Pressure controller for gaseous fuel, in particular hydrogen gas, and fuel distribution system

Abstract

The present application relates to a fuel distribution system (100) comprising: a pressure accumulator (110) for storing a gaseous fuel at an accumulator pressure; a refuelling line (120) for filling the pressure accumulator with gaseous fuel; a low-pressure line (130) for providing a supply to a drive element (140) of a vehicle from the pressure accumulator at an operating pressure; and a pressure controller (150) which is arranged between the pressure accumulator and the low-pressure line, is connected via a first connection (151) to the refueling line, via a second connection (152) to the pressure accumulator and via a third connection (153) to the low-pressure line and is configured to electronically control a fuel flow from the pressure accumulator to the low-pressure line on the basis of a pressure sensor signal for the operating pressure and to shut off a connection between the second and the third connection if the drive element does not require any gaseous fuel and / or if a supply of power to the pressure controller is interrupted. The present application also relates to a corresponding pressure controller.

Description

[0001] Pressure regulator for gaseous fuel, especially hydrogen gas and fuel distribution system

[0002] Technical field

[0003] The present disclosure relates to a pressure regulator for a gaseous fuel, in particular for hydrogen gas, and an associated fuel distribution system.

[0004] background

[0005] Gaseous fuel, especially hydrogen gas, is used as an energy carrier in mobile applications. In gaseous form, it is stored in high-pressure tanks, while in liquid form, it is stored in refrigerated low-pressure tanks. Depending on the fill level of the storage containers, the pressure decreases from the maximum fill level, dropping continuously as gas is withdrawn, for example, during ferry operations. Tank pressures of 200, 350, or 700 bar at 100% tank capacity are common in compressed gas storage systems. In cryogenic liquefied gas storage, tank pressures of less than 20 bar are used.

[0006] Hydrogen propulsion systems with multiple pressure tanks are known from the prior art, with each pressure tank having its own so-called OTV (on-tank valve), which comprises several modules. Furthermore, it is known that such hydrogen propulsion systems typically include a pressure reducer or regulator that reduces the tank pressure (e.g., 700 bar) to the operating pressure of a fuel cell or other propulsion element.

[0007] European patent application 23157106.8 and the associated PCT application PCT / EP2024 / 054014 (see Annex 1) of the applicant describe an electromechanical, actively controllable pressure regulator for gaseous fuel. The content of European patent application 23157106.8 and PCT / EP2024 / 054014 is fully incorporated herein and forms an integral part of the present application. Summary

[0008] Typically, each storage tank in a hydrogen propulsion system, or similar system, has an electrically controlled tank valve, a thermal pressure relief device, a check valve, and a shut-off valve. When distributed across multiple tanks, this creates a complex system with many components that are susceptible to potential malfunctions. This results in high maintenance and associated costs.

[0009] To address such and similar problems, the present disclosure relates to a pressure regulator and a fuel distribution system according to the claims.

[0010] The present invention thus makes it possible, in particular, to use the pressure control valve of the pressure regulator as a shut-off valve for the pressure accumulator. In other words, the tank valve typically provided for each tank is integrated into the pressure control valve. The present invention thus allows for a significant reduction in the number of assemblies and high-pressure interfaces in a hydrogen propulsion system. This is further accompanied by a reduction in costs and maintenance effort, as well as a reduction in weight. The advantages of the pressure regulator described here and in the applicant's European patent application EP 23157106.8 and in PCT / EP2024 / 054014 (see Annex 1) can still be fully utilized. Further features and advantages of the invention disclosed here are: (i) avoiding the pressure increase and / or increased leakage in mechanical pressure regulators, e.g.during the refueling process; (ii) reduced pressure loss due to the elimination of magnetic tank shut-off valves; (iii) avoidance of pressure jumps or spikes through controlled opening of the proportional valve; (iv) simplification of functionality and enabling a compact and space-saving design with superior pressure control quality and safety.

[0011] Brief description of the drawings

[0012] Fig. 1 shows a fuel distribution system according to an embodiment of the present disclosure; Fig. 2 shows a pressure regulator (as part of a fuel distribution system) for a gaseous fuel, in particular hydrogen gas, according to an embodiment of the present disclosure;

[0013] Fig. 3 shows a pressure regulator for a gaseous fuel, in particular hydrogen gas, according to an embodiment of the present disclosure;

[0014] Fig. 4 shows a pressure regulator for a gaseous fuel, in particular hydrogen gas, according to an embodiment of the present disclosure;

[0015] Fig. 5 shows a pressure regulator (as part of a fuel distribution system) for a gaseous fuel, in particular hydrogen gas, according to an embodiment of the present disclosure;

[0016] Description of exemplary embodiments

[0017] The following describes some exemplary embodiments of the present disclosure. The pressure regulators and distribution systems disclosed herein can also be used in stationary applications.

