adjusting the working state of the cooling device, thereby reducing the working temperature of the copper busbar 80 and preventing the copper busbar 80 from overheating or being damaged due to excessive temperature.

[0030] Based on the real-time data detected by the status monitoring module 70, the controller 10 calculates the predicted temperature of the copper busbar 80 within a future period (e.g., the next few minutes) using a temperature prediction algorithm. If the predicted temperature reaches or exceeds a preset temperature threshold, the controller 10 determines that the copper busbar 80 is at risk of overheating and immediately sends a start command to the cooling system 30. The cooling system 30 then starts working, forcibly cooling the copper busbar 80 to prevent its actual temperature from rising to a dangerous level.

[0031] Controller 10 can be implemented using an MCU (Microcontroller Unit) chip; it can also be based on a DSP (Digital Signal Processor) chip or an FPGA (Field-Programmable Gate Array) chip. The controller 10 can be implemented using a Programmable Gate Array (FPGA) or a custom-designed controller chip; this application does not limit the specific hardware implementation of the controller 10.

[0032] The temperature prediction algorithm is a machine learning algorithm or numerical simulation algorithm based on the heat conduction model and historical operating data. The algorithm models the relationship between current and temperature, takes into account the heat conduction characteristics of the copper busbar 80 material, the influence of the ambient temperature, and the effect of current on the temperature rise of the copper busbar 80, and predicts the temperature change trend of the copper busbar 80 within a time period so as to take appropriate control measures in advance.

[0033] After completing the temperature prediction, the controller 10 determines whether the predicted temperature of the copper busbar 80 has reached or exceeded the preset temperature threshold. If the predicted temperature of the copper busbar 80 is greater than or equal to the set temperature threshold, the controller 10 triggers the start command of the cooling system 30. The cooling system 30 is actively started before the actual surface temperature of the copper busbar 80 exceeds the threshold. This early intervention can prevent the copper busbar 80 from being in an extreme high-temperature state.

[0034] It should be noted that the temperature threshold is an upper limit temperature value set based on the temperature resistance characteristics of the copper busbar material 80, the insulation aging threshold, and the system safety margin. The specific value of the temperature threshold can be determined according to the actual application scenario and is not limited here. For example, the temperature threshold can be 60℃ or 65℃, etc.

[0035] The specific value of the set time period can be selected according to the actual application scenario, and is not limited here. As an example, if the set time period is 5 minutes, and the temperature prediction algorithm predicts that the temperature of the copper busbar 80 will exceed the temperature threshold at the 3rd minute, then the controller 10 will immediately control the cooling system 30 to start, cool the copper busbar 80 in advance, and reduce its heat load.

[0036] According to the hydrogen production system of this application, the temperature trend of copper busbar 80 within a time period can be predicted in advance by using a temperature prediction algorithm based on real-time current, temperature and environmental parameters. Thus, the cooling system 30 is actively started before the actual surface temperature of copper busbar 80 exceeds the threshold. By intervening in advance, the copper busbar 80 is prevented from being in an extreme high temperature state, its heat load is reduced, thereby extending the aging risk of copper busbar 80.

[0037] In some embodiments, the controller 10 is specifically configured to extract historical time-series data of the current current value and the current temperature, construct a long short-term memory neural network model 20 based on the historical time-series data, and use the current current value and the current temperature as input data of the long short-term memory neural network model 20 to determine the predicted temperature within a set time period.

[0038] Historical time-series data of current values, copper busbar temperature, and ambient temperature collected within a preset historical time window are extracted and preprocessed, including data cleaning, normalization, and segmentation. These data reflect the dynamic changes in current, temperature, and environmental conditions over a period of time.

[0039] Figure 2 A flowchart illustrating the temperature control method for the copper busbar 80 in a hydrogen production system according to an embodiment of this application is shown. (Refer to...) Figure 2Based on preprocessed historical time-series data, a long short-term memory neural network (LSTM) model for temperature prediction is constructed. The model includes an input layer 21, a hidden layer 22, and an output layer 23. The long short-term memory neural network model 20 is deployed in the controller 10 of the hydrogen production system to predict the temperature change trend of the copper busbar 80 in real time within a set time period.

[0040] The input layer 21 of the LSTM model is used to input historical time-series data of the current value flowing through the copper busbar 80, the temperature of the copper busbar 80, and the ambient temperature, and to attach a timestamp to each historical time-series data to ensure that the model can correctly identify and process the time sequence of the data.

[0041] Hidden layer 22 of the LSTM model is primarily used for parameter training and optimization of the input data. Specifically, the system iteratively optimizes the model based on its internal weights to adjust the weight parameters, enabling the model to more accurately predict temperature changes over a given time period. This process continuously adjusts the model weights to ensure that the prediction results match the actual temperature changes as closely as possible, thus providing high-precision temperature predictions. Finally, the predicted temperature for the given time period is output by the output layer 23 of the LSTM model.

