Testing System and Methods for High-Flow Hydrogen Dispensers Applicable to Multiple Operating Conditions

Abstract

This invention discloses a high-flow-rate hydrogen refueling machine testing system suitable for multi-dimensional operating conditions, comprising: a variable-volume gas source module for simulating the hydrogen storage structure of hydrogen refueling stations of different levels and providing hydrogen; a high-flow-rate gas source control module connected to the variable-volume gas source module for adjusting the flow rate and temperature of the output hydrogen to simulate refueling conditions under different ambient temperatures; a PLC control module electrically connected to both the variable-volume gas source module and the high-flow-rate gas source control module for controlling the selection of gas cylinder groups, monitoring system temperature and pressure data, and generating test reports according to test requirements; and a hydrogen recovery module and a gas replenishment module for recovering the tested hydrogen and dynamically replenishing it to the variable-volume gas source module. The output of the high-flow-rate gas source control module is connected to the test object, the output of the test object is connected to an existing hydrogen refueling machine testing platform, and the PLC control module is also communicatively connected to the existing hydrogen refueling machine testing platform.

Description

Technical Field

[0001] This application relates to hydrogen refueling equipment testing technology, specifically, to a high-flow hydrogen refueling machine testing system and testing method applicable to multiple operating conditions. Background Technology

[0002] Currently, hydrogen refueling machine testing equipment generally focuses on verifying refueling performance. Its working principle mainly involves simulating an on-board hydrogen supply system to collect refueling process data and comparing it with industry standards to determine whether the hydrogen refueling machine meets the refueling protocol specifications.

[0003] However, the gas supply for such equipment is highly dependent on the actual hydrogen storage facilities of existing hydrogen refueling stations, resulting in limited output flow and an inability to support testing requirements under high-flow conditions. Furthermore, there is a scarcity of specialized testing platforms for high-flow hydrogen dispensers, and these platforms generally suffer from a disconnect between testing conditions and the actual operating environment of hydrogen refueling stations. For example, they struggle to accurately reproduce complex scenarios involving different hydrogen storage structures, pressure gradients, and ambient temperature changes, leading to systematic discrepancies between laboratory test results and actual hydrogen refueling station operating data. This discrepancy prevents test conclusions from accurately reflecting the dynamic response characteristics of hydrogen dispensers under complex operating conditions, thereby hindering the optimization and iteration of hydrogen dispenser design and the improvement of reliability in field applications.

[0004] Specifically, existing testing platforms cannot effectively simulate the typical high-flow-rate operating conditions of hydrogen refueling stations in a laboratory environment. These conditions include high flow rates exceeding 10 kg / min, dynamic pressure fluctuations between 2 MPa and 70 MPa, and wide-range temperature variations from -40°C to 70°C. Consequently, the test data lacks engineering guidance value and struggles to support performance verification and safety assessment of high-flow-rate hydrogen refueling machines in real-world scenarios. These shortcomings severely restrict the industrialization of hydrogen refueling machine technology, preventing the testing process from providing effective evidence for product improvement.

[0005] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0006] The purpose of this application is to provide a testing system and method for a high-flow hydrogen dispenser suitable for multi-dimensional operating conditions. It has the advantages of effectively simulating high-flow operating conditions, different hydrogen storage structures, pressure gradients and ambient temperature changes, providing more realistic test data, improving test accuracy and reliability, thereby supporting the optimization of hydrogen dispenser design and the improvement of reliability in field applications.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0008] A high-flow-rate hydrogen refueling machine testing system suitable for multi-dimensional operating conditions includes:

[0009] Variable volume gas source module, used to simulate the hydrogen storage structure of hydrogen refueling stations of different levels and provide hydrogen;

[0010] A high-flow-rate gas source control module, connected to the variable-volume gas source module, is used to adjust the flow rate and temperature of the output hydrogen to simulate refueling conditions under different ambient temperatures.

[0011] The PLC control module is electrically connected to the variable volume gas source module and the high flow gas source control module respectively, and is used to control the selection of gas cylinder group, monitor system temperature and pressure data and generate test reports according to test requirements.

[0012] The hydrogen recovery module and the gas replenishment module are used to recover the tested hydrogen and dynamically replenish it to the variable volume gas source module.

[0013] The output of the high-flow gas source control module is connected to the object under test, the output of the object under test is connected to the existing hydrogen refueling machine test platform, and the PLC control module is also communicatively connected to the existing hydrogen refueling machine test platform.

