Fuel Cell Pump Fault Detection via Hydrogen Pressure Pulsation
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Solution Overview
Problem
Existing fuel cell systems require a dedicated sensor to measure the rotational speed of the pump for determining abnormalities, which increases complexity and cost.
Innovation Solution
Determine pump abnormalities by monitoring pressure fluctuations in the hydrogen gas supply path and detecting the presence or absence of pulsations using a pressure sensor, eliminating the need for a dedicated sensor to measure rotational speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated sensor is added to measure the rotational speed of the pump for determining abnormalities, then the reliability of pump abnormality detection is improved, but the device complexity and cost increase
Solution Approach 1:
The pressure sensor, originally designed for monitoring pressure in the hydrogen gas supply path, is repurposed to detect pump abnormalities by analyzing pressure pulsations. This multi-functional use eliminates the need for a dedicated rotational speed sensor, resolving the contradiction between detection reliability and device complexity
Solution Approach 2:
Pressure pulsations serve as an intermediary signal that indirectly reflects the pump's operational state. Instead of directly measuring rotational speed, the system uses pressure variations caused by pump operation as a mediator to detect abnormalities, avoiding the need for additional sensors
2Measurement precision
If a dedicated sensor is added to measure the rotational speed of the pump for determining abnormalities, then the measurement precision of pump operational state is improved, but the manufacturing cost increases
Solution Approach 1:
The existing pressure sensor is utilized for dual purposes: pressure monitoring and pump abnormality detection. This eliminates the need to manufacture and install additional sensors, thereby reducing manufacturing costs while maintaining measurement precision through frequency analysis of pressure pulsations
3Ease of operation
If the pump rotational speed is monitored using a dedicated sensor, then the ease of operation for pump maintenance is improved, but the device complexity increases
Solution Approach 1:
Pressure pulsations act as an intermediary indicator of pump health, providing maintenance information without requiring direct mechanical contact or additional sensors on the pump. The control device analyzes these pulsations to provide maintenance guidance, simplifying the overall system while improving ease of operation
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
Accurately determines pump normality or abnormality without additional sensors, optimizing system efficiency and reducing costs by utilizing existing pressure sensors to monitor and regulate hydrogen gas flow.
Implementation Method 1
A pulsation of a frequency approximately the same as a drive frequency of the pump can occur in the pressure within the hydrogen gas supply path, by the driving of the pump. On the other hand, if an abnormality occurs in the pump, the pulsation disappears or becomes significantly smaller.
Data Source
AI summary
The fuel cell system may include a fuel cell, a hydrogen gas supply path for supplying hydrogen gas to an anode of the fuel cell, a pump for sending off-gas discharged from the anode of the fuel cell to the hydrogen gas supply path, a pressure sensor for measuring a pressure in the hydrogen gas supply path, and a control device. The control device may acquire the amplitude of the frequency component corresponding to the drive frequency of the pump from the time-series data of the measurement value by the pressure sensor, and determine that an abnormality has occurred in the pump when the acquired amplitude is lower than the threshold value.