[0042] LSTM models, due to their superior modeling capabilities for time series data, can effectively capture long-term dependencies within the data. Using this method, the system can achieve accurate temperature prediction, providing reliable data support for temperature control system adjustments, equipment performance optimization, and energy efficiency management.

[0043] Figure 3 A schematic diagram of data transmission for the temperature control method of the copper busbar 80 in the hydrogen production system provided in an embodiment of this application is shown. (Refer to...) Figure 3 In some embodiments, the input data also includes one or more of the following: the operating status of the electrolyzer 50, the output power of the hydrogen power supply 40, and the hydrogen production rate.

[0044] By incorporating one or more parameters—such as the state of electrolyzer 50, power output, and hydrogen production rate—into the model, the prediction algorithm can perceive the overall operational status of the hydrogen production system. Specifically, the operating state of electrolyzer 50 directly affects the heat generation and current distribution throughout the hydrogen production process, thus influencing the temperature changes of the copper busbar 80. The output power of the hydrogen production power source 40 is a crucial energy source for the hydrogen production system, and fluctuations in its output power directly affect the workload and heat generation of the copper busbar 80 and other related equipment. The hydrogen production rate reflects the efficiency of the hydrogen production process and indirectly affects the system's heat accumulation and dissipation requirements. Through deep learning of the relationships between these parameters, the model can more accurately predict the thermal dynamics of the copper busbar 80, avoiding the limitations of predictions based solely on local temperature and historical current data.

[0045] When the model predicts that the surface temperature of the copper busbar 80 is about to exceed the temperature threshold, it can comprehensively consider the current hydrogen production status of the electrolyzer 50 and the power output to intelligently decide on the optimal control strategy (such as starting the cooling first and then fine-tuning the power output). This not only ensures the safety of the copper busbar 80, but also avoids drastic disturbances to the efficiency of the electrolyzer 50 or the stable production of hydrogen. It can improve the energy utilization efficiency of the system, enhance the stability and reliability of the entire system, and extend the equipment life.

[0046] In addition, the hydrogen production system can also be equipped with a monitoring backend 60. The controller 10 transmits the real-time data to the monitoring system through a communication connection with the monitoring backend 60, which facilitates remote monitoring and management by the user. This allows the user to obtain the operating status and fault information of the hydrogen production system in a timely manner, thereby improving the operability and management efficiency of the system.

[0047] In summary, by introducing multiple system operating parameters, this embodiment can not only improve the accuracy of temperature prediction, but also realize the collaborative management and global optimization of key components in the hydrogen production system.

[0048] In some embodiments, the status monitoring module 70 includes a current monitoring device and a temperature monitoring device. The current monitoring device is disposed at the current measurement node of the copper busbar 80; the temperature monitoring device is disposed on the surface of the copper busbar 80.

[0049] A current monitoring device is correspondingly set at the current measurement node of the copper busbar 80 to directly measure the current value flowing through the copper busbar 80; a temperature monitoring device is directly set on the surface of the copper busbar 80 to directly measure the surface temperature of the copper busbar 80 during operation.

[0050] A current measurement node refers to a specific location on the copper busbar 80 where a current monitoring device is installed. The selection of a current measurement node should consider factors such as uniform magnetic field distribution and distance from strong interference sources to ensure the accuracy and representativeness of the current measurement. For example, a current measurement node can be set in a straight section of the copper busbar 80 without connecting terminals.

[0051] The controller 10 synchronously receives real-time data from both the current monitoring device and the temperature monitoring device. The current value is the fundamental cause of heat generation in the copper busbar 80, while the surface temperature is the result of the combined effects of heat generation and heat dissipation. Simultaneous monitoring of both current and temperature overcomes the limitations of monitoring only a single parameter. This allows the system to not only respond to existing overheating but also provide early warnings of potential temperature rise risks through abnormal current readings, improving the accuracy of predictions.

[0052] In some embodiments, the current monitoring device includes a Rogowski coil and / or a Hall effect current sensor; wherein the Rogowski coil is sleeved on the copper busbar 80, and the Hall effect current sensor is electrically connected to the current measurement node of the copper busbar 80. According to one embodiment of this application, the temperature monitoring device includes a temperature probe and an infrared thermal imager; the temperature probe is disposed on the surface of the copper busbar 80, and the infrared thermal imager is disposed facing the surface of the copper busbar 80.

