High-Pressure Hydrogen Tank Assembly for Faster Safe Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of high-pressure hydrogen tanks for fuel-cell transportation vehicles requires significant time and effort, leading to increased costs due to complex configurations that involve a thick circular-cylindrical body and a dome-shaped portion, which are inefficient and costly to manufacture.
Innovation Solution
A high-pressure hydrogen tank design featuring a metal circular cylinder with a cap part and an outer cylinder, secured by bolts, utilizing materials like chrome molybdenum steel and a decarburized layer, with a gap and flow path to prevent hydrogen permeation and equipped with hydrogen sensors for safety, and fitting structures for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick circular-cylindrical portion with dome-shaped ends is used to reduce stress levels, then the safety and reliability of the high-pressure hydrogen tank is improved, but the production time and manufacturing complexity increase significantly
Solution Approach 1:
The tank body is divided into a thin-walled circular-cylindrical portion and a separate reinforcement structure. The circular-cylindrical portion uses a thinner wall while the reinforcement structure (composed of multiple arc-shaped reinforcement plates welded to the outer surface) provides the necessary strength, eliminating the need for a thick-walled construction and reducing manufacturing complexity.
Solution Approach 2:
The tank employs a composite structure combining the circular-cylindrical portion made of high-strength steel with the reinforcement structure made of arc-shaped reinforcement plates. This composite approach allows the thin-walled section to achieve the strength of a thick-walled section through the added reinforcement, reducing production time while maintaining safety.
2Strength
If a thick circular-cylindrical portion is used to reduce stress levels, then the strength and pressure resistance of the tank is improved, but the production costs increase due to longer production time and more effort
Solution Approach 1:
The reinforcement structure is segmented into multiple arc-shaped reinforcement plates that are welded to the outer surface of the circular-cylindrical portion. This segmentation allows for easier fabrication and assembly compared to forming a single thick-walled structure, reducing production costs while maintaining the required pressure resistance.
Solution Approach 2:
The reinforcement structure is applied locally at specific positions on the circular-cylindrical portion where additional strength is needed, rather than uniformly thickening the entire wall. This localized reinforcement reduces material costs and manufacturing complexity while achieving the required pressure resistance.
3Productivity
If a simple configuration is used to reduce production time and costs, then the productivity and ease of manufacture are improved, but the safety and reliability may be compromised
Solution Approach 1:
The reinforcement structure is designed and positioned in advance during the manufacturing process, with arc-shaped reinforcement plates welded to predetermined locations on the circular-cylindrical portion. This preliminary planning ensures that safety requirements are met without requiring complex post-processing or inspection, maintaining high production efficiency while ensuring reliability.
Solution Approach 2:
The design incorporates a feedback mechanism where the reinforcement structure's positioning and configuration are optimized based on stress analysis and safety requirements. This ensures that the simplified structure still meets safety standards through informed design decisions rather than trial and error, maintaining both productivity and reliability.
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 design allows for a simpler, safer, and cost-effective production of high-pressure hydrogen tanks that maximize storage capacity within limited space, reducing production time and costs while ensuring safety and efficient hydrogen management.
Implementation Method 1
a decarburized layer has been removed
Implementation Method 2
a hydrogen sensor for monitoring the leakage of hydrogen is provided at the exit of the leaked-hydrogen discharge hole
Implementation Method 3
a gap is formed by which the metal circular cylinder and the outer cylinder are spaced apart from each other
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A high-pressure hydrogen tank includes a metal circular cylinder configured to store high-pressure hydrogen therein, a cap part configured to cover each of opposite end portions of the metal circular cylinder, an outer cylinder surrounding an outer periphery of a circular-cylindrical portion of the metal circular cylinder, and a fastening part configured to fix the cap part to the outer cylinder.