[0018] Fig. 1 shows a fuel distribution system 100 according to an embodiment of the present disclosure, e.g. for a vehicle powered by gaseous fuel, in particular hydrogen gas, comprising: a pressure accumulator 110 for storing the gaseous fuel at a storage pressure (e.g. in several interconnected pressure cylinders, etc.), a refueling line 120 for filling the pressure accumulator 110 with gaseous fuel, a low-pressure line 130 for supplying a drive element 140 (e.g. a fuel cell) of the vehicle with gaseous fuel from the pressure accumulator at an operating pressure, and a pressure regulator 150, which is arranged between the pressure accumulator 110 and the low-pressure line 130.

[0019] The pressure regulator 150 (see Fig. 2 and Fig. 3 for further examples) is connected to the refueling line 120 via a first connection 151, to the pressure accumulator 110 via a second connection 152, and to the low-pressure line 130 via a third connection 153. It is configured to electronically control the fuel flow from the pressure accumulator 110 to the low-pressure line 130 based on a pressure sensor signal for the operating pressure of the drive element or the output pressure of the pressure regulator. The regulator also interrupts the connection between the second connection 152 and the third connection 153 when the drive element 140 does not require gaseous fuel and / or when the power supply to the pressure regulator 150 is interrupted, e.g., when the vehicle is switched off or during refueling. During refueling, the pressure accumulator 110 can be refueled via the pressure regulator 150.

[0020] Figs. 2, 3 and 4 show a pressure regulator 150 for a gaseous fuel, in particular hydrogen gas, comprising a first connection 151, which can be coupled to a refueling line (see Fig. 1) for the gaseous fuel, a second connection 152, which can be coupled to a pressure accumulator 110 for the gaseous fuel (see Fig. 1) and is in fluid communication with the first connection 151, and a third connection 153, which can be connected to a low-pressure line 130, which supplies, for example, a drive element 140 with fuel at a regulated operating pressure and variable fuel flow (see Fig. 1).

[0021] The pressure regulator 150 further comprises an electronically controlled pressure regulating valve 154, which is arranged between the second port 152 and the third port 153 and is configured to regulate an output pressure for the third port 153, e.g., the operating pressure for a fuel cell based on a pressure sensor signal (see Appendix 1), and to interrupt a connection between the second port 152 and the third port 153 when no electronic control signal is present. Thus, the pressure regulator 150 can function as an electromechanical shut-off valve for the pressure accumulator 110 with superior switching characteristics and can simultaneously be used for refueling the pressure accumulator 110.

[0022] As described in detail in Annex 1, in some implementations of the present invention, the electronically controlled pressure control valve 154 may comprise a main valve 13 and an electronically controlled proportional valve 14, wherein the main valve comprises a main valve inlet, a main valve outlet, a main valve plane inlet, and a control piston in a housing, which controls a fuel flow from the first port through the main valve to the third port, and wherein the proportional valve may be configured to supply a control pressure to the control piston of the main valve via the main valve plane inlet, thereby controlling the fuel flow based on a pressure sensor signal (e.g.,generated by a pressure sensor 169) which indicates the pressure of the gaseous fuel at the third port 153, and wherein the fuel can flow from the refueling line 120 via the first port 151 to the second port 152 and into the pressure accumulator 110 during refueling, and wherein the proportional valve and the main valve are closed during refueling or in the event of an interrupted power supply (NC configuration).

[0023] The pressure regulator 151 can further include a check valve 156, which can be arranged between the first port 151 and the refueling line 120 or after the first port 151. The check valve 156 thus closes the first port 151 when no refueling is taking place. The pressure regulator 150 can further include a manual shut-off valve 157, arranged between the first port and the pressure regulating valve 154. This allows the pressure accumulator 110 to be reversibly shut off, e.g., for maintenance purposes.

[0024] Other optional components are: a thermal pressure relief device, TPRD, 158, arranged between the second port and the pressure control valve and / or a vent valve 159, arranged between the second port and the pressure control valve, which allows, for example, the pressure accumulator 110 to be emptied in a controlled manner in the event of a fault.