[0014] Furthermore, the variable volume gas source module includes a 45MPa gas cylinder group and a 90MPa gas cylinder group, wherein the 45MPa gas cylinder group is divided into three gas intake modes: low pressure, medium pressure, and high pressure.

[0015] Furthermore, the variable volume gas source module is composed of several small-volume gas cylinders. Each gas cylinder is equipped with a needle valve at its front end, and the number of needle valves can be adjusted by a PLC control module to change the total volume of the gas cylinders involved in the gas supply.

[0016] Furthermore, the high-flow gas source control module is provided with several parallel branches, and each branch is connected to a gas cylinder group in the variable volume gas source module through a parallel branch.

[0017] Each of the parallel branches is equipped with an independent hydrogen precooling branch and a hydrogen preheating branch, and is configured with a temperature and pressure detection module to simulate the temperature change of the medium within a set temperature range.

[0018] The parallel branch is equipped with a large-range high-pressure flow controller at the aggregation end to achieve constant or fluctuating flow output.

[0019] A testing method for a high-flow-rate hydrogen dispenser applicable to multiple operating conditions includes the following steps:

[0020] S1. Equipment Connection and Leak Detection: Connect the object under test to the high-flow gas source control module, and connect the hydrogen refueling gun of the object under test to the hydrogen refueling port of the existing hydrogen refueling machine test platform;

[0021] S2. Operating Condition Adaptation and Precooling / Preheating: Test parameters, including test flow rate, pressure, time, and medium temperature, are set through the human-machine interface unit of the PLC control module; the PLC calculates and opens the corresponding number of gas cylinders based on the set test parameters;

[0022] S3. Trigger refueling: Adjust the opening of the hydrogen precooling branch and the hydrogen preheating branch. After the temperature reaches the standard, turn on the gas source output and open the needle valve of the gas cylinder through the PLC control module.

[0023] S4. Dynamic performance test: Start the test object, and hydrogen enters the existing hydrogen dispenser test platform after being pressure regulated by the test object; the PLC control module summarizes the temperature, pressure and flow data in real time, and automatically generates parameter curves of flow fluctuation, pressure fluctuation and temperature change;

[0024] S5. Data Processing and Report Generation: After the test reaches the set time, the PLC control module stops the test, calculates the filling accuracy and stability indicators based on the collected data, and generates a test report;

[0025] S6. Hydrogen recovery and dynamic gas replenishment: After the test, disconnect the tested object and turn off the variable volume gas source module; connect the recovery port of the existing hydrogen refueling machine test platform to the hydrogen recovery module, and recharge the variable volume gas source module with hydrogen through the gas replenishment module.

[0026] In summary, the present invention has the following beneficial effects:

[0027] By employing a variable-volume gas source module to simulate different hydrogen storage structures, a high-flow-rate gas source control module to adjust flow rate and temperature, a PLC control module to monitor data and generate reports, and a hydrogen recovery module to dynamically replenish gas, this system can accurately reproduce multi-dimensional operating conditions involving high flow rates, wide temperature ranges, and dynamic pressure fluctuations. This provides reliable test data and effectively simulates high-flow-rate operating conditions, different hydrogen storage structures, pressure gradients, and changes in ambient temperature, offering more realistic test data and improving test accuracy and reliability. Consequently, it supports the optimization of hydrogen dispenser design and enhances the reliability of field applications. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the high-flow hydrogen refueling machine testing system described in this invention. Detailed Implementation

[0029] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to the figures and specific embodiments.

[0030] like Figure 1As shown, this invention proposes a high-flow-rate hydrogen refueling machine testing system suitable for multi-dimensional operating conditions. The system includes a variable-volume gas source module for simulating the hydrogen storage structure of different levels of hydrogen refueling stations and providing hydrogen; a high-flow-rate gas source control module, connected to the variable-volume gas source module, for adjusting the output hydrogen flow rate and temperature to simulate refueling conditions under different ambient temperatures; a PLC control module, electrically connected to both the variable-volume gas source module and the high-flow-rate gas source control module, for controlling the selection of gas cylinder groups according to testing requirements, monitoring system temperature and pressure data, and generating test reports; and a hydrogen recovery module and a gas replenishment module for recovering the tested hydrogen and dynamically replenishing it to the variable-volume gas source module. The output of the high-flow-rate gas source control module is connected to the test object, the output of the test object is connected to the existing hydrogen refueling machine testing platform, and the PLC control module also has a communicative connection with the existing hydrogen refueling machine testing platform.

