Modular hydrogen fuel cell heavy-lift drone

Abstract

The utility model discloses a modularization hydrogen fuel cell big load unmanned plane, including frame system, hydrogen fuel cell system and hydrogen storage system of being located on frame system, hydrogen storage system is connected with hydrogen fuel cell system through pipeline, hydrogen fuel cell system includes a plurality of power unit module and is used for the support assembly of integrated fixed power unit module, each power unit module is an integrated power generating unit respectively, each power unit module is arranged with array mode through support assembly, and through the output end of parallel electric connection structure is converged, to common for unmanned plane power supply, power unit module can independently detach from support assembly. The utility model discloses through modularization parallel connection's fuel cell power unit, has realized the flexible extension of system power and the quick dismounting of single power unit, thereby has solved big load unmanned plane power demand and the difficult problem that system maintenance convenience cannot be taken into account.

Description

Technical Field

[0001] This utility model relates to the field of unmanned aerial vehicle technology, and in particular to a modular hydrogen fuel cell heavy-duty unmanned aerial vehicle. Background Technology

[0002] Thanks to the high energy density of hydrogen and the high efficiency of proton exchange membrane fuel cells, hydrogen fuel cell systems are increasingly being used in the field of unmanned aerial vehicles (UAVs) to significantly extend their flight time. Meanwhile, the only reaction byproduct is water, aligning with the development concept of green aviation.

[0003] Existing hydrogen fuel cell drones, especially rotary-wing models, generally adopt a single fuel cell system architecture. This architecture centrally positions a single fuel cell stack and its auxiliary systems (such as controllers and DC-DC converters) at the center of the drone's fuselage, utilizing its high energy density to replace or supplement traditional lithium batteries to provide power for flight. Relevant prior art can be found in Chinese patent documents such as CN119734869A and CN120089761A.

[0004] However, the aforementioned existing technical solutions have the following obvious drawbacks, which limit their application in medium and large-sized heavy-duty drones: First, power scalability is poor. Current technologies mostly use air-cooled fuel cell stacks, whose single-stack power is limited by heat dissipation capacity and has a clear upper limit. The market lacks mature and reliable high-power (e.g., tens of kilowatts and above) air-cooled fuel cell stack products, making it difficult for hydrogen fuel cells based on a single system architecture to meet the huge propulsion power requirements of medium and large UAVs (takeoff weight exceeding 150kg).

[0005] Secondly, the system suffers from low maintainability. As the core power unit of the drone, the reliability of the fuel cell system is paramount. In existing integrated solutions, the fuel cell stack and its accessories are fixed inside the fuselage, resulting in complex connections and inconvenient disassembly and assembly. Once the system malfunctions, cumbersome on-site repairs or complete replacement are required, a time-consuming and labor-intensive process that severely reduces the drone's uptime and operational efficiency.

[0006] Therefore, there is an urgent need for a hydrogen fuel cell drone system that can effectively overcome the power limitations of a single stack and has efficient maintenance capabilities. Utility Model Content

[0007] To address the aforementioned technical problems, the purpose of this invention is to provide a modular hydrogen fuel cell-powered heavy-duty unmanned aerial vehicle (UAV). This invention achieves flexible expansion of system power and rapid assembly / disassembly of individual power units through modular parallel fuel cell power units, thereby solving the dilemma of balancing the power requirements of heavy-duty UAVs with the ease of system maintenance.

[0008] To achieve the above-mentioned technical objectives and effects, this utility model is implemented through the following technical solution: A modular hydrogen fuel cell heavy-duty unmanned aerial vehicle (UAV) includes a frame system, a hydrogen fuel cell system mounted on the frame system, and a hydrogen storage system. The hydrogen storage system is connected to the hydrogen fuel cell system via pipelines. The hydrogen fuel cell system includes multiple power unit modules and a support assembly for integrating and fixing the power unit modules. Each power unit module is an integrated power generation unit. The power unit modules are arranged in an array via the support assembly, and their outputs are combined through a parallel electrical connection structure to jointly power the UAV. The power unit module can be independently detached from the bracket assembly.

