Integrated Hydrogen Pressure Actuator with Bypass for Limp Home
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Solution Overview
Problem
Conventional hydrogen supply systems in fuel cell vehicles face issues such as passive hydrogen gas supply, inability to actively increase hydrogen flow, pressure unbalance between electrodes, hydrogen leakage, and potential vehicle shutdown due to pressure control actuator failures, lacking a limp home mode for emergency operations.
Innovation Solution
An integrated pressure control actuator assembly with a pressure control actuator and bypass valve, integrated in a single body, actively controls hydrogen gas pressure and flow, and includes a control mechanism to detect failures and switch to a bypass mode, ensuring stable hydrogen supply and limp home operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a low-pressure regulator is used to control hydrogen pressure, then the system structure is simple, but the hydrogen supply is passive and cannot actively increase the supply amount
Solution Approach 1:
The patent replaces the traditional mechanical low-pressure regulator with a pressure control actuator that uses electromagnetic or electronic control mechanisms. This actuator can actively modulate the hydrogen supply based on real-time pressure feedback and control signals, enabling dynamic adjustment of hydrogen flow rate and pressure to meet varying power demands of the fuel cell stack.
2Productivity
If a separate hydrogen recirculation system is added to increase hydrogen supply, then the hydrogen supply amount increases, but the system complexity increases
Solution Approach 1:
The pressure control actuator serves multiple functions: it regulates pressure, controls flow rate, and enables active hydrogen supply adjustment. By integrating these functions into a single component, the patent eliminates the need for separate recirculation systems while achieving the desired increase in hydrogen supply capability.
3Volume of moving object
If the pressure control actuator is integrated with valves and flow paths, then the system volume is reduced and manufacturing cost is lowered, but the failure detection and bypass capability must be maintained
Solution Approach 1:
The patent integrates the pressure control actuator, control valves, and flow paths into a single unified assembly. This consolidation reduces system volume and simplifies manufacturing while incorporating built-in failure detection mechanisms and bypass capabilities to maintain reliability.
Solution Approach 2:
The integrated assembly includes pre-designed bypass pathways and failure detection sensors that are built into the structure. These features provide redundant pathways for hydrogen flow in case of actuator failure, ensuring continuous operation and maintaining reliability despite the compact integrated design.
Data Source
AI summary
An integrated pressure control actuator assembly of a hydrogen supply system includes: a start/stop solenoid valve, a bypass valve, and a pressure control actuator, which are integrally formed in a single body; a normal flow path formed on the body, through which hydrogen gas is transferred from the start/stop solenoid valve to the pressure control actuator; an auxiliary flow path formed on the body, through which hydrogen gas is transferred according to opening and closing of the bypass valve connected to the normal flow path; and a control means for controlling the opening and closing of the bypass valve by detecting a failure of the pressure control actuator. The assembly enables the fuel cell vehicle to be driven in a limp home mode in the event of an emergency by adjustment of the pressure of hydrogen.