Crank-Angle Pressure Sensing for Hydrogen Engine Leak Detection

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Solution Overview

Problem

Existing fuel leak detection systems for hydrogen combustion engines are inadequate, failing to effectively detect and respond to fuel leaks, which can lead to fuel accumulation in unintended areas and combustion inefficiencies.

Innovation Solution

A system utilizing an electronic control unit (ECU) to monitor pressure variations in the crank angle domain, coupled with high data rate pressure sensors, to detect hydrogen fuel leaks by identifying abnormal pressure differentials during fuel injection events, and adjust engine operations to maintain hydrogen levels below flammability limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If existing fuel leak detection systems are used for hydrogen combustion engines, then the system structure is simple, but the detection precision and reliability are insufficient to effectively detect fuel leaks

Engineering Contradiction:

Improvefuel leak detection precisionVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The detection system is segmented into multiple independent components: high data rate pressure sensors positioned at specific locations, crank angle domain analysis modules, and pressure differential calculation units. This segmentation allows each component to perform a specific function with high precision while maintaining overall system manageability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical or simple electronic detection systems with an advanced pressure measurement and analysis system that operates in the crank angle domain. This substitution enables precise detection of fuel leaks by analyzing pressure variations correlated with engine crank angle positions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high data rate pressure sensors and crank angle domain monitoring are implemented, then fuel leak detection precision improves, but the device complexity and computational requirements increase

Engineering Contradiction:

Improvefuel leak detection reliabilityVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements continuous feedback by monitoring pressure variations in real-time during engine operation, comparing measured pressure differentials against expected values, and immediately identifying deviations that indicate fuel leaks. This feedback mechanism enhances reliability by providing continuous verification of system integrity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary analysis of pressure data in the crank angle domain before making leak detection determinations. By pre-processing and correlating pressure measurements with crank angle positions, the system prepares detection data in advance, improving reliability while managing computational complexity through structured analysis

Inventive Principle:

Principle #10Preliminary action

3Productivity

If fuel leaks are not detected promptly, then the system operation continues normally, but fuel accumulates in unintended areas creating flammability risks

Engineering Contradiction:

Improveengine operation continuityVSAvoidfuel accumulation and flammability risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system rushes through the detection process by using high data rate pressure sensors that capture pressure variations at extremely high frequencies. This rapid sampling allows the system to skip over normal pressure fluctuations and quickly identify the characteristic pressure signatures of fuel leaks, enabling prompt detection and response

Inventive Principle:

Principle #21Skipping (Rushing through)

Solution Approach 2:

The system takes preliminary anti-action by continuously monitoring for fuel leak conditions and preparing to interrupt engine operation if leaks are detected. By maintaining constant surveillance and having immediate response protocols ready, the system prevents fuel accumulation before it reaches dangerous levels

Inventive Principle:

Principle #9Preliminary anti-action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Rapid detection and control of hydrogen fuel leaks, preventing accumulation and ensuring safe engine operation by reducing hydrogen levels to prevent flammability risks.

Implementation Method 1

measuring pressure variation of the hydrogen fuel in a crank angle domain during operation of the spark-ignited combustion engine

Methodology Applied

Scientific EffectPressure variation measurement:

Data Source

PatentUS20250334484A1System and method for detecting fuel leaks in hydrogen combustion engines

Publication Date: 2025.10.30 CUMMINS INC

AI summary

Fuel leak detection is disclosed for a spark-ignited combustion engine that combusts hydrogen fuel. Pressure measurements of the hydrogen fueling system are taken in the crank angle domain of the engine. A hydrogen fuel leak condition is detected in response to a pressure variation that occurs during a crank angle-based injection event that differs from an expected pressure variation.