Fuel Cell Injector Failure Detection via Hydrogen Pump Power

Solution Overview

Problem

The existing fuel cell systems require additional sensors to detect failures in components, increasing manufacturing costs and complexity.

Innovation Solution

A fuel cell system that uses the fluctuation range of power consumed by a hydrogen pump to determine injector failure without the need for an additional sensor, by controlling the injector and hydrogen pump through a controller that assesses the power consumption changes during opening and closing cycles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sensor is added to detect injector failure, then detection reliability is improved, but manufacturing cost and device complexity increase

Engineering Contradiction:

Improvedetection reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hydrogen pump is made to serve dual functions: its primary function of circulating hydrogen gas and a secondary function of serving as a detection device for injector failure. By monitoring the pump's power consumption, the system can detect injector failures without requiring separate detection devices, thus achieving multi-functionality and reducing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The hydrogen pump monitors its own operational state by measuring its own power consumption. This self-diagnostic capability allows the system to detect injector failures using information already available from the pump's operation, eliminating the need for external sensors and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

2Reliability

If a sensor is added to detect injector failure, then detection reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvedetection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The hydrogen pump is made to serve dual functions: its primary function of circulating hydrogen gas and a secondary function of serving as a detection device for injector failure. By monitoring the pump's power consumption, the system can detect injector failures without requiring separate detection devices, thus achieving multi-functionality and reducing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The hydrogen pump monitors its own operational state by measuring its own power consumption. This self-diagnostic capability allows the system to detect injector failures using information already available from the pump's operation, eliminating the need for external sensors and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

3Device complexity

If power consumption monitoring is used instead of sensors, then device complexity is reduced, but measurement precision may be affected

Engineering Contradiction:

Improvedevice complexityVSAvoidmeasurement precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system establishes a feedback mechanism where the power consumption of the hydrogen pump is continuously monitored and compared against expected values during different operational states (injector open/closed). This feedback allows the system to detect deviations indicating injector failures with sufficient precision for diagnostic purposes.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system detects injector failures by monitoring changes in power consumption parameters of the hydrogen pump. By analyzing variations in electrical power consumption corresponding to injector state changes, the system achieves adequate measurement precision for failure detection without requiring dedicated sensors.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10797331B2Fuel cell system and determination method including injector failure determination based on circulation hydrogen pump power consumption

Publication Date: 2020.10.06 TOYOTA JIDOSHA KK

AI summary

A fuel cell system determines whether or not the injector is failed using a determination result, the determination result showing whether or not a fluctuation range determined for power consumed by a hydrogen pump is a predetermined value or less, the fluctuation range being generated by opening and closing of the injector.