Hydrogen Crawler Fuel System With Flameless Residual Gas Burnoff
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Solution Overview
Problem
The deployment of hydrogen-powered crawler vehicles is limited due to issues with hydrogen production, distribution, and the high flammability of hydrogen, which requires heavy sealed tanks and poses safety concerns, especially when parked in enclosed environments.
Innovation Solution
A hydrogen-powered crawler vehicle with a catalytic combustion chamber and control system to burn residual hydrogen in a flameless condition, using a modulating shut-off valve and pressure-reducing valve to manage hydrogen flow, and a control unit to ensure safe operation and evacuation of residual hydrogen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealed tanks are used to prevent hydrogen leakage, then hydrogen containment is improved, but vehicle weight increases
Solution Approach 1:
The system performs preliminary action by actively managing and evacuating residual hydrogen from ducts before the vehicle enters enclosed spaces or before shutdown. The control unit activates pumps and opens valves to remove hydrogen from the common rail and ducts, preventing accumulation and eliminating the need for overly heavy sealed tanks.
Solution Approach 2:
The control system uses feedback from sensors (hydrogen concentration detectors, pressure sensors) to continuously monitor hydrogen levels in ducts and reservoirs. Based on this feedback, the control unit dynamically adjusts valve positions and pump operation to maintain safe hydrogen levels, enabling lighter tank designs while ensuring safety.
2Quantity of substance
If hydrogen is stored at high pressure (700 bar), then storage capacity is improved, but pressure reduction complexity increases
Solution Approach 1:
The pressure reducing valve performs preliminary pressure reduction from 700 bar to operational pressure (50-60 bar) before hydrogen enters the common rail and ducts. This preliminary action simplifies the overall system by handling pressure reduction at the source rather than requiring complex pressure management throughout the entire hydrogen distribution system.
3Ease of operation
If hydrogen feeding is continuous to maintain pressure, then engine readiness is improved, but hydrogen evaporation into environment increases
Solution Approach 1:
Instead of continuous hydrogen feeding, the system uses periodic action by shutting off hydrogen supply when the engine is not in use and only activating it when needed. The control unit manages intermittent hydrogen feeding based on engine operation status, preventing continuous evaporation while maintaining engine readiness through on-demand supply.
Solution Approach 2:
The control system uses feedback from engine operation status and hydrogen level sensors to intelligently control the shut-off valve. When the engine is running or about to start, hydrogen feeding is activated; when the engine is off, feeding is shut off. This feedback-based control eliminates unnecessary hydrogen evaporation while ensuring engine readiness when needed.
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
Reduces hazards associated with residual hydrogen leaks by ensuring safe and efficient hydrogen management, allowing the vehicle to be parked in enclosed spaces without risk of flammable emissions.
Implementation Method 1
a catalytic combustion chamber to burn hydrogen in flameless condition
Data Source
AI summary
A hydrogen-powered crawler vehicle (1) has a chassis (2); a reservoir (5) configured to hold pressurized hydrogen; a hydrogen-powered fuel-injected internal combustion engine (4) comprising a common rail to feed hydrogen to a plurality of injectors (41); a duct (7) to feed hydrogen from the reservoir (5) to the common rail (6); a catalytic combustion chamber (13) to burn hydrogen in flameless condition; an additional duct (14) to selectively connect the common rail (6) with said catalytic combustion chamber (13); and an exhaust duct (17) to evacuate the products of combustion from the catalytic combustion chamber (13).