[0031] For ease of understanding, the following explains some key terms in this embodiment:

[0032] Variable Volume Gas Source Module: This module is configured to simulate the hydrogen storage structures of different levels of hydrogen refueling stations and is responsible for providing the hydrogen required for testing. Its "variable volume" feature is designed to simulate different hydrogen storage capacities or gas consumption states of real hydrogen refueling stations by adjusting the total volume of available gas.

[0033] High-flow-rate gas source control module: This module connects to the variable-volume gas source module and its function is to regulate the flow rate and temperature of the output hydrogen. This regulation capability allows for the simulation of various refueling conditions under different ambient temperatures, especially those involving high flow rates.

[0034] PLC Control Module: This module is electrically connected to both the variable volume gas source module and the high flow rate gas source control module. As the central control unit, it is responsible for selecting the gas cylinder group according to test requirements, monitoring the internal temperature and pressure data of the system, and generating detailed test reports. Furthermore, this module also communicates with the existing hydrogen refueling machine test platform.

[0035] Hydrogen recovery module and gas replenishment module: These two modules work together. The hydrogen recovery module collects hydrogen for use after testing. The gas replenishment module dynamically replenishes the recovered hydrogen back to the variable volume gas source module, or performs other replenishments, to ensure continuous system operation and efficient resource utilization.

[0036] Test Object: This term refers to the specific high-flow-rate hydrogen dispenser or its key components that are being tested. It receives and processes hydrogen from the high-flow-rate gas source control module and then delivers the hydrogen to the existing hydrogen dispenser test platform.

[0037] Existing hydrogen refueling machine testing platform: This platform represents the existing hydrogen refueling machine testing infrastructure. The system of this application is integrated with this platform, enabling the test object to deliver hydrogen to it for further analysis and data acquisition, thereby utilizing existing testing capabilities.

[0038] This embodiment provides a high-flow hydrogen refueling machine testing system suitable for multi-dimensional operating conditions.

[0039] As one implementation method, a variable volume gas source module can consist of one or more large-capacity gas cylinders connected and isolated by valves to achieve a rough adjustment of the total gas supply volume. For example, multiple gas cylinders of the same pressure rating can be connected in parallel, and the number of gas cylinders participating in the gas supply can be changed by opening and closing valves, thereby adjusting the total gas supply volume.

[0040] Furthermore, the high-flow-rate gas source control module can be configured with one or more flow regulating valves to control the output flow rate of hydrogen by adjusting the valve opening. Alternatively, multiple parallel fixed-flow branches can be set up, and discrete flow outputs can be obtained by switching between different branches.

[0041] Furthermore, the PLC control module can be configured to connect to the actuators of the variable volume air source module and the high flow rate air source control module via hardwiring. Temperature and pressure data within the system can be acquired by independent sensors and displayed on a local instrument. The generation of test reports requires testing personnel to summarize and analyze the recorded data.

[0042] Therefore, the hydrogen recovery module and the gas replenishment module can be configured to collect the tested hydrogen into a separate storage tank after the test. For example, a simple collection container can be set up, and the tested hydrogen can be introduced into it through a pipeline. When a gas source needs to be replenished, the operator can start the compressor to transfer the hydrogen in the collection container to the variable volume gas source module.

[0043] Specifically, the output of the high-flow gas source control module is connected to the input of the device under test (DUT) via a pipeline. The output of the DUT is then connected to the hydrogen filling port of the existing hydrogen refueling machine test platform via interfaces such as a hydrogen refueling gun. The PLC control module can establish a communication connection with the existing hydrogen refueling machine test platform through standard industrial communication protocols, such as RS485 or Ethernet, to achieve data exchange.

[0044] This system effectively solves the problem that existing testing platforms cannot reproduce the real high-flow-rate operating conditions of hydrogen refueling stations under laboratory conditions. By providing a variable-volume gas source, precise and adjustable flow and temperature control, integrated intelligent management, and efficient hydrogen recovery and dynamic replenishment functions, this system can simulate the hydrogen storage structure of a real hydrogen refueling station, high-flow-rate refueling under different ambient temperatures, and complex pressure and temperature changes. Therefore, the test results accurately reflect actual usage scenarios, providing reliable guidance for the design, optimization, and application of high-flow-rate hydrogen dispensers.

