Hydrogen Tank Shut-Off Valve With Pressure-Differential Main Actuation
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Solution Overview
Problem
Existing shut-off valves for hydrogen tanks in motor vehicles are large and require strong electromagnets due to large pilot-control valve strokes, making them unsuitable for compact installations like cylinder necks, and there is a need for a safe mechanism to prevent uncontrolled fuel leakage in case of line breakage or accidents.
Innovation Solution
A compact shut-off valve design with a small pilot-control valve stroke and a larger main valve stroke, utilizing an electromagnet for a small magnet armature movement, a driver to transfer motion, and a pressure differential to operate the main valve without continuous electromagnet assistance, along with a sealing mechanism to prevent pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a large pilot-control valve stroke is used in existing shut-off valves, then the main valve can be reliably actuated, but the electromagnet and overall valve size become large, making them unsuitable for compact installations like cylinder necks
Solution Approach 1:
The valve stroke is segmented into two distinct phases: a small pilot-control valve stroke (1-3 mm) actuated by the electromagnet, and a larger main valve stroke (5-15 mm) actuated by pressure differential. This segmentation allows the electromagnet to be small while still achieving reliable main valve actuation through the amplification effect of the pressure differential mechanism.
Solution Approach 2:
The pilot-control valve acts as an intermediary that amplifies the small electromagnet movement into a large main valve stroke. By controlling the pressure differential through the pilot valve, a small electromagnetic force can trigger a large mechanical displacement of the main valve, resolving the contradiction between small size and reliable actuation.
2Reliability
If a strong electromagnet is used to achieve a large pilot-control valve stroke, then the main valve can be actuated reliably, but the electromagnet size and power consumption increase
Solution Approach 1:
The system uses pneumatic pressure differential to amplify the electromagnet's effect. The pilot-control valve regulates high-pressure gas to create a pressure differential that acts on the main valve, allowing a weak electromagnet to control a much larger force through fluid pressure amplification.
Solution Approach 2:
The system changes the operating parameters by using pressure differential as the primary actuation mechanism for the main valve, rather than relying on electromagnetic force alone. This parameter change allows the electromagnet to operate at low power while still achieving reliable main valve actuation through the pressure amplification mechanism.
3Volume of moving object
If the pilot-control valve stroke is minimized for compact design, then the electromagnet size is reduced, but the force required for actuation becomes very small
Solution Approach 1:
The system performs preliminary action by first actuating the pilot-control valve to establish the pressure differential condition, and then the main valve is automatically actuated by the accumulated pressure differential. This two-stage preliminary action allows the system to overcome the small force limitation of the miniaturized electromagnet.
Solution Approach 2:
The pressure differential acts as an intermediary force that amplifies the small electromagnet force. The pilot-control valve regulates this intermediary pressure to create a force multiplication effect, allowing a weak electromagnet to control a much stronger main valve through the pressure differential mechanism.
4Reliability
If the main valve stroke is made large for complete closure, then the sealing effectiveness is improved, but the force required to move the main valve increases
Solution Approach 1:
The system uses pneumatic pressure differential to provide the force needed for large main valve stroke. High-pressure gas acts on the main valve surface to generate the necessary actuation force, enabling a large stroke for complete sealing without requiring a proportionally large electromagnetic force.
Solution Approach 2:
The system transitions from one-dimensional electromagnetic actuation to two-dimensional actuation by combining electromagnetic force (for pilot valve) with pneumatic pressure force (for main valve). This dimensional change allows the main valve to achieve large stroke and high sealing force through pressure differential rather than electromagnetic force alone.
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 compact, efficient shut-off valve that can be installed in a cylinder neck, effectively preventing hydrogen leakage by minimizing electromagnet size and utilizing pressure differentials for operation, ensuring safety and compactness.
Implementation Method 1
The electromagnet comprises a magnet armature and a coil, wherein the magnet armature is arranged movably such that, when the coil is electrically energized, the magnet armature moves through a magnet armature stroke in the direction of the base plate
Implementation Method 2
a larger main valve stroke of the main valve generated by a pressure difference between the control chamber and a high-pressure connection of the shut-off valve
Data Source
AI summary
The invention presented relates to a shut-off valve (100) for closing a tank (201). The shut-off valve (100) comprises a control chamber (101), a pilot-control valve (103), a main valve (105), an electromagnet (107), a driver (109), and a base plate (111), wherein the electromagnet (107) comprises a magnet armature (115) and a coil (113), wherein the pilot-control valve (103) is supported movably in the magnet armature (115), wherein the magnet armature (115) is arranged movably such that, when the coil (113) is electrically energized, the magnet armature (115) moves through a magnet armature stroke (119) in the direction of the base plate (111), wherein the driver (109) is configured to move the pilot-control valve (103) out of a basic position of the pilot-control valve (103), and through a pilot-control valve stroke (121) also in the direction of the base plate (111), into a pilot-control position during a movement of the magnet armature (115), wherein the main valve (105) is movable through a main valve stroke (135) in the direction of the base plate (111), wherein the main valve (105) is configured to move the pilot-control valve (103) out of the pilot-control position, and further in the direction of the base plate (111), during a movement through the main valve stroke (135).