[0009] Furthermore, the array arrangement is a matrix arrangement of M rows × N columns, where M and N are both positive integers not less than 1.

[0010] Furthermore, the support assembly includes a fuel cell stack support for fixing a single row of power unit modules, and a system support for connecting multiple rows of the fuel cell stack supports.

[0011] Furthermore, the fuel cell stack support has fuel cell stack mounting holes, and the power unit module is detachably fixed to the fuel cell stack support by screws passing through the fuel cell stack mounting holes.

[0012] Furthermore, the parallel electrical connection structure includes busbars that connect the output terminals of the longitudinally arranged power unit modules in parallel, and a main busbar for connecting each of the busbars in parallel.

[0013] Furthermore, the main copper busbar is equipped with a positive terminal for power supply from the UAV, a negative terminal for power supply from the UAV, and a current sensor for monitoring the total output current.

[0014] Furthermore, each of the power unit modules includes at least a hydrogen fuel cell stack, a DC converter, and a hydrogen fuel cell controller.

[0015] Furthermore, the hydrogen fuel cell controller and DC converter are directly or indirectly mounted on the end plate of the hydrogen fuel cell stack; a fan mounting plate is also integrated and fixed on the end plate of the hydrogen fuel cell stack, and a cooling fan is mounted on the fan mounting plate.

[0016] Furthermore, the cooling fan of the hydrogen fuel cell stack is directed downwards towards the drone.

[0017] Furthermore, the frame system includes an arm assembly, a leg assembly, and a top frame assembly, and a power assembly is also installed on the frame system.

[0018] The beneficial effects of this utility model are as follows: This invention forms a regular battery matrix by arranging multiple identical power unit modules in a horizontal and vertical array using a fuel cell stack support and a system support. This mechanical layout allows the system to no longer rely on a single high-power fuel cell stack, but instead achieves a significant increase in overall output power by connecting multiple power unit modules in parallel, thereby meeting the high power requirements of heavy-duty UAVs.

[0019] In this invention, the power generated by each power unit module is first initially collected vertically through the busbar branch copper busbar, and then the current from each branch is finally merged through the main busbar. This hierarchical busbar electrical structure features clear and neat wiring, effectively reducing system internal resistance and connection complexity, and ensuring efficient and reliable power output to the drone.

[0020] In this invention, each power unit module is detachably fixed to the fuel cell stack support. When a module needs maintenance, maintenance personnel only need to unscrew a few mechanical fixing screws and disconnect the corresponding electrical copper busbar connection to remove the module from the entire unit. This design simplifies the maintenance operation of the fuel cell system and greatly facilitates the maintenance of the entire hydrogen fuel cell system. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the modular hydrogen fuel cell heavy-duty unmanned aerial vehicle of this utility model.

[0022] Figure 2 This is a schematic diagram of the hydrogen fuel cell system in this utility model.

[0023] Figure 3 This is a partial structural diagram of the power unit module in this utility model.

[0024] Figure 4 for Figure 3 A schematic diagram of the power unit module from another perspective.

[0025] Figure 5 This is a schematic diagram of the power unit module in this utility model.

[0026] Figure 6 for Figure 5 A schematic diagram of the power unit module from another perspective.

[0027] In the diagram, 1: boom; 2: top frame assembly; 201: transverse square tube; 202: longitudinal square tube; 3: leg assembly; 4: hydrogen storage system; 5: power unit module; 501: hydrogen fuel cell stack; 502: DC converter; 503: hydrogen fuel cell controller; 504: air inlet; 505: drain inlet; 506: fan mounting plate; 507: cooling fan; 508: end plate; 509: DC mounting component; 510 511: Side plate; 512: Intake valve; 513: Drain valve; 514: Positive output of fuel cell stack; 515: Positive output copper busbar of DC; 516: Negative output copper busbar of DC; 6: Fuel cell stack support; 7: System support; 8: Busbar branch copper busbar; 9: Main busbar copper busbar; 10: Positive power supply for UAV; 11: Negative power supply for UAV; 12: Current sensor; 13: Motor; 14: ESC; 15: Propeller. Detailed Implementation

[0028] The technical solutions of this utility model will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0029] like Figures 1 to 6 A preferred embodiment of a modular hydrogen fuel cell heavy-duty unmanned aerial vehicle (UAV) is shown, comprising a frame system, a hydrogen fuel cell system, and a hydrogen storage system.