[0045] In some of the embodiments described above in this application, a variable volume gas source module is proposed to simulate the hydrogen storage structure and provide hydrogen for hydrogen refueling stations of different levels. However, in its implementation, there is a lack of clear division of gas cylinder groups of different pressure levels and graded gas extraction mode, which makes it impossible to accurately simulate the diverse pressure conditions and gas extraction needs in actual hydrogen refueling stations, thereby affecting the test system's ability to reproduce real high-flow refueling scenarios.

[0046] In this regard, this application further proposes the specific structure of the variable volume gas source module, which includes a 45MPa gas cylinder group and a 90MPa gas cylinder group, wherein the 45MPa gas cylinder group is divided into three gas intake modes: low pressure, medium pressure and high pressure.

[0047] The 45MPa cylinder group refers to a set of hydrogen storage cylinders with a designed working pressure limit of 45 MPa. It is primarily used to simulate the hydrogen storage pressure range of a 35MPa hydrogen refueling station or as an intermediate pressure source for a 70MPa hydrogen refueling station. The 90MPa cylinder group refers to a set of hydrogen storage cylinders with a designed working pressure limit of 90 MPa. It is primarily used to simulate the hydrogen storage pressure range of a 70MPa hydrogen refueling station, providing higher pressure reserves to meet high-flow-rate refueling requirements. These two types of cylinder groups can be physically independent, each equipped with independent pipelines, valves, and safety devices, and selectively switched via a PLC control module to adapt to different test conditions. Alternatively, they can be implemented through cascaded hydrogen storage. For example, the 90MPa cylinder group can act as a high-pressure main storage tank, connected to the 45MPa cylinder group via a high-pressure reducing valve or booster pump, thereby providing hydrogen at different pressure levels at different test stages.

[0048] Furthermore, the 45MPa gas cylinder group is divided into three gas intake modes: low-pressure, medium-pressure, and high-pressure. The low-pressure intake mode obtains hydrogen at relatively low pressure from the 45MPa cylinder group, for example, during the initial refueling stage or when refueling low-pressure vehicles. The medium-pressure intake mode obtains hydrogen at medium pressure, for example, during the middle of the refueling process or simulating the typical operating pressure of a 35MPa refueling station. The high-pressure intake mode obtains hydrogen at pressure close to the upper limit of the 45MPa cylinder group, for example, at the end of the refueling process or when a higher pressure differential is required for rapid refueling. These three intake modes can be implemented by configuring multiple parallel pressure regulating valves at the output end of the 45MPa cylinder group, each preset with a different output pressure, and selectively opened by a PLC control module according to test requirements. Another implementation method is to group the multiple cylinders within the 45MPa cylinder group, and use a PLC control module to open different groups of cylinders in a preset sequence and combination, thereby providing hydrogen at different pressure ranges at different stages.

[0049] In some of the solutions mentioned above in this application, a variable volume gas source module is proposed to simulate the hydrogen storage structure of hydrogen refueling stations of different levels and provide hydrogen. However, in this process, there are shortcomings in how to achieve fine adjustment of the volume to more accurately simulate the actual hydrogen storage structure, which limits the flexibility of the test.

[0050] In this regard, this application further proposes that the variable volume gas source module is composed of several small volume gas cylinders, each gas cylinder is equipped with a needle valve at the front end, and the number of needle valves is adjusted by the PLC control module to change the total volume of the gas cylinders participating in the gas supply.

[0051] Specifically, the phrase "composed of several small-volume gas cylinders" means that the variable-volume gas source module is not composed of a single large hydrogen storage container, but rather of multiple relatively small-volume independent gas cylinders connected in a suitable manner (e.g., in parallel). For example, the variable-volume gas source module can be composed of a series of standard gas cylinders of the same volume connected in parallel, and the total gas supply volume can be changed by selectively activating these cylinders; or, the variable-volume gas source module can be composed of gas cylinders of different volume specifications to provide more flexible volume configuration options.

[0052] The phrase "each gas cylinder has a needle valve at its front end" refers to a needle valve, a type of precision valve with a needle-shaped valve core, which enables precise control of the fluid passage. In this context, it is primarily used to control the opening and closing of the gas cylinder. Having a needle valve at the front end of each gas cylinder means that each independent small-volume gas cylinder is equipped with an independent control interface. These needle valves can be automated valves driven by electric or pneumatic actuators, remotely controlled via external signals to achieve fast and accurate opening and closing operations. In practical applications, considering the needs of automated testing, automatically controlled valves are typically used.