[0053] The Rogowski coil is non-contactly mounted on the copper busbar 80. Its operating principle is based on the laws of electromagnetic induction and Ampere's circuital law. When alternating current flows through the copper busbar 80, a changing magnetic field is generated, which induces a voltage signal in the coil that is proportional to the rate of change of current. This signal is processed by an external integrator to reconstruct a measurement value that is precisely proportional to the original current waveform.

[0054] Hall effect current sensors are typically electrically connected to the current measurement node of a copper busbar 80, forming a closed-loop magnetic circuit. The copper busbar 80 generates a concentrated magnetic field at the air gap of the sensor's built-in magnetic core. The Hall element located in the air gap senses this magnetic field strength and outputs a corresponding Hall voltage. After amplification and processing, an output signal linearly related to the measured current is obtained. Hall sensors can measure both DC and AC currents, have fast response times, good electrical isolation, and typically offer higher measurement accuracy and lower zero-point drift.

[0055] Rogowski coils and Hall effect current sensors can be used individually or in combination to create redundancy or meet different measurement needs. Both Rogowski coils and Hall effect current sensors can convert large currents on the copper busbar 80, which are difficult to measure directly, into low-power electrical signals that can be safely and accurately read by the controller 10 through magneto-electric conversion, thereby achieving real-time current monitoring.

[0056] The temperature monitoring device includes a temperature probe and an infrared thermal imager. The temperature probe typically refers to a contact-type temperature sensing element, such as a thermocouple or a resistance temperature detector (RTD). In this embodiment, the temperature probe can be installed on the surface of the copper busbar 80 at a temperature measuring point (such as at a joint or at the point of highest current density) using thermally conductive adhesive, clamps, or welding. Its working principle is to directly convert the physical quantity of temperature into an electrical signal using the thermoelectric effect (thermocouple) or the characteristic of resistance changing with temperature (RTD).

[0057] An infrared thermal imager is a non-contact temperature measurement device. In this embodiment, the infrared thermal imager can be installed in a stable position facing the surface of the copper busbar 80. The infrared thermal imager can detect the infrared radiation energy naturally emitted by the surface of the copper busbar 80 and convert it into a thermal image reflecting the temperature distribution. Using an infrared thermal imager can not only display the temperature at a specified point, but also present the temperature field distribution of the entire surface of the copper busbar 80, and identify local hot spots.

[0058] In some embodiments, the controller 10 is electrically connected to the hydrogen production power supply 40, and the controller 10 is further configured to control the hydrogen production power supply 40 to reduce its output power when the predicted temperature of the copper busbar 80 is greater than or equal to a temperature threshold.

[0059] When the controller 10 determines that the predicted temperature of the copper busbar 80 is greater than or equal to the temperature threshold and has executed the control command to start the cooling system 30, if the predicted temperature rise trend is still not effectively suppressed, its output power can be reduced by a certain proportion or in steps. Since the heat load of the copper busbar 80 mainly comes from the Joule heat generated by the current, reducing the output power of the hydrogen production power supply 40 will directly reduce the current flowing through the copper busbar 80, thereby reducing the heat load and achieving rapid control of the temperature of the copper busbar 80.

[0060] Linking the temperature control of the copper busbar 80 with the operating status of the hydrogen production power supply 40 solves the problem of insufficient system linkage caused by the independent operation of each subsystem in the past, and improves the intelligence and reliability of the control: by combining predictive temperature management and active power control, the system can intervene before potential overheating faults occur, which not only protects the copper busbar 80 itself, but also avoids the impact of high current overload on the hydrogen production power supply 40, and improves the stability and safety of large-scale hydrogen production systems under high temperature and high current conditions.

[0061] It should be noted that the extent to which the power output of the hydrogen generator 40 is reduced can be determined based on the actual application scenario, and is not limited here. For example, when the temperature of the copper busbar 80 is below the temperature threshold, the hydrogen generator 40 operates at full capacity (100%). When the predicted temperature of the copper busbar 80 is greater than or equal to the temperature threshold, the output is reduced to 80% or 50% of the rated value to lower the temperature of the copper busbar 80.

[0062] In some embodiments, the condition monitoring module 70 further includes a deformation monitoring device for monitoring the deformation of the copper busbar 80. The controller 10 is connected to the deformation monitoring device and is further configured to determine the cooling intensity level based on the predicted temperature of the copper busbar 80 and / or the deformation of the copper busbar 80, and control the cooling system 30 to operate at a level corresponding to the cooling intensity level.

[0063] The deformation monitoring device is used to monitor the deformation of the copper busbar 80 under thermal stress and electrodynamic force in real time. The controller 10 is connected to the deformation monitoring device and, based on the predicted temperature of the copper busbar 80 and / or the real-time monitored deformation of the copper busbar 80, jointly determines an optimal cooling intensity level, and then controls the cooling system 30 to operate at a specific speed corresponding to that level to cool the copper busbar 80.