[0030] The frame system constitutes the main load-bearing structure of the UAV, including an arm assembly, a landing gear assembly 3, and a top frame assembly 2. The top frame assembly 2 includes a horizontal square tube 201 and a vertical square tube 202 connected to each other; the landing gear assembly 3 is located below the top frame assembly 2; the arm assembly includes multiple outwardly extending arms 1 connected to the top frame assembly 2.

[0031] The hydrogen storage system 4 is connected to the hydrogen fuel cell system via a high-pressure pipeline to provide a hydrogen source for the fuel cell reaction.

[0032] The hydrogen fuel cell system adopts a modular architecture design, which includes multiple identical power unit modules 5, a support assembly for integrating the fixed power unit modules 5, and parallel electrical connection structures.

[0033] Each power unit module 5 is an independent integrated power generation unit, comprising a hydrogen fuel cell stack 501, a DC converter 502, and a hydrogen fuel cell controller 503. The hydrogen fuel cell stack 501 is composed of several stacked single cells, connected on both sides by high-strength alloy end plates 508 via side plates 510 to form a robust whole. The hydrogen fuel cell stack 501 is equipped with a dedicated air inlet 504 and a drain 505. A cooling fan 507 is fixed to the end plate 508 of the hydrogen fuel cell stack 501 via a fan mounting plate 506, and its exhaust direction is optimized to face downwards towards the drone for better heat dissipation. To achieve high integration, other key components of the power unit module 5 are directly or indirectly mounted on the end plate 508 of the hydrogen fuel cell stack 501. Specifically, a DC mounting component 509 is fixed to the end plate 508 for mounting the DC converter 502. The hydrogen fuel cell controller 503 is further integrated onto the DC converter 502. In addition, the inlet valve 511 for controlling the flow of hydrogen and the drain valve 512 for discharging reaction products are also installed near the corresponding interfaces on the end plate 508. In terms of electrical connections, the power generated by the hydrogen fuel cell stack 501 is led to the input terminal of the DC converter 502 through the stack output positive electrode 513 and the stack output negative electrode 514. After voltage conversion and regulation, the power is output through the DC output positive electrode copper busbar 515 and the DC output negative electrode copper busbar 516.

[0034] The support assembly includes a fuel cell stack support 6 and a system support 7. Multiple power unit modules 5 are first fastened to the fuel cell stack support 6 with screws to form a single row of modules. Then, multiple such module groups are connected and fixed longitudinally by the system support 7, ultimately forming a regular array of M rows × N columns, where M and N are both positive integers not less than 1.

[0035] In terms of electrical parallel connection, a hierarchical busbar scheme is adopted. The parallel electrical connection structure includes busbar branches 8 and main busbars 9. Multiple power unit modules 5 on the same vertical column have their DC output positive and negative copper busbars connected in parallel through a busbar branch 8. Then, all busbar branches 8 are connected to the main busbar 9 for total current collection. The main busbar 9 is equipped with a positive terminal 10 for UAV power supply, a negative terminal 11 for UAV power supply, and a current sensor 12 for monitoring the total output current.

[0036] The assembled hydrogen fuel cell system is mounted on the rack system via system support 7. The hydrogen storage system 4 is typically arranged symmetrically on the stand assemblies 3 on both sides of the rack system.

[0037] The drone's power components, including motor 13, ESC 14 and propeller 15, are mounted at the end of arm 1 and draw power from main busbar 9.