[0053] The phrase "adjusting the number of needle valves to change the total volume of gas cylinders involved in gas supply via the PLC control module" refers to the PLC control module (Programmable Logic Controller) being the core control unit of the entire testing system, responsible for receiving instructions, processing data, and issuing control signals. Here, the PLC control module's role is to precisely control the opening and closing status of the needle valves at the front end of each gas cylinder based on preset test parameters or operator input. The PLC control module can calculate the number of needle valves to be opened and the corresponding gas cylinder combinations based on the target total volume set by the user on the human-machine interface, using internal algorithms, and send electrical signals to drive the corresponding needle valve actuators. Furthermore, the PLC control module can also dynamically adjust the number of open needle valves based on real-time monitored system pressure, flow rate, and other data to maintain specific gas supply characteristics or simulate complex filling conditions.

[0054] The aforementioned technical solution designs the variable-volume gas source module as a combination of several small-volume gas cylinders, with an independent needle valve at the front end of each cylinder. This allows the system to adjust the total gas supply volume in a discrete yet precise manner. The introduction of a PLC control module enables automated and precise adjustment of the number of these needle valves on and off, allowing for flexible changes in the total volume of the gas cylinders involved in the gas supply according to testing requirements. This design overcomes the limitations of traditional single or fixed-volume gas sources in simulating hydrogen storage structures at different levels of hydrogen refueling stations, significantly improving the flexibility and accuracy of the testing system. For example, by precisely controlling the number of cylinders opened, various effective hydrogen storage volumes, ranging from buffer tanks in small hydrogen refueling stations to multi-stage hydrogen storage tanks in large stations, can be simulated, enabling laboratory test results to more realistically reflect actual refueling conditions. Furthermore, automated control reduces manual intervention, improves test repeatability and reliability, and ensures the validity of test data, thereby more effectively guiding the design optimization and practical application of hydrogen refueling machines.

[0055] In some of the embodiments described above in this application, a high-flow-rate gas source control module is proposed to adjust the flow rate and temperature of the output hydrogen to simulate refueling conditions under different ambient temperatures. However, in its implementation, the existing control method may not be able to efficiently simulate changes over a wide temperature range or achieve accurate constant and fluctuating flow output, resulting in test results that do not match actual operating conditions.

[0056] In this regard, this application further proposes that the high-flow gas source control module is provided with several parallel branches, and each is connected to a gas cylinder group in the variable volume gas source module through a parallel branch; each of the parallel branches is provided with an independent hydrogen pre-cooling branch and a hydrogen pre-heating branch, and is equipped with a temperature and pressure detection module to simulate the temperature change of the medium within a set temperature range; the parallel branches are equipped with a large-range high-pressure flow controller at the aggregation end to achieve constant or fluctuating flow output.

[0057] Specifically, the parallel branches in the high-flow-rate gas source control module are designed to enhance the system's ability to handle large flows of hydrogen and provide a flexible gas source selection mechanism. Each parallel branch can independently control the direction and state of hydrogen flow within it, thereby achieving precise management of different gas cylinder groups. For example, these parallel branches can consist of independent pipes and valves, which can be switched on and off and have their flow adjusted via a PLC control module to adapt to different testing requirements. Alternatively, multi-way switching valves can be used to connect to each gas cylinder group, and the action of the switching valves can select the gas cylinder group participating in the gas supply, thus achieving flexible configuration of the parallel branches.

[0058] Each parallel branch has an independent hydrogen pre-cooling branch and a hydrogen pre-heating branch, equipped with temperature and pressure detection modules. This is to accurately simulate hydrogen refueling conditions under different ambient temperatures, ensuring the realism of the test. The independent pre-cooling branch can use a refrigerant circulation system (such as liquid nitrogen or a chiller unit) combined with a heat exchanger, precisely controlling the cooling degree of the hydrogen by adjusting the refrigerant flow rate or temperature. The independent pre-heating branch can use an electric heater or a steam heater combined with a heat exchanger, precisely controlling the heating degree of the hydrogen by adjusting the heating power or steam flow rate; alternatively, it can utilize ambient temperature for preheating via an ambient heat exchanger. Simultaneously, the configured temperature and pressure detection modules, such as high-precision platinum resistance temperature sensors and pressure sensors, can monitor and provide real-time feedback of hydrogen temperature and pressure data during the pre-cooling / pre-heating process, ensuring that the medium temperature changes accurately simulate the set temperature range.

