Retarder Thermal Management for Hydrogen Fuel Cell Trucks
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Solution Overview
Problem
The existing cooling systems for hydrogen fuel cell trucks are inefficient and costly due to the use of a brake resistor to consume surplus electrical energy during regenerative braking, which is unnecessary when sufficient auxiliary braking force is provided by the retarder alone, and the brake resistor is expensive and energy management is inefficient.
Innovation Solution
A cooling system that distributes thermal energy generated by the retarder to a stack cooling system for removal, using a retarder radiator, heat exchanger, and stack cooling system to cool the retarder and fuel cell stack, allowing the electric fan and water pump to consume surplus electrical energy and generate additional auxiliary braking force, thereby reducing the need for the brake resistor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a brake resistor is used to consume surplus electrical energy during regenerative braking, then energy management is achieved, but system cost increases and energy efficiency decreases
Solution Approach 1:
The patent converts the harmful thermal energy generated by the retarder into a beneficial resource by using it to cool the fuel cell stack. Instead of allowing the retarder heat to waste away or requiring additional cooling systems, the invention routes this thermal energy through a heat exchanger to provide cooling for the fuel cell, thereby eliminating the need for a brake resistor and improving overall energy efficiency
Solution Approach 2:
The patent merges the retarder cooling function with the fuel cell stack cooling function by integrating their thermal management systems. The heat exchanger serves as a bridge that combines these two separate cooling needs into a single unified system, allowing thermal energy from the retarder to be reused for stack cooling, thereby eliminating redundant components like the brake resistor
2Temperature
If a separate cooling system is used for the retarder, then cooling effectiveness is ensured, but system complexity and cost increase
Solution Approach 1:
The patent makes the cooling system universal by enabling it to serve multiple functions: cooling the retarder during auxiliary braking operations and cooling the fuel cell stack during normal operation. The heat exchanger acts as a multi-functional component that dynamically switches between serving the retarder cooling needs and the stack cooling needs, thereby eliminating the requirement for separate dedicated cooling systems
Solution Approach 2:
The patent combines the retarder cooling system and fuel cell stack cooling system into a single integrated thermal management system. By merging these two separate cooling functions through the heat exchanger, the system reduces component count and complexity while maintaining adequate cooling effectiveness for both the retarder and stack under various 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
This solution provides sufficient cooling for the retarder, eliminates the need for the brake resistor, reduces costs, and enhances auxiliary braking performance by utilizing the stack cooling system to manage thermal and electrical energy effectively.
Implementation Method 1
a heat exchanger configured for allowing the retarder cooling fluid to be cooled by the stack cooling fluid
Implementation Method 2
a stack cooling system configured for cooling the fuel cell stack
Data Source
AI summary
A cooling system and method for an auxiliary braking device of a hydrogen fuel cell truck, are provided in consideration that auxiliary braking force generated by the regenerative braking of the motor may be unnecessary and the brake resistor may be unnecessary when a sufficient amount of auxiliary braking force is generated alone by the operation of a retarder. A portion of thermal energy generated by the retarder is distributed to a stack cooling system so that the portion of thermal energy is removed by the stack cooling system. Accordingly, due to sufficient cooling of the retarder, a sufficient amount of auxiliary braking force is provided, and the brake resistor that has consumed surplus electrical energy generated by regenerative braking is removed.