Pressure Switch Adaptive Control for Fuel Cell Tank Reliability
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Solution Overview
Problem
The high cost and complexity of using two pressure sensors in hydrogen storage systems for fuel cell vehicles, along with associated wiring and controller connections, pose a challenge for reliable and efficient pressure regulation.
Innovation Solution
A pressure switch is used in conjunction with a pressure sensor to monitor on-off cycling and compute an adaptive control term, allowing the system to balance pressure oscillations and compensate for faulty sensor readings, thereby reducing the need for a second pressure sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two pressure sensors are used to measure pressure downstream of the regulator, then reliability and redundancy are improved, but cost and device complexity increase significantly
Solution Approach 1:
The patent combines a pressure sensor and a pressure switch into a single integrated device. The pressure sensor provides continuous pressure measurement while the pressure switch provides on/off control based on pressure thresholds. This merging eliminates the need for separate redundant pressure sensors while maintaining reliability through the complementary functions of both components within the single device.
Solution Approach 2:
The integrated device performs multiple functions: continuous pressure monitoring via the pressure sensor, on/off control via the pressure switch, and diagnostic capabilities through the controller. This multi-functionality replaces what would traditionally require multiple separate components, reducing system complexity while maintaining or improving reliability.
2Reliability
If two pressure sensors are used with associated wiring and controller connections, then measurement redundancy is improved, but assembly complexity and potential fault sources increase
Solution Approach 1:
By integrating the pressure sensor and pressure switch into a single device with shared wiring and controller connections, the patent reduces the number of separate components that need to be assembled. This merging simplifies the assembly process while maintaining measurement redundancy through the complementary sensing mechanisms within the integrated device.
3Device complexity
If a pressure switch is used instead of a second pressure sensor, then cost and device complexity are reduced, but the ability to independently verify pressure measurements is worsened
Solution Approach 1:
The controller monitors the on/off cycling of the pressure switch and uses this feedback to verify pressure measurements. By comparing the pressure switch states with expected pressure conditions based on the pressure sensor readings, the controller can detect discrepancies and verify measurement accuracy, compensating for the lack of a second independent pressure sensor.
Solution Approach 2:
The controller acts as an intermediary that processes information from both the pressure sensor and pressure switch to verify pressure measurements. It uses the pressure switch on/off states as intermediate data points to cross-validate the continuous pressure readings, maintaining measurement verification capability without requiring a second pressure sensor.
Data Source
AI summary
A method and system for controlling a pressure regulator in a gas storage system using a pressure switch as a pressure measurement device. A controller uses supply pressure data and gas flow demand data to compute a feed-forward control term, and uses data from a pressure sensor downstream of the pressure regulator to compute a feedback control term. During normal operation, with pressure downstream of the regulator oscillating about a set point pressure, on-time and off-time periods of a pressure switch are monitored, and an adaptive control term is computed which balances on-time and off-time. If the pressure sensor fails, excessive switch on-time or off-time will be detected; in response to this, the feedback control term is disregarded, and an adaptive control term is computed which aims to restore balanced on-time and off-time of the switch, thus indicating that the actual pressure is oscillating about the set point.