[0059] The parallel branch is equipped with a large-range, high-pressure flow controller at the converging end. Its function is to achieve precise control of the hydrogen output flow rate, whether it is a constant flow rate or a fluctuating flow rate simulating the actual refueling process. This controller can employ a mass flow controller (MFC) combined with a high-pressure regulating valve and advanced feedback control algorithms to achieve precise flow regulation; alternatively, it can combine a venturi or orifice flow meter with a proportional-integral-derivative (PID) controller and an electric regulating valve to achieve closed-loop flow control, ensuring the stability and accuracy of the flow output.

[0060] Through the above technical solution, the high-flow-rate gas source control module, by setting up several parallel branches, can effectively improve hydrogen processing capacity and allow for flexible selection and combination of gas sources. Independent hydrogen pre-cooling and pre-heating branches, combined with a temperature and pressure detection module, enable the system to accurately simulate a wide range of medium temperature changes, thus overcoming the problem of inaccurate temperature simulation in existing technologies. Furthermore, the large-range, high-pressure flow controller configured at the aggregation end can achieve accurate output of constant or fluctuating flow rates, solving the problem of inflexible flow control in existing technologies. Overall, this solution allows the testing system to more efficiently and realistically simulate the refueling process under multi-dimensional operating conditions, significantly improving the matching degree between test results and actual operating conditions, and providing reliable data support for the design optimization and performance verification of high-flow-rate hydrogen dispensers.

[0061] Existing testing platforms are unable to reproduce the real high-flow-rate operating conditions of hydrogen refueling stations under laboratory conditions. In response, this application proposes a testing method for high-flow-rate hydrogen refueling machines applicable to multiple operating conditions.

[0062] In the equipment connection and leak detection steps, the device under test is connected to the high-flow gas source control module, and the hydrogen refueling nozzle of the device under test is connected to the hydrogen refueling port of the existing hydrogen refueling machine test platform to ensure the correctness and sealing of the initial system settings. In the operating condition adaptation and pre-cooling / preheating steps, test parameters, including test flow rate, pressure, time, and medium temperature, are set through the human-machine interface unit of the PLC control module. The PLC calculates and opens the corresponding number of gas cylinders according to the set test parameters, thereby simulating the changes in the hydrogen storage structure of different hydrogen refueling stations. Furthermore, the opening degree of the hydrogen pre-cooling branch and the hydrogen preheating branch is adjusted to prepare for temperature control. In the triggering refueling step, after the temperature reaches the target, the gas source output is turned on, and the needle valve of the gas cylinder is opened through the PLC control module to ensure that the temperature and flow rate of the gas source output meet the set values. In the dynamic performance testing step, the tested object is started, and hydrogen enters the existing hydrogen dispenser test platform after being pressure-regulated by the tested object. The PLC control module summarizes temperature, pressure, and flow data in real time and automatically generates parameter curves for flow fluctuations, pressure fluctuations, and temperature changes, enabling real-time monitoring of dynamic changes during high-flow-rate dispensing. In the data processing and report generation step, after the test reaches the set time, the PLC control module stops the test, calculates dispensing accuracy and stability indicators based on the collected data, and generates a test report. In the hydrogen recovery and dynamic replenishment step, after the test is completed, the tested object is disconnected and the variable volume gas source module is shut down. The recovery port of the existing hydrogen dispenser test platform is connected to the hydrogen recovery module, and hydrogen is refilled into the variable volume gas source module through the replenishment module, realizing the recycling of hydrogen and the sustainable operation of the system.

[0063] Through the above technical solution, this application can accurately simulate the high-flow-rate operating conditions of a real hydrogen refueling station. Specifically, the PLC control module dynamically adjusts the number of gas cylinders, thus simulating the hydrogen storage structure of different levels of hydrogen refueling stations; based on the opening adjustment of the hydrogen pre-cooling and hydrogen preheating branches, accurate reproduction of ambient temperature changes is achieved; given that real-time data is aggregated to form parameter curves, the transient characteristics of pressure fluctuations and temperature changes are captured; considering the hydrogen recovery and dynamic replenishment mechanisms, long-term testing requirements are supported. Overall, this method effectively reproduces the core elements of real operating conditions through parameter-driven precise control and the synergistic effect between steps. The test data accurately reflects the actual usage scenario, providing reliable guidance for the design, optimization, and application of high-flow-rate hydrogen dispensers.