[0064] Cooling intensity ratings refer to different cooling power or capacity levels quantified according to cooling requirements. For example, for air-cooled systems, cooling intensity ratings can correspond to low, medium, and high fan speeds. For liquid-cooled systems, cooling intensity ratings can correspond to low, medium, and high coolant flow rates within the liquid-cooled system.

[0065] The deformation of the copper busbar 80 is mainly due to repeated thermal expansion and contraction cycles. Abnormal or continuously increasing deformation may indicate loose connecting bolts, material fatigue, failure of the supporting structure, or localized overheating leading to a decline in mechanical properties. When the deformation is detected to exceed the normal fluctuation range or show an increasing trend, even if the current predicted temperature has not reached an extreme high level, the controller 10 may increase the cooling intensity level to prevent physical structural damage caused by thermomechanical stress and improve the reliability of the system.

[0066] In some embodiments, the deformation monitoring device is disposed at at least one of the bolted connection of the copper busbar 80, the fixing point of the supporting insulator, and the right-angle bend.

[0067] Bolted connections refer to the locations where electrical and mechanical connections are achieved by fastening bolts between copper busbars 80 or between copper busbars 80 and equipment terminals. Due to the difference in thermal expansion coefficients between the copper busbar 80 body and the bolts, complex alternating stresses will be generated at this location under temperature cycling, which can easily lead to relaxation of contact pressure.

[0068] The insulator fixing point refers to the installation and fixing position used to fix and support the copper busbar 80, keeping it insulated from the grounding structure. This fixing point is subjected to multi-directional forces from the copper busbar 80, such as vertical gravity, horizontal thrust or tension caused by thermal expansion and contraction, and huge electrodynamic impact during short circuits.

[0069] The right-angle bend refers to the abrupt change in geometric shape formed by the bending of the copper busbar 80 to adapt to the wiring space. It is the area where the stress is most concentrated on the copper busbar 80 body. Under repeated changes in load current, the bend is prone to local overheating due to stress concentration.

[0070] By deploying deformation monitoring devices in areas prone to deformation, these devices can detect early signs of failure in the early stages of physical deformation, before significant temperature rise, enabling predictive maintenance and preventing the escalation of faults. Simultaneously, they can accurately pinpoint the fault location, shortening troubleshooting time.

[0071] In some embodiments, the deformation monitoring device includes a fiber Bragg grating sensor and / or a distributed sensing fiber; wherein the fiber Bragg grating sensor is disposed at at least one of the bolted connection, the fixing point of the supporting insulator, and the right-angle bend of the copper busbar 80, and the distributed sensing fiber is laid along the length of the copper busbar 80.

[0072] A fiber Bragg grating sensor is a periodic refractive index modulation structure formed within the core region of a single-mode optical fiber using processes such as laser interferometry. When a broadband beam of light passes through the fiber Bragg grating sensor, the grating reflects a very narrow, specific center wavelength. When the environment in which the fiber Bragg grating sensor is located changes, it causes a change in the grating's period or the effective refractive index of the fiber core, resulting in a linear shift in the reflected Bragg wavelength. By monitoring the wavelength shift using a high-precision demodulator, the deformation value can be calculated.

[0073] Fiber Bragg grating sensors can be installed at one of the following locations on the copper busbar 80: bolt connection, support insulator fixing point, or right-angle bend, to detect the most critical risk points and save costs. Alternatively, they can be installed at multiple locations on the copper busbar 80, including bolt connection, support insulator fixing point, and right-angle bend, to improve detection accuracy.

[0074] Distributed sensing fiber refers to sensing fiber based on the principles of optical time-domain reflection or optical frequency-domain reflection. Laser pulses or scanning light are injected into the sensing fiber, and its backscattered light signals are received. When the optical properties of any point along the fiber change due to deformation, the corresponding backscattered signal at that point will change. By analyzing the amount of signal change, the magnitude of the deformation can be quantified.

[0075] Distributed sensing optical fibers are laid or embedded tightly on the surface of the copper busbar 80 in a straight line, spiral or loop manner, so that they are fully coupled with the deformation field of the copper busbar 80, and can sense the deformation of the copper busbar 80.

[0076] Fiber optic sensors are made of glass, are completely insulated and passive, and are unaffected by the strong electromagnetic field and high voltage of the hydrogen production system, which can improve the accuracy of measurements.

[0077] In some embodiments, the controller 10 is specifically configured to determine the cooling intensity level based on the difference between the predicted temperature of the copper busbar 80 and the temperature threshold; and control the cooling system 30 to operate at a level corresponding to the cooling intensity level.

