Hydrogen Refueling Cooling Control via Expansion Valve
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Solution Overview
Problem
Hydrogen refuelling stations face challenges in maintaining sufficient cooling power due to insufficient thermal inertia in cooling systems, particularly during rapid changes in cooling demand, and struggle to control refrigerant temperature and superheat effectively, leading to inefficient cooling and potential overheating in hydrogen tanks.
Innovation Solution
An electronic controller is connected to the expansion valve to dynamically control cooling power by measuring the temperature differential between the refrigerant at the outlet and inlet of the heat exchanger, adjusting the refrigerant flow, and using a bypass conduit to manage refrigerant flow and pressure, ensuring consistent evaporation pressure and superheat levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal inertia is increased in the heat exchanger to store cold for high demand, then cooling capacity during peak demand is improved, but device complexity and response speed to load changes deteriorate
Solution Approach 1:
The patent implements dynamic control of the expansion valve based on real-time temperature differential feedback between heat exchanger inlet and outlet. This allows the refrigeration system to rapidly adjust cooling capacity in response to changing load demands without relying on large thermal inertia, thereby maintaining reliability while reducing device complexity
Solution Approach 2:
The patent employs a feedback control mechanism where temperature sensors at the heat exchanger inlet and outlet provide continuous temperature differential information to the expansion valve controller. This feedback loop enables automatic adjustment of refrigerant flow to match actual cooling demand, eliminating the need for oversized thermal storage and reducing system complexity
2Use of energy by moving object
If counter-current heat exchanger is used to improve cooling efficiency, then energy efficiency is improved, but control precision of refrigerant temperature and superheat deteriorates
Solution Approach 1:
The patent uses temperature differential feedback from the heat exchanger to dynamically control the expansion valve, providing precise control over refrigerant flow and superheat. This feedback mechanism compensates for the challenges of counter-current heat exchanger operation, maintaining both high efficiency and precise temperature control
Solution Approach 2:
The patent dynamically adjusts the expansion valve opening based on temperature differential measurements, changing the refrigerant flow parameters in real-time. This allows the system to optimize the balance between cooling efficiency and temperature control precision by continuously adapting to operating conditions
3Loss of energy
If refrigeration system operates at low load during standby or low demand, then energy consumption is reduced, but cooling power sufficiency deteriorates
Solution Approach 1:
The patent implements dynamic load following control where the expansion valve automatically adjusts refrigerant flow to match actual cooling demand. During low demand periods, the system operates at low energy consumption while maintaining the ability to rapidly increase cooling power when demand increases, based on real-time temperature differential feedback
Solution Approach 2:
The patent maintains the refrigeration system in a ready state during standby modes, with the control system continuously monitoring temperature differential. This preliminary positioning allows the system to quickly respond to demand changes without sacrificing cooling power sufficiency, while minimizing energy consumption during low-demand periods
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
This solution enables efficient and rapid adjustment of cooling power to match changing demand, maintaining the required temperature range for hydrogen refuelling, ensuring stable and efficient cooling of hydrogen tanks, even during fast load changes and standby modes.
Implementation Method 1
an expansion valve (10) configured for controlling an amount of refrigerant flowing towards the heat exchanger (7)
Implementation Method 2
a heat exchanger (7) located in the transfer circuit (4) and comprising a heat exchange section between the gas flowing in the transfer circuit (4) and the evaporator section (11)
Implementation Method 3
a compressor (8) configured for compressing the refrigerant
Implementation Method 4
a condenser section (9) arranged in series between the compressor (8) and the expansion valve (10)
Data Source
Figure 1~4
Figure 5~9
AI summary
A device for refuelling containers with pressurized gas, comprising a pressurized gas source (2), a transfer circuit (4) intended to be removably connected to a container (3), the device (1) comprising a refrigeration system for cooling the gas flowing from the gas source (2) prior to its entering into the container (3), the refrigeration system comprising a refrigerant cooling loop circuit (20) comprising, arranged in series, a compressor (8), a condenser section (9), an expansion valve (10) and an evaporator section (11), the refrigeration system comprising a cold source (12) in heat exchange with the condenser section (9) and a heat exchanger (7) located in the transfer circuit (4), the device comprising an electronic controller (21) connected to the expansion valve (10) and configured for controlling cooling power produced by the refrigeration system via the control of the opening of the expansion valve (10), the device comprising a differential temperature sensor (17, 18) system measuring the difference between the temperature of the refrigerant in the refrigerant cooling loop circuit (20) at the outlet of the heat exchanger (7) and the temperature of the refrigerant in the cooling loop circuit (20) at the inlet of the heat exchanger, the electronic controller (21) being configured for controlling the cooling power produced as a function of this temperature differential.