[0064] The following example will provide a more detailed explanation of the above technical solution:

[0065] In a scenario where performance verification is being conducted on a new high-flow-rate hydrogen dispenser, testers need to simulate dispensing conditions under high pressure, high flow rate, and extreme temperatures.

[0066] First, the testers connected the hydrogen dispenser under test (the object under test) to the output of the high-flow gas source control module, and connected the hydrogen dispensing nozzle of the hydrogen dispenser under test to the hydrogen dispensing port of the existing hydrogen dispenser test platform. The PLC control module established electrical connections with the variable volume gas source module and the high-flow gas source control module, and established a communication connection with the existing hydrogen dispenser test platform.

[0067] To simulate the hydrogen storage structures of different levels of hydrogen refueling stations, the variable volume gas source module was configured to include separate 45MPa and 90MPa gas cylinder groups. The 45MPa cylinder group is further subdivided into low-pressure, medium-pressure, and high-pressure gas extraction modes to provide more flexible pressure selection. The variable volume gas source module consists of several small-volume gas cylinders, each equipped with a needle valve at its front end. Through a PLC control module, testers can precisely adjust the number of needle valves on and off, thereby changing the total volume of the gas cylinders involved in the gas supply to simulate hydrogen refueling stations with different storage capacities. For example, when simulating a medium-capacity 45MPa hydrogen refueling station, the PLC control module will open the needle valves of a specific number of cylinders in the 45MPa cylinder group to provide the required hydrogen volume.

[0068] The high-flow-rate gas source control module has several parallel branches, each connected to a gas cylinder group in the variable-volume gas source module via a parallel branch. Each parallel branch has an independent hydrogen pre-cooling branch and a hydrogen pre-heating branch, and is equipped with a temperature and pressure detection module. This allows the system to simulate medium temperature changes within a set temperature range. For example, when simulating a filling condition of -30°C, the PLC control module will instruct the hydrogen pre-cooling branch to operate, reducing the hydrogen temperature to the target value. Compared with existing technologies where the gas source temperature is not adjustable or has a limited adjustment range, this system can achieve a wider range of temperature simulations.

[0069] Before the refueling test begins, the test personnel set the test parameters through the human-machine interface of the PLC control module, including the test flow rate (e.g., 15 kg / min), pressure (e.g., 70 MPa), time, and medium temperature (e.g., -30°C). Based on these set parameters, the PLC control module calculates and opens the needle valves of the corresponding number of 90MPa gas cylinder groups in the variable volume gas source module to ensure a sufficient supply of hydrogen.

[0070] Once the hydrogen pre-cooling branch adjusts the hydrogen temperature to -30°C, the PLC control module activates the gas supply output. Hydrogen passes through the high-flow-rate gas supply control module, whose parallel branch is equipped with a large-range, high-pressure flow controller at the aggregation end to achieve constant or fluctuating flow output. This solves the problem that existing testing platforms struggle to reproduce high-flow-rate conditions and pressure fluctuations under laboratory conditions. The hydrogen then undergoes pressure regulation control by the tested object before entering the existing hydrogen dispenser testing platform.

[0071] Throughout the refueling process, the PLC control module aggregates temperature, pressure, and flow data in real time from the temperature and pressure detection module and the existing hydrogen refueling machine test platform, and automatically generates parameter curves for flow fluctuations, pressure fluctuations, and temperature changes. This allows testers to comprehensively evaluate the dynamic performance of the hydrogen refueling machine under test under multi-dimensional operating conditions, rather than just its static refueling performance.

[0072] After the set time has elapsed, the PLC control module stops the test. The system calculates the filling accuracy and stability indicators based on the collected data and automatically generates a detailed test report.

[0073] After the test, the hydrogen dispenser under test was disconnected, and the cylinder needle valve of the variable volume gas source module was closed. The recovery port of the existing hydrogen dispenser test platform is connected to the hydrogen recovery module, and the hydrogen used in the test is recharged back to the variable volume gas source module through the gas replenishment module. This hydrogen recovery and dynamic gas replenishment mechanism not only improves the utilization rate of hydrogen and reduces testing costs, but also ensures the long-term stable operation of the test system, avoiding the problems of hydrogen waste and frequent gas source replenishment in existing technologies.

