Hydrogen Fueling Integrity Checks via Sensor Cross-Referencing
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Solution Overview
Problem
During hydrogen fueling of Compressed Hydrogen Storage Systems (CHSS), there is a risk of faulty data transmission due to malfunctioning in-board sensors, which can lead to inaccurate fueling parameters, potentially causing overfilling or overheating of the hydrogen tank.
Innovation Solution
A system with a communication component, calculation component, and error component that receives and calculates parameters related to the CHSS tank, determines a tank volume error, and adjusts the fueling mode to either conservative or non-conservative based on this error to ensure safe and accurate fueling, using redundancies in hydrogen tank filling stations to verify the correctness of communicated parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If full-communication fueling is used to transmit real-time data from in-tank sensors to the hydrogen tank filling station, then fueling efficiency and speed are improved, but the risk of faulty data transmission due to sensor failure increases
Solution Approach 1:
The system implements feedback by continuously monitoring tank parameters (temperature, pressure, volume) during fueling and comparing actual measurements against expected values. When deviations are detected, the system adjusts fueling operations in real-time to maintain safety and accuracy.
Solution Approach 2:
The system performs preliminary integrity checks on sensor data before using it to control fueling operations. By validating data quality in advance and establishing baseline expectations for sensor readings, the system prevents faulty data from compromising fueling safety.
2Speed
If in-tank sensors are relied upon for real-time data during fueling, then fueling speed is improved, but the risk of overfilling or overheating due to sensor failure increases
Solution Approach 1:
The system introduces an intermediary validation layer between the in-tank sensors and the fueling control system. This intermediary layer cross-checks sensor readings against physical laws, expected parameter ranges, and real-time fueling conditions to filter out faulty data before it can cause harmful effects.
Solution Approach 2:
The system prepares compensatory measures in advance by establishing safety margins, maximum fill limits, and emergency shutdown protocols. These pre-established protective measures act as a cushion against potential sensor failures, preventing overfilling or overheating even if sensors provide incorrect data.
3Measurement precision
If communicated parameters from vehicle sensors are used directly for fueling control, then fueling accuracy is improved, but the risk of inaccurate parameters due to sensor malfunction increases
Solution Approach 1:
The system implements feedback loops that continuously compare communicated parameters from vehicle sensors with independently calculated parameters based on fueling station measurements. Discrepancies trigger validation protocols or conservative fueling modes to maintain accuracy and reliability.
Solution Approach 2:
The system creates redundant copies of parameter measurement through multiple independent methods (vehicle sensors, station sensors, calculated values). By cross-referencing these copies, the system can identify and correct faulty readings, ensuring accurate and reliable parameter data for fueling control.
Data Source
AI summary
According to one or more aspects, systems and techniques for hydrogen fueling with integrity checks are provided herein. Communicated parameters measured by on-board sensors of a vehicle may be cross-referenced against calculated parameters measured by sensors of a fueling station. For example, communicated parameters relating to a compressed hydrogen storage system (CHSS) tank of a vehicle to be fueled may be received at different time intervals. Calculated parameters may be calculated based on a mass of hydrogen fuel dispensed by a hydrogen fueling station from a reference point to one of the time intervals and densities of the CHSS tank of the vehicle at respective time intervals. An error may be calculated between the communicated parameters and the calculated parameters. A fueling mode, such as a conservative fueling mode or a non-conservative fueling mode, may be determined based on the calculated error.