Fuel Cell Injector Failure Detection Under High-Load Pressure Control
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Solution Overview
Problem
The existing fuel cell system takes a long time to detect injector failures in normal mode and has limited timing for efficient failure detection, especially in high-load conditions.
Innovation Solution
A fuel cell system with a control device that opens and closes injectors based on a fuel gas pressure command value, using a failure determination unit to perform injector failure detection when the current output from the fuel cell is above a detection-effective current threshold, allowing for quicker and more efficient failure determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the driving command is output to each of all the plurality of injectors in normal mode and pressure is measured by the sensor disposed on the downstream side of the injectors, then the closing failure of the injectors can be detected, but it takes long time until the detection for the plurality of injectors is completed
Solution Approach 1:
The detection process is segmented into two distinct modes: normal mode for general operation and high-load mode specifically for failure detection. By separating the detection function from normal operation, the system can dedicate specific conditions (high-load mode with all injectors activated) to rapid failure detection without interfering with regular fuel cell operation, thus reducing detection time while maintaining reliability
Solution Approach 2:
The system performs preliminary action by proactively switching to high-load mode to activate all injectors before actual failure occurs. This preliminary activation of all injectors under controlled high-load conditions creates optimal detection conditions, allowing the pressure sensor to quickly identify any injector that fails to respond, thereby reducing the time from detection start to failure confirmation
2Reliability
If the detection of the closing failure is performed only in the normal mode without performing the detection in the high load mode, then the detection can be performed under stable conditions, but the timing for performing the detection is limited and the detection cannot be efficiently performed
Solution Approach 1:
The system dynamically adjusts operating modes based on detection needs. It transitions between normal mode (for stable operation) and high-load mode (for efficient detection) as needed. This dynamic switching allows the system to leverage the stability of normal mode for accurate baseline measurements while utilizing high-load mode for rapid failure detection, thereby improving both detection accuracy and efficiency
Solution Approach 2:
The system implements periodic action by regularly switching between normal mode and high-load mode for detection purposes. The control device periodically initiates high-load mode to perform failure detection on all injectors, then returns to normal mode for stable operation. This periodic cycling ensures that detection is performed at appropriate intervals without compromising overall system stability or efficiency
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 approach significantly reduces the time required to confirm injector failures and enables efficient detection, preventing potential damage from insufficient fuel gas supply during power generation.
Implementation Method 1
a fuel cell configured to generate electric power by an electrochemical reaction between an oxygen-containing gas and a fuel gas
Implementation Method 2
a pressure sensor configured to detect the pressure of the fuel gas on a downstream side of the plurality of injectors
Data Source
AI summary
In a fuel cell system for supplying a fuel gas from a fuel container to a fuel cell through injectors, in a case where a generated current of the fuel cell is equal to or greater than a detection-effective current threshold, failure determination for the injectors is performed based on a fuel gas pressure command value and a gas pressure detection value detected by each of pressure sensors provided downstream of the injectors.