Hydrogen Refueling Adapter for Cross-Pressure Compatibility
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Solution Overview
Problem
Hydrogen fuel vehicles face incompatibility issues between 700 bar and 350 bar refueling systems, leading to mechanical connection problems and safety concerns due to temperature increases and lack of IR communication, limiting the use of hydrogen refueling stations.
Innovation Solution
A refueling adapter with a first filling port for the vehicle's fuel tank, a second filling port for the dispenser nozzle, an adapter controller for communication with the vehicle's fueling system, and a valve to selectively open and close the fluid connection, allowing the adapter to match incompatible dispensing types and pressures, and provide fail-safe refueling by monitoring temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a vehicle designed for 700 bar system is connected to a 350 bar refueling station, then refueling can be performed, but mechanical connection is problematic or impossible and safety concerns arise due to temperature increases
Solution Approach 1:
The patent employs an adapter as an intermediary device that connects the 350 bar dispenser nozzle to the 700 bar vehicle inlet. The adapter includes a first connection interface for the 350 bar dispenser and a second connection interface for the 700 bar vehicle, enabling mechanical compatibility between incompatible pressure systems while maintaining safety through controlled fluid connection.
Solution Approach 2:
The adapter system changes the pressure parameter by providing a transition from 350 bar at the dispenser side to 700 bar at the vehicle side. The adapter controller monitors and manages the pressure transition, allowing the same physical connection to serve different pressure requirements safely.
2Productivity
If a 350 bar refueling station with high flow nozzles is used for 700 bar vehicles, then refueling speed may be increased, but temperature increases and lack of precooling raise safety concerns
Solution Approach 1:
The adapter controller implements feedback control by monitoring the refueling process and communicating with the vehicle fueling system. The controller can detect temperature increases and automatically interrupt the refueling process when safety thresholds are exceeded, providing real-time safety management without requiring manual intervention.
Solution Approach 2:
The system dynamically adjusts the refueling process by enabling or disabling the fluid connection through the valve controlled by the adapter controller. This dynamic control allows the system to optimize refueling speed when conditions are safe and immediately stop when temperature thresholds are exceeded, adapting to real-time conditions.
3Device complexity
If 350 bar refueling stations are used without IR communication, then infrastructure complexity is reduced, but automatic termination of refueling in case of overheating cannot be achieved
Solution Approach 1:
The adapter controller serves as an intermediary communication device that bridges the gap between the simple 350 bar dispenser infrastructure and the sophisticated 700 bar vehicle system with IR communication capabilities. The adapter controller handles the communication protocol translation and safety monitoring, allowing vehicles to automatically terminate refueling when overheating occurs even at stations without advanced communication infrastructure.
4Adaptability or versatility
If an adapter is introduced to enable compatibility between different dispensing types, then adaptability is improved, but device complexity increases
Solution Approach 1:
The adapter is designed as a universal interface that can connect different dispensing types (350 bar and 700 bar) through standardized connection protocols. The adapter controller provides multi-functional capabilities including pressure regulation, temperature monitoring, communication translation, and automatic safety termination, consolidating multiple functions into a single device.
Data Source
AI summary
A refueling adapter for an alternative fuel vehicle includes a first filling port that is fluidly coupled to an inlet nozzle of a fuel tank of the alternative fuel vehicle. The first filling port is configured to fit an inlet nozzle of a first dispensing type. A second filling port fluidly coupled to a dispenser nozzle of an alternative fuel dispenser. The second filling port is configured to fit a dispenser nozzle of a second dispensing type, the second dispensing type being different from the first dispensing type. An adapter controller is configured to communicate with a vehicle fueling system of the alternative fuel vehicle and a valve providing a fluid connection between the first filling port and the second filling port and is operated by the adapter controller to selectively open and close the fluid connection.