[0078] Controller 10 first calculates the difference between the predicted temperature of copper busbar 80 and the temperature threshold. This difference reflects the degree of deviation of the current temperature from the set temperature threshold. If the predicted temperature of copper busbar 80 is higher than the temperature threshold, the system will trigger the cooling control logic.

[0079] Based on the temperature difference, the system determines the required cooling intensity level for the cooling system 30. If the temperature difference is large, the system selects a higher cooling intensity; if the temperature difference is small, it selects a lower cooling intensity. For example, when the temperature difference exceeds a certain value, the system can be set to the maximum cooling level to quickly lower the temperature; if the difference is small, a lower cooling intensity is used to maintain a stable temperature.

[0080] Once the cooling intensity level is determined, the system will control the cooling system 30 to operate at the level corresponding to that intensity level. The cooling system 30 adjusts the cooling effect by adjusting fan speed, compressor power, or other related mechanisms to ensure that the temperature of the copper busbar 80 is within a safe range. The specific control method for the gear level can be flexibly set according to the design requirements of the equipment and is not limited here.

[0081] The automatic switching of cooling strategies based on temperature change trends can not only effectively prevent the copper busbar temperature from getting too high, but also improve energy utilization efficiency, reduce unnecessary energy consumption, and ensure the long-term stable operation of the equipment.

[0082] It should be noted that each cooling intensity level corresponds to a specific combination of operating speeds for one or more actuators (such as fans and liquid cooling systems) of the cooling system 30. As an example, it can be pre-set that when the difference between the predicted temperature of the copper busbar 80 and the temperature threshold is in the first range, a low cooling intensity is determined, and only the cooling fan is activated and runs at low speed; when the difference is in the second range, a medium cooling intensity is determined, the cooling fan is activated and runs at high speed, and the circulating liquid cooling system is activated to enhance heat dissipation; when the difference reaches the third range, a high cooling intensity is determined, and the fan and liquid cooling system can be controlled to operate at full power to achieve maximum cooling capacity.

[0083] Finally, the controller 10 generates control commands that match the determined cooling intensity level, driving the cooling system 30 to operate in the corresponding gear combination, thereby realizing dynamic switching of the operating mode of the cooling system 30 and optimizing energy consumption.

[0084] In some embodiments, the cooling system 30 includes a fan, and the controller 10 is further configured to control the fan to operate at a first speed when the predicted temperature of the copper busbar 80 is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a first deformation threshold; and to control the fan to operate at a second speed when the predicted temperature of the copper busbar 80 is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a second deformation threshold, wherein the second speed is greater than the first speed, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

[0085] When the predicted temperature of copper busbar 80 is greater than or equal to the first temperature threshold, it indicates that the predicted temperature of copper busbar 80 is slightly high, requiring only mild cooling. Similarly, if the deformation of copper busbar 80 is greater than or equal to the first deformation threshold, it indicates that copper busbar 80 may experience minor stress anomalies, requiring mild cooling. At this time, controller 10 sets the fan to operate at the first speed. Moderate airflow is achieved through a lower fan speed, effectively avoiding overcooling while ensuring energy-efficient system operation.

[0086] When the predicted temperature of copper busbar 80 is greater than or equal to the second threshold, it indicates a rapid temperature rise and a high thermal risk, requiring stronger cooling measures. Similarly, if the deformation of copper busbar 80 is greater than or equal to the second deformation threshold, it indicates that the deformation has reached a level that may affect the reliability of electrical connections or the integrity of the mechanical structure. At this time, controller 10 sets the fan to operate at the second speed. The second speed is higher than the first speed, providing stronger airflow and effectively reducing the temperature of copper busbar 80, preventing system efficiency degradation or equipment damage due to overheating.

[0087] It should be noted that the specific level of the fan speed can be determined according to the actual application scenario, and is not limited here.

[0088] As an example, the first temperature threshold is 50℃ and the second temperature threshold is 60℃. That is, when the predicted temperature of the copper busbar 80 is 50℃≤T<60℃, the fan is controlled to run at low speed with a first speed of 1000RPM / min; when the predicted temperature of the copper busbar 80 is T≥60℃, the fan is controlled to run at medium speed with a second speed of 2000RPM / min.

[0089] As an example, the first deformation threshold is 0.2%, and the second deformation threshold is 0.3%. That is, when the deformation of the copper busbar is 0.2% ≤ ε < 0.3%, the fan is controlled to run at low speed with a first speed of 1000 RPM / min; when the deformation of the copper busbar is ε ≥ 0.3%, the fan is controlled to run at medium speed with a second speed of 2000 RPM / min.

