Fuel Cell Pressure Sensor Offset Calibration
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Solution Overview
Problem
Pressure sensors in fuel cell systems experience offsets, leading to inaccurate hydrogen pressure readings, which can result in excessive or insufficient hydrogen supply, degrading fuel efficiency and potentially damaging the fuel cell stack, with existing calibration methods prone to errors and carbon corrosion issues.
Innovation Solution
A method where a controller receives hydrogen pressure sensing values, counts the time for pressure increase from a first to a second pressure after the fuel cell system starts, calculates an offset value using stored data, and calibrates the sensor in real-time to prevent excessive or insufficient hydrogen supply, avoiding exposure to atmospheric pressure and thus preventing carbon corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing calibration methods are used to correct pressure sensor offsets, then measurement precision is improved, but reliability deteriorates due to errors and carbon corrosion issues
Solution Approach 1:
The patent applies preliminary action by performing calibration at a predetermined initial state (atmospheric pressure condition) before actual fuel cell operation begins. The controller stores calibration values obtained at this initial state and uses them for subsequent real-time corrections during operation, avoiding the need to perform calibration operations under varying pressure conditions that could cause carbon corrosion.
Solution Approach 2:
The patent creates an inert environment by conducting calibration operations at atmospheric pressure conditions rather than under fuel cell operating conditions. This prevents carbon corrosion that would occur if calibration were performed under hydrogen/oxygen environment, while still achieving accurate offset correction through the stored calibration values.
2Device complexity
If pressure sensor offset is not calibrated, then device complexity is reduced, but measurement precision deteriorates leading to excessive or insufficient hydrogen supply
Solution Approach 1:
The patent implements self-service by enabling the pressure sensor to automatically perform offset correction using calibration values stored in the controller. The sensor itself does not require external calibration operations or complex calibration mechanisms - it simply applies the pre-stored calibration values to correct its readings, achieving accurate measurement without increasing device complexity.
Solution Approach 2:
The calibration values are predetermined and stored before operation begins. This preliminary preparation eliminates the need for complex real-time calibration mechanisms during fuel cell operation, maintaining simple device architecture while ensuring accurate pressure measurements through pre-computed correction values.
3Measurement precision
If calibration is performed under fuel cell operating conditions, then measurement precision is improved, but object-affected harmful factors increase due to carbon corrosion
Solution Approach 1:
The patent performs calibration at atmospheric pressure conditions before fuel cell operation begins, storing the calibration values for later use. This preliminary calibration avoids exposing the fuel cell stack to carbon corrosion during calibration operations, while the stored values ensure accurate pressure measurement during actual operating conditions.
Solution Approach 2:
The patent conducts calibration in an inert atmospheric environment rather than under fuel cell operating conditions involving hydrogen and oxygen. This prevents carbon corrosion that would occur during calibration if the fuel cell stack were exposed to these reactive gases, while still achieving accurate offset correction through the pre-stored calibration data.
Data Source
AI summary
A method of calibrating an offset of a pressure sensor, by which an offset of a sensing value of a pressure sensor, which detects a pressure of hydrogen in a fuel cell system, is accurately calibrated. The method includes receiving, by a controller, a sensing value of a pressure sensor which detects a hydrogen pressure in a state where a hydrogen supply starts after a start of a fuel cell system; counting, by the controller, a time for which the sensing value of the pressure sensor increases from a first pressure P1 to a second pressure P2; calculating, by the controller, an offset value corresponding to the counted time by use of stored setting data; and calibrating, by the controller, a subsequent sensing value of the pressure sensor by the calculated offset value in real time when the offset value is calculated.