Hydrogen Storage Container Safety Shutdown System
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Solution Overview
Problem
Current on-board hydrogen storage systems face challenges due to low energy density, leading to over-design and increased costs, as they require large high-pressure containers that suffer from material fatigue and strain, necessitating over-engineering to ensure safety and longevity.
Innovation Solution
A safety warning and shutdown system that includes a fill cycle counter, sensors (such as strain gauges or acoustic emissions generators), and a controller to deactivate the hydrogen storage container after a predetermined number of fill cycles, preventing further use and ensuring safe retirement of the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure containers are designed with over-engineering to ensure safety and longevity, then reliability is improved, but weight and cost increase
Solution Approach 1:
The patent applies preliminary action by implementing a fill cycle counter that tracks and monitors the number of fill cycles before material fatigue sets in. This allows the system to proactively manage container lifecycle, taking preventive action (shutdown) before reliability degrades, thereby avoiding the need for excessive over-engineering and reducing container weight
Solution Approach 2:
The patent implements feedback through a monitoring system that tracks fill cycles and provides information to a control mechanism. This feedback loop enables dynamic adjustment of system operation based on actual container usage, allowing optimal design without excessive safety margins and reducing unnecessary weight
2Reliability
If high-pressure containers are designed with over-engineering to ensure safety and longevity, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
By implementing preliminary action through fill cycle tracking and monitoring, the system proactively manages container lifecycle before material fatigue compromises safety. This allows manufacturers to produce containers with optimized rather than excessive safety margins, reducing manufacturing costs while maintaining reliability
Solution Approach 2:
The feedback mechanism tracking fill cycles enables dynamic operational adjustment based on actual container condition. This eliminates the need for conservative over-design, allowing cost-effective manufacturing while ensuring safety through active monitoring and preventive shutdown
3Ease of operation
If the electrical solenoid valve is located outside the container, then ease of operation and maintenance are improved, but device complexity increases
Solution Approach 1:
The patent applies the extraction principle by removing the electrical solenoid valve from inside the container and placing it externally. This separates the control function from the storage function, improving accessibility for operation and maintenance while managing complexity through functional separation
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 reduces the need for over-design, lowers production and maintenance costs, and ensures safe operation by monitoring and managing the container's lifecycle, thereby extending the system's effectiveness and reducing weight penalties.
Implementation Method 1
the sensor is a strain gauge placed in the fuel container. The strain gauge may be a number of different gauges known in the art. In one implementation, the sensor comprises a strain gauge utilizing embedded optical fibers to measure the strain in the container.
Implementation Method 2
In another implementation, the sensing system incorporates an acoustic emissions generator and receiver to monitor structural strains due to pressurization of the container.
Implementation Method 3
an electrical solenoid valve, a pressure transducer, and a temperature transducer
Implementation Method 4
an electrical solenoid valve, a pressure transducer, and a temperature transducer
Data Source
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Figure 3
Figure 4
AI summary
The present disclosure provides an alternative, cost-effective safety feature for on-board hydrogen storage containers incorporating a fill cycle sensor with a driver warning and shutdown system. The system monitors the number of times a hydrogen container is filled, and then takes action at a predetermined termination point. A controller monitors each time the hydrogen container is filled above 90% of the rated pressure or mass. Once the predetermined termination point of fill cycles is reached, the disclosed device/method will either disable the valve or refueling mechanism such that fuel supply to the vehicle is shutoff and the container cannot be filled again, essentially assuring the end of the life of the container.