[0090] In other embodiments, when the predicted temperature of the copper busbar 80 is greater than a third temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a third deformation threshold, the controller 10 sets the fan to operate at a third speed. Specifically, taking a third temperature threshold of 75°C and a third deformation threshold of 0.4% as an example, that is, when the predicted temperature T of the copper busbar 80 is greater than 75°C and / or the third deformation threshold ε is greater than 0.4%, the fan is controlled to operate at high speed, with a speed of 3000 RPM / min.

[0091] As an example, due to power grid fluctuations, the current in electrolytic cell 50 surged from 7000A to 9000A. The LSTM model predicted that the temperature of copper busbar 80 would reach 88℃ after 5 minutes. Controller 10 proactively activated air cooling, controlling the fan to run at 3000RPM / min and limiting the electrolysis current to 8500A. In actual operation, the temperature of copper busbar 80 stabilized at 81℃, avoiding over-temperature shutdown caused by a passive response after the temperature exceeded the limit.

[0092] It should be noted that when either the predicted temperature or deformation of the copper busbar 80 reaches a threshold, the cooling system 30 can be triggered to perform the corresponding refrigeration operation. This ensures that the hydrogen production system can respond promptly when the temperature has not risen significantly but the deformation is abnormal, or when the deformation is normal but the predicted temperature exceeds the limit, thereby improving the safety of the system.

[0093] In other embodiments, when the predicted temperature of the copper busbar 80 is greater than or equal to a first temperature threshold and the deformation of the copper busbar 80 is greater than or equal to a first deformation threshold, the controller 10 can determine that the system is at risk of overload and will immediately execute a shutdown action for maintenance.

[0094] In some embodiments, the cooling system 30 further includes a liquid cooling system, and the controller 10 is further configured to control the fan to stop working and start the liquid cooling system when the predicted temperature of the copper busbar 80 is greater than or equal to a third temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a third deformation threshold. The third temperature threshold is greater than the first temperature threshold and the third deformation threshold is greater than the second deformation threshold.

[0095] A liquid cooling system typically refers to a circulating cooling device, which includes a coolant circulation pump, a liquid cooling plate thermally coupled to the copper busbar 80, a radiator, and a storage tank. It directly absorbs heat from the copper busbar 80 by forcibly circulating coolant within the liquid cooling plate, and then dissipates the heat to the environment through the radiator, resulting in a relatively high heat dissipation capacity.

[0096] When the predicted temperature of copper busbar 80 is greater than or equal to the third temperature threshold and / or the deformation of copper busbar 80 is greater than or equal to the third deformation threshold, it indicates that the temperature of copper busbar 80 is about to reach a critical high temperature, or the deformation is approaching the critical point of the material's safety limit, requiring stronger cooling measures. In this case, the control system will first stop the fan, as the fan's cooling effect is no longer effective in this high-temperature environment. Subsequently, the liquid cooling system will start working, with flowing coolant cooling the copper busbar 80, providing more efficient heat exchange. The start-up of the liquid cooling system can remove a large amount of heat through a large flow of coolant, rapidly reducing the temperature of copper busbar 80, thereby preventing overheating of copper busbar 80 from causing equipment failure or reducing system efficiency.

[0097] As an example, when the load current suddenly increases to 8000A, the model predicts that the temperature of the copper busbar 80 will reach 80℃ after 5 minutes, triggering a pre-cooling command and controlling the operation of the cooling system 30. If the current temperature is in the range of 50℃~60℃, the fan is started and the speed is dynamically adjusted (e.g., 2000RPM / min for 7000A current, 2500RPM / min for 8000A current); when the temperature is >75℃, the system switches to liquid cooling. If the temperature exceeds 100℃ or the deformation value ε ≥ 0.3%, the controller 10 automatically reduces the current of the electrolytic cell 50 to 80% of the rated value and triggers an audible and visual alarm.

[0098] This method, through the coordinated control of the fan and liquid cooling system, ensures that the hydrogen production system can flexibly respond to temperature changes and deformation. When the temperature of the copper busbar 80 does not reach an excessively high level, the fan maintains mild cooling by operating at low speed, avoiding unnecessary energy consumption and maintaining a stable working environment. When the temperature of the copper busbar 80 exceeds the set range or the deformation exceeds the deformation threshold, the fan stops working, and the liquid cooling system takes over to provide more intense cooling, ensuring more precise and efficient temperature control.

