Hydrogen Component Verification Panel for 70 MPa Vehicle Testing
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Solution Overview
Problem
Current testing methods for 70 MPa hydrogen systems are inadequate as they rely on bench testing, which is complex and not suitable for rapid or simple testing of individual components.
Innovation Solution
A verification device for vehicle-mounted hydrogen system components, comprising a high-pressure pipeline, manual valves, quick connectors, a test panel with pressure reducers, flow meters, and multi-way connectors, along with sensors for real-time monitoring, allowing for the testing of individual components under real vehicle conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bench testing is used for 70 MPa hydrogen system components, then comprehensive system testing is achieved, but testing complexity increases and single component testing efficiency decreases
Solution Approach 1:
The testing system is segmented into modular components: high-pressure test section (70 MPa hydrogen system), test panel with pressure reducer, flow meter, and low-pressure test section. This segmentation allows independent testing of single components while maintaining the option for system-level testing, resolving the contradiction between comprehensive verification and testing efficiency.
Solution Approach 2:
A test panel is introduced as an intermediary device between the high-pressure hydrogen system and the low-pressure test components. The test panel includes a pressure reducer that mediates the pressure transition, enabling safe and efficient testing of individual components without requiring complete system disassembly or complex high-pressure test benches.
2Reliability
If complete hydrogen system test bench is used, then system-level integration testing is achieved, but testing time and resource consumption increase
Solution Approach 1:
The testing system is designed with dynamic configurability, allowing the test panel to be connected to different components (stack, compressor, valve) as needed. The quick connectors and manual valves enable rapid reconfiguration between single-component testing and system-level testing, reducing time loss while maintaining reliability verification capabilities.
3Measurement precision
If real vehicle testing is implemented, then actual operating condition data is obtained, but testing complexity and data collection difficulty increase
Solution Approach 1:
The test panel is designed with multi-functionality to handle various testing scenarios: single component testing (stack, compressor, valve), system-level testing, and real vehicle integration testing. The universal design with standard connectors and multiple measurement points (pressure sensors, flow meters, temperature sensors) simplifies data collection across different testing modes while ensuring measurement precision under real operating conditions.
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 device enables efficient and accurate testing of hydrogen system components, providing real-time data on pressure, temperature, and flow, thus ensuring the safety and reliability of the components, and allowing for easy disassembly and addition of new test pieces.
Implementation Method 1
a pressure reducer, a flow meter and a low-pressure multi-way connector are arranged on the test panel, wherein the pressure reducer, the flow meter, and the low-pressure multi-way connector are connected in sequence
Implementation Method 2
a pressure reducer, a flow meter and a low-pressure multi-way connector are arranged on the test panel
Implementation Method 3
a pressure sensor of medium and low pressure is internally arranged in the pressure reducer for real-time monitoring of gas pressure after pressure reduction
Implementation Method 4
a low-pressure pressure sensor and a temperature sensor are internally arranged in the low-pressure multi-way connector, and the low-pressure pressure sensor is connected to the temperature sensor for real-time monitoring of stability of low pressure and stability of gas temperature in gas circuit
Data Source
AI summary
The verification device for a component of a vehicle-mounted hydrogen system includes a high-pressure pipeline (1), a first manual valve (2), a high-pressure quick connector (3), a test panel (4), and a stack (5), wherein the high-pressure pipeline (1), the first manual valve (2), the high-pressure quick connector (3), the test panel (4) and the stack (5) are connected in sequence, and a pressure reducer (401), a flow meter (402) and a low-pressure multi-way connector (403) are arranged on the test panel (4), wherein the pressure reducer (401), the flow meter (402) and the low-pressure multi-way connector (403) are connected in sequence. The device according to the disclosure can provide real vehicle testing of the hydrogen system fittings and valves under different vehicle conditions, collect the real-time status of the 70 MPa hydrogen system fittings and valves under real vehicle conditions and obtain real data through components such as sensors and flow meters, providing strong evidence for verification of the safety and reliability of the fittings and valves, and at the same time, the device is easy to disassemble and allows for the addition of new external test pieces.