Fuel Cell Cooling Control for Valve Failure Backup
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Solution Overview
Problem
Fuel cell systems with valves lacking return springs fail to maintain necessary cooling, compromising the durability and safety of vehicles, construction machines, and flying objects, as well as passenger safety due to inadequate cooling.
Innovation Solution
A fuel cell system design that includes a controller to detect valve failures, maximizing the RPM of the pump, cooling fan, and air conditioning system blower to ensure maximum cooling performance, even in the absence of a return spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a valve without return spring is used to reduce size and weight, then valve weight is reduced, but cooling reliability deteriorates when valve function fails
Solution Approach 1:
The controller continuously monitors valve operation status and detects failures. When a valve failure is detected, the controller activates alternative cooling measures by controlling the pump and cooling fan to operate in a state that ensures sufficient cooling, thereby maintaining cooling reliability despite valve failure.
Solution Approach 2:
The system prepares alternative cooling measures in advance by designing a control mechanism that can detect valve failures and automatically activate compensatory cooling operations. This beforehand preparation ensures that cooling reliability is maintained even when the valve fails, cushioning against the potential harm of inadequate cooling.
2Device complexity
If a valve without return spring is used to simplify structure, then device complexity is reduced, but cooling performance deteriorates when valve function fails
Solution Approach 1:
The controller monitors valve operation and detects failures. Upon detecting valve failure, the controller activates alternative cooling measures by controlling the pump and cooling fan to maintain sufficient cooling performance, thereby compensating for the simplified valve structure's limitations.
Solution Approach 2:
The control system provides multi-functionality by enabling the pump and cooling fan to operate in different modes. When the valve functions normally, standard operation is used. When valve failure is detected, the controller switches to an alternative operation mode that ensures sufficient cooling, making the system adaptable to different conditions.
3Temperature
If maximum RPM of pump and cooling fan is controlled during valve failure, then cooling degree is maintained, but energy consumption increases
Solution Approach 1:
The controller activates alternative cooling measures by controlling the pump and cooling fan to operate at maximum RPM only when valve failure is detected. This partial action is applied selectively rather than continuously, providing excessive cooling capacity only when necessary to maintain sufficient cooling degree during failure conditions, thereby limiting energy consumption to only when required.
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
The system secures a sufficient cooling degree and ensures safety and durability by maintaining optimal operating conditions despite valve failures, particularly in small-sized and lightweight valves.
Implementation Method 1
a first cooling line having first cooling water that passes via the fuel cell stack and circulates therein
Implementation Method 2
a first radiator disposed on the first cooling line and that cools the first cooling water
Implementation Method 3
a first cooling fan that blows exterior air to the first radiator
Implementation Method 4
a valve that switches a flow path of the first cooling water to the fuel cell stack or the first radiator
Implementation Method 5
a controller connected to the first cooling fan, the first pump, and the valve, and the controller is configured to detect a failure of the valve
Data Source
AI summary
A fuel cell system includes a fuel cell stack, a first cooling line having first cooling water that passes via the fuel cell stack and circulates therein, a first radiator that cools the first cooling water, an air conditioning system that forms a heating loop with a first cooling line, a first cooling fan that blows exterior air to the first radiator, a first pump that pumps the first cooling water, a valve that switches a flow path of the first cooling water to the fuel cell stack or the first radiator, and a controller connected to the first cooling fan, the first pump, and the valve, and configured to detect a failure of the valve, control RPMs of the first pump and the first cooling fan to respective maximum levels, and control an RPM of a blower of the air conditioning system to a maximum level.