[0099] In some embodiments, the cooling system 30 further includes a liquid cooling system, and the controller 10 is further configured to control the liquid cooling system to operate at a first flow rate when the predicted temperature of the copper busbar 80 is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a first deformation threshold; and to control the liquid cooling system to operate at a second flow rate when the predicted temperature of the copper busbar 80 is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a second deformation threshold, wherein the second flow rate is greater than the first flow rate, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

[0100] The cooling system 30 includes a liquid cooling system for temperature control of the copper busbar 80. The system dynamically adjusts the operating flow rate of the liquid cooling system based on the difference between the predicted temperature of the copper busbar 80 and the temperature threshold to achieve precise temperature control management.

[0101] When the predicted temperature of copper busbar 80 is greater than or equal to the first temperature threshold, it indicates that the predicted temperature of copper busbar 80 is slightly high, requiring only a mild cooling effect. Similarly, if the deformation of copper busbar 80 is greater than or equal to the first deformation threshold, it indicates that copper busbar 80 may experience minor stress anomalies, requiring a mild cooling effect. At this time, controller 10 controls the liquid cooling system to operate at the first flow rate. In this case, the liquid cooling system will provide coolant at a lower flow rate, with moderate cooling capacity, maintaining temperature stability through mild cooling operations and avoiding unnecessary energy waste.

[0102] When the predicted temperature of copper busbar 80 is greater than or equal to the second threshold, it indicates a rapid temperature rise and a high thermal risk, requiring stronger cooling measures. Similarly, if the deformation of copper busbar 80 is greater than or equal to the first deformation threshold, it indicates that the deformation has reached a level that may affect the reliability of electrical connections or the integrity of the mechanical structure. At this time, controller 10 controls the liquid cooling system to operate at a second flow rate. The second flow rate is greater than the first flow rate, meaning the liquid cooling system will provide coolant at a higher flow rate. This is because when the temperature difference is large, the cooling demand increases sharply, and the system needs to increase the water flow rate and the amount of coolant flowing to accelerate the cooling process and ensure that the temperature of copper busbar 80 drops to a safe range.

[0103] During actual operation, the flow rate of the liquid cooling system is dynamically adjusted according to the predicted temperature changes of the copper busbar 80. By monitoring temperature changes in real time, the system can continuously optimize the flow rate of the liquid cooling system based on the predicted temperature and deformation of the copper busbar 80. If the temperature decreases, the flow rate of the liquid cooling system will automatically decrease, and vice versa, to achieve precise temperature control, ensuring that the temperature of the copper busbar 80 is always maintained within a safe range, while improving the energy utilization efficiency of the cooling system 30 and reducing unnecessary energy waste.

[0104] It should be noted that the specific flow rate level of the liquid cooling system can be determined based on the actual application scenario, and is not limited here.

[0105] As an example, the first temperature threshold is 50℃ and the second temperature threshold is 60℃. That is, when the predicted temperature of the copper busbar 80 is 50℃≤T<60℃, the liquid cooling system is controlled to operate in a high-efficiency energy-saving mode with a first flow rate of 270L / min; when the predicted temperature of the copper busbar 80 is T≥60℃, the liquid cooling system is controlled to operate in a precise adjustment mode with a second flow rate of 540L / min.

[0106] As an example, the first deformation threshold is 0.2%, and the second deformation threshold is 0.3%. That is, when the deformation of the copper busbar is 0.2% ≤ ε < 0.3%, the liquid cooling system is controlled to operate in a high-efficiency energy-saving mode with a first flow rate of 270 L / min; when the deformation of the copper busbar is ε ≥ 0.3%, the system is controlled to operate at a medium speed with a second rotation speed of 2000 RPM / min.

[0107] In other embodiments, when the predicted temperature of the copper busbar 80 is greater than a third temperature threshold and / or the deformation of the copper busbar 80 is greater than or equal to a third deformation threshold, the controller 10 controls the liquid cooling system to operate in full-power cooling mode. Specifically, taking a third temperature threshold of 75°C and a third deformation threshold of 0.4% as an example, that is, when the predicted temperature T of the copper busbar 80 is greater than 75°C and / or the third deformation threshold ε is greater than 0.4%, the liquid cooling system is controlled to operate at full speed, with a third flow rate of 900 L / min.

[0108] In some embodiments, the controller 10 is further configured to generate a mechanical fault signal when the predicted temperature of the copper busbar 80 is less than a first temperature threshold and the deformation value detected by the deformation monitoring device is greater than or equal to a third deformation threshold.

[0109] If the predicted temperature of copper busbar 80 is less than the first temperature threshold, it indicates that no significant risk of temperature rise is predicted based on the current and foreseeable current load. If the deformation value of copper busbar 80 is greater than or equal to the third deformation threshold, it indicates that the physical form of copper busbar 80 has changed significantly, for example, due to insufficient bolt preload at a connection point caused by long-term vibration.

