Hydrogen Tank Fill Detection Using Pressure Differential Sensing
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Solution Overview
Problem
Existing fuel cell electric vehicles (FCEVs) require complex mechanisms like fuel tank doors to initiate fueling operations, which are prone to failure and add complexity, and existing systems require the vehicle to be powered during fueling.
Innovation Solution
A fuel delivery system with sensors and a controller that detects fill operations based on pressure and temperature differentials in the fuel line, allowing for fuel delivery control without a fuel tank door and enabling fueling with the vehicle powered or unpowered.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuel tank door mechanism is used to initiate fueling operations, then the fueling process can be started, but the system complexity increases and reliability decreases due to potential mechanical failures
Solution Approach 1:
The patent removes the fuel tank door mechanism entirely from the system. Instead of using a mechanical door to initiate fueling, the system directly monitors pressure differential across the fuel tank to detect fueling operations, eliminating the complex mechanical component that was causing reliability issues.
Solution Approach 2:
The system uses the natural pressure differential that occurs during fueling as a self-indicating signal. The fueling process itself creates the pressure change that the sensors detect, allowing the system to automatically recognize and respond to fueling operations without requiring external mechanical triggers or user intervention.
2Ease of operation
If the vehicle must be powered during fueling operations, then control systems can monitor the process, but the fueling process is restricted and less convenient
Solution Approach 1:
The patent replaces the requirement for an active powered control system with a passive sensing approach. By using pressure sensors to detect fueling operations, the system can identify and respond to fueling events regardless of whether the vehicle's main power system is active, enabling fueling in both powered and unpowered states.
3Measurement precision
If pressure sensors are used to detect fueling operations, then the detection accuracy improves, but the system can only detect pressure changes
Solution Approach 1:
The patent makes the pressure sensing system multi-functional by using it both to detect fueling operations and to control the fuel delivery process. The same pressure differential detection that identifies fueling initiation also provides feedback for controlling the fuel transfer, eliminating the need for separate sensing and control systems.
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
Enables reliable detection of fueling without additional components and allows fueling with the vehicle powered or unpowered, simplifying the process and reducing potential failures.
Implementation Method 1
detecting a pressure differential between an inlet and a fuel tank based on data from the one or more sensors to have the fuel provided to the fuel tank
Implementation Method 2
the characteristic differential is at least one of a pressure differential or a temperature differential
Data Source
AI summary
A fuel system includes a controller and a fuel delivery system having a fuel line. The fuel delivery system is fluidly coupled to a fuel tank. The fuel line defines an inlet and is adapted to extend between the inlet and the fuel tank to transport the fuel. The one or more sensor devices are configured to provide data indicative of a characteristic of the fuel. The controller is configured to detect a characteristic differential between the inlet and the fuel tank based on data from the one or more sensor devices to identify occurrence of a fill operation, and control the fuel delivery system for the fill operation in response to detecting the characteristic differential identifying occurrence of the fill operation.