Mobile Hydrogen Dispenser With Mechanical Pressure-Flow Control
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Solution Overview
Problem
Existing mobile hydrogen refueling systems for fuel cell vehicles are cumbersome, expensive, and prone to equipment failures due to their reliance on complex PLC-controlled cascade filling systems and high-pressure hydrogen cylinders, which limits their availability and convenience, especially in areas with underdeveloped refueling infrastructure.
Innovation Solution
A mobile hydrogen dispenser using a purely mechanical solution with pressure regulators and orifice plates to achieve a controlled, constant mass flow rate and pressure ramp rate, eliminating the need for electronic controls and external power sources, and allowing partial filling of hydrogen tanks through pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a PLC-controlled cascade filling system is used, then the filling process can be automated and controlled, but the device complexity and cost increase significantly
Solution Approach 1:
The system uses self-regulating mechanical components (pressure regulators, orifice plates, check valves) that automatically control the filling process without external power or electronic controls. The pressure differential between the hydrogen source and tank naturally drives the filling operation, with mechanical regulators maintaining set pressures and flow rates throughout the process.
Solution Approach 2:
The patent replaces electronic control systems (PLCs, sensors, motors) with purely mechanical control components. Pressure regulators, orifice plates, and check valves mechanically control flow and pressure without requiring electricity, eliminating the need for complex electronic automation while maintaining filling process control.
2Quantity of substance
If high-pressure hydrogen cylinders are used for mobile refueling, then sufficient hydrogen can be provided, but the weight and required infrastructure increase
Solution Approach 1:
The system uses pneumatic pressure from the hydrogen source to drive the filling operation. Hydrogen gas pressure naturally flows from the source through mechanical regulators and orifice plates into the vehicle tank, eliminating the need for heavy mechanical compressors while maintaining adequate hydrogen transfer capability.
Solution Approach 2:
The mechanical pressure regulator system can accommodate various hydrogen source configurations (cylinders, tube trailers, storage tanks) and different vehicle tank requirements without needing different equipment. The same mechanical components handle different pressure ranges and flow rates by adjusting regulator settings and orifice selections.
3Measurement precision
If electronic controls and external power sources are used, then precise control is achieved, but the reliability decreases due to more failure points
Solution Approach 1:
The system uses simple, robust mechanical components that are inherently more reliable than complex electronics. Pressure regulators, orifice plates, and check valves have no moving electrical contacts, no software, and no power requirements, making them highly reliable and resistant to failure in remote or harsh environments.
Solution Approach 2:
Electronic control systems are completely replaced with mechanical control components. Pressure regulators provide precise pressure control through mechanical spring-loaded valves, orifice plates provide flow restriction through fixed or adjustable openings, and check valves prevent backflow mechanically - all without electronics or external power.
4Ease of operation
If a mobile dispenser is made lightweight and portable, then ease of deployment improves, but the hydrogen storage capacity may be limited
Solution Approach 1:
The system is designed as a modular mobile dispenser that can be easily transported and deployed. The hydrogen source, dispenser mechanism, and connecting components are configured as portable units that can be moved to different locations and connected to vehicle tanks without requiring fixed infrastructure or heavy equipment.
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 solution provides a reliable, safe, and efficient method for partially filling hydrogen tanks without the need for electronic controls or external power, reducing equipment failures and operational complexity, and enabling refueling in areas with limited infrastructure, while being lightweight and portable.
Implementation Method 1
The backpressure regulator is a dome-loaded or spring-and-dome loaded backpressure regulator that is adapted and configured to maintain a pressure of gas in said first supply line between said orifice plate and said backpressure regulator at or below a variable set point pressure of the backpressure regulator
Implementation Method 2
The differential pressure regulator is adapted and configured to maintain a constant pressure differential ΔP between a pressure of hydrogen in the reference pressure line and a pressure of hydrogen in the first pilot line
Implementation Method 3
allowing partial filling of hydrogen tanks through pressure equalization
Data Source
AI summary
A mobile dispenser may be used to at least partially fill hydrogen tanks of fuel cell-powered vehicles. The dispenser uses a purely mechanical control of the fill using an orifice plate across which a pressure differential is maintained through use of a backpressure regulator whose reference pressure is controlled by a differential pressure regulator. Because it does need or use electrical power, it may be used in situations where no electrical power is available or convenient.