[0025] Further optional components are: a first particulate filter 160, preferably with a fin diameter of 10 pm, arranged before or after the first port 151; and / or a second particulate filter 161 arranged between the second port 152 and the pressure control valve 154; a pressure relief valve 162 arranged after the pressure control valve 154 to prevent overpressure at the third port 153, for example to protect the fuel cell; and / or a service interface unit (SIU) 163 arranged after the pressure control valve 154. For example, a separate line can be connected via a quick-release coupling to allow for the controlled discharge of fuel, e.g., fuel still present in the fuel cell, during servicing. Fig. 5 shows a pressure regulator 150 for a gaseous fuel similar to the embodiments described above with reference to Figs. 1 to 4.The pressure regulator 150 can further comprise a second shut-off valve 502, which is arranged between the second port and the pressure regulating valve. To improve safety in the event of a fault, the shut-off valve 502 can be electromechanically controlled. In particular, the second shut-off valve can be a magnetic shut-off valve implemented in a normally closed configuration, so that, for example, when the vehicle is switched off, the shut-off valve 502 is always closed. Further details on the operation of the pressure regulators and systems described herein are contained in Annex 1, which forms an integral part of this disclosure.

Claims

Patent claims 1. Fuel distribution system (100) for a vehicle powered by gaseous fuel, in particular hydrogen gas, comprising: a pressure accumulator (no) for storing the gaseous fuel at a storage pressure; a refueling line (120) for filling the pressure accumulator with gaseous fuel; a low-pressure line (130) for supplying a drive element (140) of the vehicle with gaseous fuel from the pressure accumulator at an operating pressure; and a pressure regulator (150) arranged between the pressure accumulator and the low-pressure line, which is: connected to the refueling line via a first connection (151); connected to the pressure accumulator via a second connection (152); and connected to the low-pressure line via a third connection (153).and is designed to electronically control the fuel flow from the pressure accumulator to the low-pressure line based on a pressure sensor signal for the operating pressure and to interrupt a connection between the second and third ports when the drive element does not require gaseous fuel and / or when the pressure regulator's power supply is interrupted.

2. Pressure regulator (150) for a gaseous fuel, in particular hydrogen gas, comprising: a first port (151) that can be coupled to a refueling line for the gaseous fuel; a second port (152) that can be coupled to a pressure accumulator for the gaseous fuel and is in fluid communication with the first port; a third port (153) that can be connected to a low-pressure line; and an electronically controlled pressure control valve (154) which is arranged between the second port and the third port and is configured to control an output pressure for the third port based on a pressure sensor signal, and to interrupt a connection between the second port and the third port when no electronic control signal is present.

3. Pressure regulator according to claim 2, wherein the electronically controlled pressure control valve (154) comprises a main valve (13) and an electronically controlled proportional valve (14), wherein the main valve comprises a main valve inlet, a main valve outlet, a main valve plane inlet, and a control piston in a housing, which regulates a fuel flow from the first port through the main valve to the third port; and wherein the proportional valve is configured to deliver a control pressure to the control piston of the main valve via the main valve plane inlet and thereby regulate the fuel flow based on a pressure sensor signal indicating the pressure of the gaseous fuel at the third port; and wherein, during refueling, the fuel can flow from the refueling line via the first port to the second port and into the pressure accumulator;and wherein the proportional valve and the main valve are closed during refueling or in the event of an interrupted power supply; 4. Pressure regulator according to claim 2 or 3, further comprising a check valve (156) arranged between the first connection and the refueling line or after the first connection.

5. Pressure regulator according to any one of claims 2 to 4, further comprising a manual shut-off valve (157) arranged between the second port and the pressure regulating valve; and / or a thermal pressure relief device, TPRD, (158) arranged between the second port and the pressure regulating valve; and / or a venting valve (159) arranged between the second port and the pressure regulating valve.

6. Pressure regulator according to one of claims 2 to 5, further comprising a first particle filter (160), preferably with a lamella diameter of 10 mm, arranged before or after the first port; and / or a second particle filter (161) arranged between the second port and the pressure regulating valve.

7. Pressure regulator according to any one of claims 2 to 6, further comprising: a pressure relief valve (162) arranged downstream of the pressure control valve to prevent overpressure at the third port; and / or a service interface unit, SIU, (163) arranged downstream of the pressure control valve.

8. Pressure regulator according to any one of claims 1 to 7, further comprising: a second shut-off valve (502), preferably electromechanically controllable, arranged between the second port and the pressure regulating valve.

9. Pressure regulator according to claim 8, wherein the second shut-off valve is a magnetic Shut-off valve implemented in a normally closed configuration.

Images