Modular Gas Filling Assembly for Precise Hydrogen Piping
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Solution Overview
Problem
Conventional gas filling devices for vehicles face assembly challenges due to loose bolt fastening holes, frame distortion, and complex plumbing connections, which can lead to assembly errors and potential hydrogen gas leaks.
Innovation Solution
The gas filling device is composed of modular units with positioning holes and a base frame, allowing for simplified assembly by using temporary pins and binding bands to connect units and devices accurately, reducing assembly steps and errors, and facilitating the installation of heavy equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If devices are installed and connected to a frame after the entire frame is assembled, then the frame structure can be completed, but assembly errors cause distortion of the frame structure and increase the difficulty of installation
Solution Approach 1:
The gas filling device is divided into multiple independent units (first unit housing heat exchanger, second unit housing display, third unit housing flow meter, fourth unit housing filling hoses). Each unit can be assembled and positioned separately, then connected to the base frame using positioning holes, which eliminates frame distortion and simplifies installation procedures.
Solution Approach 2:
Positioning holes are pre-formed in the base frame at predetermined locations before device installation. These positioning holes guide the accurate placement of each unit, ensuring precise alignment and preventing assembly errors that would otherwise distort the frame structure.
2Ease of operation
If the gas pipe cooling unit is installed within the frame while being moved by multiple people, then the heavy device can be positioned, but the risk of damaging metal seals increases
Solution Approach 1:
The gas pipe cooling unit is integrated into the first unit as a predetermined assembly rather than being installed separately as a heavy component. This segmentation allows the cooling unit to be positioned as part of a smaller, more manageable unit module, reducing the risk of seal damage during installation.
Solution Approach 2:
Positioning holes and positioning pins act as intermediaries to guide the accurate placement of units and their internal components. The positioning pins insert through aligned positioning holes to ensure precise positioning of the first unit (containing the cooling unit) relative to the base frame, preventing misalignment that could damage metal seals.
3Manufacturing precision
If piping connections are made by skilled workers, then accurate connection can be achieved, but the assembly process requires high skill and is time-consuming
Solution Approach 1:
Piping connections are pre-established within each unit module (e.g., primary side piping and secondary side piping are predetermined in the first unit). This segmentation allows piping to be assembled in controlled, smaller sections rather than attempting complex connections across the entire frame, improving both accuracy and efficiency.
Solution Approach 2:
Piping routes and connections are predetermined and pre-assembled within each unit before final installation. The positioning holes and positioning pins enable accurate alignment of these pre-assembled units, eliminating the need for skilled workers to perform complex on-site piping connections and significantly improving assembly productivity.
4Manufacturing precision
If units are connected using positioning holes and pins, then assembly errors are reduced, but additional components are required
Solution Approach 1:
The positioning holes serve multiple functions: they guide the placement of positioning pins for accurate alignment, provide pathways for binding bands to secure units to the base frame, and act as reference points for piping and cable connections. This multi-functionality reduces the need for separate alignment components, offsetting the addition of positioning pins.
Solution Approach 2:
Positioning pins act as simple intermediary components that bridge the positioning holes in the base frame and the corresponding holes in each unit. These pins provide straightforward mechanical alignment without requiring complex fastening mechanisms, achieving high assembly precision with minimal added complexity.
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 configuration simplifies assembly, reduces labor, minimizes frame distortion, and prevents hydrogen gas leaks by ensuring accurate connections and reducing the risk of damaging metal seals, thereby enhancing safety and efficiency.
Implementation Method 1
a lower unit 10 that houses a heat exchanger 13
Data Source
AI summary
To provide a gas filling device in which its assembly work is simplified by unitizing a housing body and the total number of assembly steps is reduced, thereby achieving high production efficiency. A gas filling device 100 according to the present invention including a lower unit 10 housing a heat exchanger 13 on a base frame 1; an intermediate unit 20 located above the lower unit 10 and housing a display; a top unit 30 located above the intermediate unit 20 and housing a flow meter 33; and side units 40 located on both sides of the lower unit 10 and the intermediate unit 20 and housing filling hoses having filling nozzles at their tips.