Hydrogen Fleet Refueling Control for Parallel High-Pressure Filling
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Solution Overview
Problem
Refueling a small fleet of hydrogen fueled vehicles, such as ten or fewer, is challenging due to the high cost and inefficiency of existing hydrogen refueling stations, which require sequential filling and high cooling rates, making it difficult to achieve cost-effective refueling.
Innovation Solution
A system comprising a bulk hydrogen storage tank, pump/chiller assembly, and high-pressure hydrogen dispensers, controlled by a controller that determines optimal operating parameters for concurrent refueling of multiple vehicles based on fleet and refueling data, using a fast fill storage container for high-pressure hydrogen delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrogen refueling is performed at conventional refueling stations, then hydrogen can be replenished in vehicles, but the refueling cost is very high and the process is inefficient
Solution Approach 1:
The refueling system is segmented into multiple high-pressure hydrogen dispensers that can simultaneously serve multiple vehicles, dividing the refueling process into parallel operations rather than sequential ones. This segmentation enables concurrent refueling of multiple vehicles, dramatically improving productivity while reducing total energy consumption compared to sequential processing at conventional stations
Solution Approach 2:
The system operates at high pressure (700 bar) to enable faster refueling rates and reduces cooling requirements during the refueling process. By changing the pressure parameter from conventional low-pressure refueling to high-pressure refueling, the system achieves both faster refueling speeds and lower electrical consumption for the cooling system
2Adaptability or versatility
If hydrogen refueling stations are established to refuel vehicles, then vehicle refueling is enabled, but the stations are not widespread and are less available compared to conventional refueling stations
Solution Approach 1:
The refueling system is designed with multiple high-pressure hydrogen dispensers that can simultaneously serve multiple vehicles from a fleet, making the system universally applicable to various vehicle types and fleet sizes. This multi-functional design allows a single station to serve multiple purposes and vehicle models, increasing adaptability without requiring complex vehicle-specific refueling infrastructure
Solution Approach 2:
The system includes a bulk hydrogen storage tank that is pre-filled with hydrogen before refueling vehicles. This preliminary storage action allows the refueling station to operate independently of continuous hydrogen supply during refueling operations, simplifying the overall system architecture and reducing the need for complex hydrogen delivery infrastructure at the station location
3Productivity
If a fleet of vehicles is refueled sequentially at conventional stations, then each vehicle can be refueled, but the process is time-consuming and costly
Solution Approach 1:
The refueling system is segmented into multiple high-pressure hydrogen dispensers that can simultaneously serve multiple vehicles, dividing the refueling process into parallel operations rather than sequential ones. This segmentation enables concurrent refueling of multiple vehicles, dramatically improving productivity while reducing total energy consumption compared to sequential processing at conventional stations
Solution Approach 2:
The system maintains continuous refueling operation by having multiple dispensers operate simultaneously on different vehicles, eliminating idle time between refueling operations. The bulk hydrogen storage tank ensures continuous supply without interruption, maintaining useful action throughout the refueling process and minimizing downtime for the fleet
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 enables efficient and cost-effective refueling of a small fleet of vehicles with reduced electrical and carbon dioxide consumption, allowing simultaneous refueling of multiple vehicles without sequential connection, thereby lowering costs and improving operational efficiency.
Implementation Method 1
a pump/chiller assembly (30) including a compressor (32) configured to pump hydrogen fuel
Implementation Method 2
a chiller (34) configured to chill the hydrogen fuel
Implementation Method 3
a plurality of high pressure hydrogen dispensers (40) configured to selectively couple to a corresponding plurality of hydrogen fueled vehicles
Data Source
AI summary
A system and method for refueling a fleet of hydrogen fueled vehicles is provided. The system includes a bulk hydrogen storage tank, a pump/chiller assembly, a plurality of high pressure hydrogen dispenser and a controller. The pump/chiller assembly includes a compressor configured to pump hydrogen fuel and a chiller configured to chill the hydrogen fuel. The plurality of high pressure hydrogen dispensers are configured to selectively couple to a corresponding plurality of hydrogen fueled vehicles of a fleet of vehicles. The controller: receives fleet parameters indicative of operating conditions of the fleet of vehicles; receives refueler data indicative of operating conditions of the system; determines, based on the fleet parameters and the refueler data, optimal operating parameters used to achieve efficient refueling of the fleet of vehicles; and implements the optimal operating parameters into the system.