[0110] When the predicted temperature is within the normal range but the deformation is large, it indicates that the cause of the deformation is not the current or expected thermal stress, but a mechanical fault. At this time, the controller 10 generates a mechanical fault signal, which makes it easier for maintenance personnel to inspect and eliminate hidden dangers and avoid potential short circuit accidents.

[0111] In this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0112] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A hydrogen production system, characterized in that, include: A hydrogen production power source and an electrolyzer, wherein the hydrogen production power source and the electrolyzer are connected by a copper busbar; A status monitoring module is coupled to the copper busbar and configured to monitor the current and temperature of the copper busbar; A cooling system, thermally coupled to the copper busbar, the cooling system being configured to cool the copper busbar; The controller is connected to the status monitoring module and the cooling system respectively. The controller is configured to determine the predicted temperature of the copper busbar within a set time period based on the temperature prediction algorithm and the parameters monitored by the status monitoring module. If the predicted temperature of the copper busbar is greater than or equal to the temperature threshold, the controller will start the cooling system.

2. The hydrogen production system according to claim 1 is characterized in that, The status monitoring module includes: A current monitoring device is correspondingly installed at the current measurement node of the copper busbar; A temperature monitoring device is installed on the surface of the copper busbar.

3. The hydrogen production system according to claim 2, characterized in that, The current monitoring device includes a Rogowski coil and / or a Hall effect current sensor; The Rogowski coil is sleeved on the copper busbar, and the Hall effect current sensor is electrically connected to the current measurement node of the copper busbar.

4. The hydrogen production system according to claim 2, characterized in that, The temperature monitoring device includes a temperature probe and an infrared thermal imager; The temperature probe is disposed on the surface of the copper busbar, and the infrared thermal imager is disposed facing the surface of the copper busbar.

5. The hydrogen production system according to any one of claims 1-4, characterized in that, The controller is electrically connected to the hydrogen production power source, and the controller is further configured to control the hydrogen production power source to reduce its output power when the predicted temperature of the copper busbar is greater than or equal to a temperature threshold.

6. The hydrogen production system according to any one of claims 1-4, characterized in that, The status monitoring module also includes a deformation monitoring device for monitoring the deformation of the copper busbar. The controller is connected to the deformation monitoring device and is further configured to determine the cooling intensity level based on the predicted temperature of the copper busbar and / or the deformation of the copper busbar, and control the cooling system to operate at a level corresponding to the cooling intensity level.

7. The hydrogen production system according to claim 6, characterized in that, The deformation monitoring device is installed at at least one of the following locations: the bolt connection of the copper busbar, the fixing point of the supporting insulator, and the right-angle bend.

8. The hydrogen production system according to claim 7, characterized in that, The deformation monitoring device includes a fiber Bragg grating sensor and / or distributed sensing fiber optics. The fiber Bragg grating sensor is disposed at at least one of the bolted connection, the fixing point of the supporting insulator, and the right-angle bend of the copper busbar, and the distributed sensing fiber is laid along the length of the copper busbar.

9. The hydrogen production system according to claim 6, characterized in that, The cooling system includes a fan, and the controller is further configured to control the fan to operate at a first speed when the predicted temperature of the copper busbar is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar is greater than or equal to a first deformation threshold; and to control the fan to operate at a second speed when the predicted temperature of the copper busbar is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar is greater than or equal to a second deformation threshold, wherein the second speed is greater than the first speed, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

10. The hydrogen production system according to claim 9, characterized in that, The cooling system further includes a liquid cooling system, and the controller is further configured to control the fan to stop working and start the liquid cooling system when the predicted temperature of the copper busbar is greater than or equal to a third temperature threshold and / or the deformation of the copper busbar is greater than or equal to a third deformation threshold, wherein the third temperature threshold is greater than the first temperature threshold and the third deformation threshold is greater than the second deformation threshold.

11. The hydrogen production system according to claim 6, characterized in that, The cooling system further includes a liquid cooling system, and the controller is further configured to control the liquid cooling system to operate at a first flow rate when the predicted temperature of the copper busbar is greater than or equal to a first temperature threshold and / or the deformation of the copper busbar is greater than or equal to a first deformation threshold; and to control the liquid cooling system to operate at a second flow rate when the predicted temperature of the copper busbar is greater than or equal to a second temperature threshold and / or the deformation of the copper busbar is greater than or equal to a second deformation threshold, wherein the second flow rate is greater than the first flow rate, the second temperature threshold is greater than the first temperature threshold, and the second deformation threshold is greater than the first deformation threshold.

12. The hydrogen production system according to claim 6, characterized in that, The controller is also configured to generate a mechanical fault signal when the predicted temperature of the copper busbar is less than the temperature threshold and the deformation value detected by the deformation monitoring device is greater than or equal to a third deformation threshold.

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