[0074] Through the above examples, this system can effectively simulate complex operating conditions such as hydrogen storage structures, high-flow refueling, wide-range temperature changes, and pressure fluctuations at different hydrogen refueling stations. It solves the technical problems that existing testing platforms cannot truly reflect the actual conditions of hydrogen refueling stations and that test data does not match actual use, providing a reliable testing method for the design and verification of high-flow hydrogen dispensers.

[0075] In this document, the terms "upper," "lower," "front," "back," "left," "right," "top," "bottom," "inner," "outer," "vertical," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used for the clarity of expressing the technical solution and for the convenience of description, and therefore should not be construed as limiting the present invention.

[0076] In this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, which includes not only the elements listed but also other elements not expressly listed.

[0077] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A testing system for a high-flow-rate hydrogen dispenser suitable for multi-dimensional operating conditions, characterized in that, include: Variable volume gas source module, used to simulate the hydrogen storage structure of hydrogen refueling stations of different levels and provide hydrogen; A high-flow-rate gas source control module, connected to the variable-volume gas source module, is used to adjust the flow rate and temperature of the output hydrogen to simulate refueling conditions under different ambient temperatures. The PLC control module is electrically connected to the variable volume gas source module and the high flow gas source control module respectively, and is used to control the selection of gas cylinder group, monitor system temperature and pressure data and generate test reports according to test requirements. The hydrogen recovery module and the gas replenishment module are used to recover the tested hydrogen and dynamically replenish it to the variable volume gas source module. The output of the high-flow gas source control module is connected to the object under test, the output of the object under test is connected to the existing hydrogen refueling machine test platform, and the PLC control module is also communicatively connected to the existing hydrogen refueling machine test platform.

2. The high-flow-rate hydrogen refueling machine testing system applicable to multi-dimensional operating conditions according to claim 1, characterized in that, The variable volume gas source module includes a 45MPa gas cylinder group and a 90MPa gas cylinder group. The 45MPa gas cylinder group is divided into three gas intake modes: low pressure, medium pressure, and high pressure.

3. The high-flow-rate hydrogen refueling machine testing system applicable to multi-dimensional operating conditions according to claim 2, characterized in that, The variable volume gas source module is composed of several small-volume gas cylinders. Each gas cylinder is equipped with a needle valve at its front end, and the number of needle valves can be adjusted by a PLC control module to change the total volume of the gas cylinders involved in the gas supply.

4. The high-flow-rate hydrogen refueling machine testing system applicable to multi-dimensional operating conditions according to claim 1, characterized in that, The high-flow gas source control module is provided with several parallel branches, and each branch is connected to a gas cylinder group in the variable volume gas source module through a parallel branch. Each of the parallel branches is equipped with an independent hydrogen precooling branch and a hydrogen preheating branch, and is configured with a temperature and pressure detection module to simulate the temperature change of the medium within a set temperature range. The parallel branch is equipped with a large-range high-pressure flow controller at the aggregation end to achieve constant or fluctuating flow output.

5. A testing method for a high-flow-rate hydrogen dispenser applicable to multi-dimensional operating conditions, characterized in that, Includes the following steps: S1. Equipment Connection and Leak Detection: Connect the object under test to the high-flow gas source control module, and connect the hydrogen refueling gun of the object under test to the hydrogen refueling port of the existing hydrogen refueling machine test platform; S2. Operating Condition Adaptation and Precooling / Preheating: Test parameters, including test flow rate, pressure, time, and medium temperature, are set through the human-machine interface unit of the PLC control module; the PLC calculates and opens the corresponding number of gas cylinders based on the set test parameters; S3. Trigger refueling: Adjust the opening of the hydrogen precooling branch and the hydrogen preheating branch. After the temperature reaches the standard, turn on the gas source output and open the needle valve of the gas cylinder through the PLC control module. S4. Dynamic performance test: Start the test object, and hydrogen enters the existing hydrogen dispenser test platform after being pressure regulated by the test object; the PLC control module summarizes the temperature, pressure and flow data in real time, and automatically generates parameter curves of flow fluctuation, pressure fluctuation and temperature change; S5. Data Processing and Report Generation: After the test reaches the set time, the PLC control module stops the test, calculates the filling accuracy and stability indicators based on the collected data, and generates a test report; S6. Hydrogen recovery and dynamic gas replenishment: After the test, disconnect the tested object and turn off the variable volume gas source module; connect the recovery port of the existing hydrogen refueling machine test platform to the hydrogen recovery module, and recharge the variable volume gas source module with hydrogen through the gas replenishment module.

Images