To ensure the safety of operation, various checks must be carried out strictly by the process during the operation of the hydrogen filling machine, including sensor status, whether the communication connection is normal, and whether there is leakage in the pipeline. The following will introduce the hydrogen filling process under 70MPa and 35MPa pressure respectively.
1. 70MPa hydrogen filling process
Selection mode and filling amount
The user selects the filling mode and the required filling amount and presses the “Start” button to start the hydrogen filling machine.
Signal detection
Detect station control signal: If normal, continue the process; otherwise, the process ends.
Detect infrared communication with the vehicle: If normal, continue the process; otherwise, the process ends.
Data reading and calculation
Read the pressure, capacity, and temperature of the vehicle bottle from the vehicle infrared communication.
Calculate the boost rate and end pressure according to the ambient temperature and the table data.
Use the formula: Final filling pressure = 63.8461 + 0.3067 × vehicle bottle temperature.
Preliminary pressure detection
After clearing the total amount of the flow meter, open the hydrogenation valve.
If the current hydrogenation pressure is greater than the set value, continue the process; otherwise, terminate the process.
Leak detection
Close the hydrogenation valve and record the pressure P2.
Wait for 5 seconds and record the pressure P3 again.
If P3 – P2 is greater than the set value, it is judged as a pipeline leak and the process is terminated; otherwise, continue the process.
Hydrogenation process monitoring
Open the hydrogenation valve and pressure pump to start hydrogenation.
Continuously monitor the following parameters:
- The current hydrogenation pressure and the predicted pressure deviation (formula: Pset = P3 + ΔP × T / 6).
- Whether the hydrogen flow rate is less than the maximum flow rate.
- Whether the pressure of the vehicle bottle is lower than the set value.
- Whether the hydrogenation pressure is lower than the high-pressure threshold.
- Whether the temperature of the vehicle bottle is lower than 85°C.
If any condition is not met, terminate the hydrogenation process immediately.
Bluesky hydrogenation machine controller function introduction
2. 35MPa hydrogenation process
Select mode and filling the amount
The user selects the filling mode and the required filling amount and presses the “Start” button to start the hydrogenation machine.
Initial pressure detection
Check whether the hydrogenation pressure is greater than 2MPa.
If normal, continue the process; otherwise, terminate the process.
Signal detection
Check the station control signal: if normal, continue the process; otherwise, terminate the process.
Hydrogenation and monitoring
Open the hydrogenation valve and pressure pump to start hydrogenation.
Real-time monitoring of the following parameters:
- Whether the station control signal is normal.
- Whether the onboard bottle temperature is lower than 85°C.
- Whether the hydrogen flow rate is less than the maximum flow rate.
- If any condition is not met, terminate the hydrogenation process immediately.
The hydrogenation machine can efficiently complete the hydrogenation task while ensuring safety by strictly implementing the above process. To learn more about hydrogenation knowledge, please follow us!