[0038] The working principle of this modular hydrogen fuel cell heavy-duty drone is as follows: High-pressure hydrogen is output from the hydrogen storage system 4, and after pressure reduction, it is delivered in parallel to each power unit module 5 through pipelines. Inside each power unit module 5, hydrogen enters the anode of the hydrogen fuel cell stack 501, while air enters the cathode; the two undergo an electrochemical reaction within the stack, generating water and direct current, and the reacted water is discharged through the drain valve 512. The generated electrical energy is drawn from the positive output electrode 513 and the negative output electrode 514 of the stack and enters the DC converter 502 for voltage boosting and stabilization. The electrical energy stabilized by the DC converter 502 is output to the parallel electrical connection structure through the DC output positive electrode copper busbar 515 and the DC output negative electrode copper busbar 516 of each module. The system adopts a hierarchical busbar scheme: the outputs of modules in the same vertical column are initially connected in parallel through busbar branches 8, and each busbar branch 8 is then connected to the main busbar 9 for overall busbar connection. A current sensor 12 mounted on the main copper busbar 9 monitors the total output in real time. Its positive and negative terminals 10 and 11, which supply power to the UAV, deliver the collected electrical energy to the power unit (including motor 13, ESC 14, and propeller 15) installed at the end of the arm 1. The hydrogen fuel cell controller 503 controls the operation of the hydrogen fuel cell stack 501 within each module. The motor 13 in the power unit drives the propeller 15 to generate precise lift, enabling stable flight and maneuverability of the UAV. All power unit modules 5 work collaboratively in parallel array to meet the high power demands of heavy-load flight. Their modular design ensures system power scalability and ease of maintenance.

[0039] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention.

[0040] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A modular hydrogen fuel cell heavy-duty unmanned aerial vehicle (UAV), comprising a frame system, a hydrogen fuel cell system mounted on the frame system, and a hydrogen storage system, wherein the hydrogen storage system is connected to the hydrogen fuel cell system via pipelines, characterized in that: The hydrogen fuel cell system includes multiple power unit modules and a support assembly for integrating and fixing the power unit modules; each power unit module is an integrated power generation unit; the power unit modules are arranged in an array through the support assembly, and their output terminals are combined through a parallel electrical connection structure to jointly power the drone; The power unit module can be independently detached from the bracket assembly.

2. The modular hydrogen fuel cell heavy-duty UAV according to claim 1, characterized in that, The array is a matrix arrangement of M rows × N columns, where M and N are both positive integers not less than 1.

3. The modular hydrogen fuel cell heavy-duty UAV according to claim 1, characterized in that, The support assembly includes a fuel cell stack support for fixing a single row of power unit modules, and a system support for connecting multiple rows of the fuel cell stack supports.

4. The modular hydrogen fuel cell heavy-duty UAV according to claim 3, characterized in that, The fuel cell stack support has fuel cell stack mounting holes, and the power unit module is detachably fixed to the fuel cell stack support by screws passing through the fuel cell stack mounting holes.

5. The modular hydrogen fuel cell heavy-duty UAV according to claim 1, characterized in that, The parallel electrical connection structure includes busbars that connect the output terminals of the longitudinally arranged power unit modules in parallel, and a main busbar for connecting each of the busbars in parallel.

6. The modular hydrogen fuel cell heavy-duty UAV according to claim 5, characterized in that, The main copper busbar is equipped with a positive terminal for power supply to the UAV, a negative terminal for power supply to the UAV, and a current sensor for monitoring the total output current.

7. The modular hydrogen fuel cell heavy-duty UAV according to claim 1, characterized in that, Each of the power unit modules includes at least a hydrogen fuel cell stack, a DC converter, and a hydrogen fuel cell controller.

8. The modular hydrogen fuel cell heavy-duty UAV according to claim 7, characterized in that, The hydrogen fuel cell controller and DC converter are directly or indirectly mounted on the end plate of the hydrogen fuel cell stack; a fan mounting plate is also integrated and fixed on the end plate of the hydrogen fuel cell stack, and a cooling fan is mounted on the fan mounting plate.

9. The modular hydrogen fuel cell heavy-duty UAV according to claim 8, characterized in that, The cooling fan of the hydrogen fuel cell stack is directed downwards towards the drone.

10. The modular hydrogen fuel cell heavy-duty UAV according to claim 1, characterized in that, The frame system includes a boom assembly, a leg assembly, and a top frame assembly, and a power assembly is also installed on the frame system.

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