Fuel Cell Cooling Sensor Cross-Check for Stack Temperature Reliability
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Solution Overview
Problem
Existing fuel cell systems face challenges in maintaining suitable temperature ranges for fuel cell stacks due to potential failures in temperature sensors, which can lead to inadequate cooling and system inefficiencies.
Innovation Solution
The proposed fuel cell system includes temperature sensors configured to measure refrigerant temperatures at specific points within the system, with a controller that checks for sensor malfunctions by comparing measured values and providing notifications for any discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If temperature sensors are installed to monitor refrigerant temperatures in fuel cell stacks, then temperature control capability is improved, but system reliability deteriorates due to potential sensor failures
Solution Approach 1:
The system implements feedback by comparing temperature measurements from multiple sensors (first temperature sensor in supply passage, second temperature sensor in return passage, third temperature sensor in circulating passage) to detect sensor malfunctions. When sensor readings deviate from expected ranges or from each other, the system identifies the faulty sensor and switches to using only reliable sensor data for temperature control decisions.
Solution Approach 2:
The system performs preliminary malfunction detection by continuously monitoring sensor readings and comparing them against predetermined ranges and each other. This preliminary detection occurs before the malfunction can cause significant temperature control issues, allowing the system to proactively switch to a safe operating mode using only reliable sensor data.
2Reliability
If multiple temperature sensors are deployed to ensure reliable temperature monitoring, then measurement reliability is improved, but device complexity increases
Solution Approach 1:
The system segments temperature monitoring into three distinct measurement points: supply passage temperature (first sensor), return passage temperature (second sensor), and circulating passage temperature (third sensor). Each sensor monitors a specific segment of the refrigerant circulation, and the control device independently evaluates each sensor's reliability based on its readings and predetermined ranges.
Solution Approach 2:
The control device performs multiple functions: it uses temperature readings for normal temperature control, simultaneously performs malfunction detection by comparing readings against predetermined ranges, and switches between different sensor combinations based on reliability assessment. This multi-functionality reduces the need for separate dedicated malfunction detection hardware.
3Reliability
If temperature sensor malfunction detection is implemented, then system safety is improved, but control complexity increases
Solution Approach 1:
The system performs self-diagnosis by automatically detecting sensor malfunctions through comparison of temperature readings against predetermined ranges and mutual consistency checks. The control device autonomously identifies faulty sensors and switches to using only reliable sensor data without requiring external intervention or complex diagnostic procedures.
Solution Approach 2:
The system treats temperature sensor readings as expendable data points that can be discarded when malfunctions are detected. Rather than attempting to repair or recalibrate sensors, the system simply switches to using readings from reliable sensors, effectively discarding faulty sensor data and replacing it with alternative measurement sources.
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 enables effective monitoring and maintenance of temperature sensors, ensuring that fuel cell stacks are properly cooled and operated within optimal temperature ranges, thereby enhancing system efficiency and reliability.
Implementation Method 1
The first temperature sensor may be configured to measure a temperature of the refrigerant in the supply passage at a position upstream of a merging point of the supply passage and the circulating passage
Implementation Method 2
The second temperature sensor may be configured to measure a temperature of the refrigerant in the supply passage at a position downstream of the merging point
Implementation Method 3
The third temperature sensor may be configured to measure a temperature of the refrigerant in the return passage
Implementation Method 4
a cooler which cools the plurality of fuel cell stacks
Data Source
AI summary
An FC system disclosed herein may comprise a plurality of FC units, a cooler, and a controller. Each of the FC units may comprise a FC stack, a supply passage/a return passage/a circulating passage through which refrigerant passes, and first temperature sensor. The supply passage supplies the refrigerant from the cooler to the FC stack. The return passage returns the refrigerant to the cooler. The circulating passage is connected to the supply passage and the return passage. The first temperature sensor is configured to measure a temperature of the refrigerant in the supply passage at a position upstream of a merging point of the supply passage and the circulating passage. When measured values of the first temperature sensors of the plurality of the FC units do not match, the controller is configured to provide notification about malfunction of the first temperature sensor.