Fuel Cell Cooling Module Frozen Coolant Detection
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Solution Overview
Problem
Fuel cell systems face challenges in maintaining coolant hydration and cooling efficiency, particularly in sub-zero Celsius environments where water in the coolant storage tank can freeze, leading to blockages and preventing the system from restarting or operating at full power until the frozen coolant is thawed.
Innovation Solution
A cooling module with a tank, pump, and heating element is used to control the coolant, where sensors detect the presence or absence of sufficient liquid coolant and initiate the pump to transport and heat the coolant, ensuring it remains in a liquid state, using methods such as vapor pressure and temperature measurement, and strain gauges to monitor changes in the coolant's phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the coolant is stored in a tank in sub-zero environments, then the fuel cell system can operate in cold conditions, but the coolant may freeze and block the flow paths
Solution Approach 1:
The heating element is activated before the coolant can freeze, preemptively maintaining the coolant above freezing temperature. The controller monitors temperature and initiates heating action in advance to prevent phase change and flow blockage.
Solution Approach 2:
Temperature sensors continuously monitor the coolant temperature and provide feedback to the controller. The controller adjusts the heating element activation and pump operation based on real-time temperature data to maintain reliable coolant flow.
2Productivity
If the pump is activated to transport coolant, then the fuel cell system can be restarted, but the pump cannot operate with frozen coolant
Solution Approach 1:
The system preemptively activates the heating element and melts frozen coolant before attempting to restart the pump. This ensures the coolant is in liquid form and ready for pump operation, enabling successful system restart.
Solution Approach 2:
The controller monitors temperature and coolant phase status through sensors, and only activates the pump when sufficient liquid coolant is detected. This feedback control prevents pump damage from attempting to move frozen coolant.
3Reliability
If the heating element heats all the coolant, then the frozen coolant is melted, but excessive energy is consumed
Solution Approach 1:
The heating element melts only the necessary amount of frozen coolant required for system operation rather than heating all coolant to a high temperature. This partial action approach provides sufficient liquid coolant while minimizing energy consumption.
Solution Approach 2:
Temperature sensors and flow sensors provide feedback to the controller to monitor when sufficient liquid coolant is available. The controller deactivates the heating element once the minimum required liquid coolant volume is achieved, preventing excessive energy use.
4Extent of automation
If sensors are installed to detect coolant phase, then the pump can be activated at the right time, but the device complexity increases
Solution Approach 1:
Temperature sensors and flow sensors provide feedback signals to the controller, which automatically activates the pump when liquid coolant is detected. This feedback mechanism enables automated pump activation without complex control logic.
Solution Approach 2:
The sensor system automatically detects coolant phase and triggers pump activation without requiring external intervention or complex decision-making algorithms. The system serves itself by using simple threshold-based detection and control.
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
This solution ensures a reliable supply of liquid coolant for hydration and cooling, enabling the fuel cell system to start and operate efficiently by melting only the necessary amount of frozen coolant, conserving energy and time, and utilizing heat generated by the fuel cell system to maintain above-freezing temperatures.
Implementation Method 1
a heating element within the coolant in the tank, the heating element configured to heat the coolant
Implementation Method 2
the heating element configured to be in thermal communication with the coolant and thereby heat the water coolant; the phase of the water coolant corresponds to the presence or absence of sufficient liquid coolant
Implementation Method 3
The sensor may measure change of at least one of vapor pressure and vapor temperature
Implementation Method 4
The sensor may measure change of at least one of vapor pressure and vapor temperature
Implementation Method 5
the sensor may be one or more submersible strain gauges placed in the coolant, an electro-mechanical switch, for example a bimetallic switch, a thermocouple, or a float
Implementation Method 6
a pump in fluid communication with the coolant in the tank and the fuel cell system, the pump being configured to transport the coolant to the fuel cell system
Implementation Method 7
the heating element may include exhaust from the fuel cell system, the exhaust being of sufficient temperature to melt at least a portion of the coolant when the coolant is in its frozen state
Data Source
AI summary
Disclosed is a cooling module for use in a fuel cell system, the module includes a tank configured to receive a coolant therein, a coolant, a pump in fluid communication with the coolant in the tank and the fuel cell system, the pump being configured to transport the coolant to the fuel cell system, a heating element within the coolant in the tank, the heating element configured to heat the coolant, and at least one sensor in signal communication with a controller and in fluid communication with the tank. The sensor is configured to detect a change corresponding to the presence or absence of sufficient liquid coolant to initiate said pump, and the controller processes sensor data and is configured to actuate the pump.