CN114335619A - Fault monitoring processing method and system for fuel cell intake flow sensor and vehicle - Google Patents
Fault monitoring processing method and system for fuel cell intake flow sensor and vehicle Download PDFInfo
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- CN114335619A CN114335619A CN202111661548.7A CN202111661548A CN114335619A CN 114335619 A CN114335619 A CN 114335619A CN 202111661548 A CN202111661548 A CN 202111661548A CN 114335619 A CN114335619 A CN 114335619A
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Abstract
The invention discloses a fault monitoring and processing method and system for a fuel cell intake flow sensor and a vehicle, wherein the method comprises the following steps: electrifying and finishing initialization; detecting whether the air inlet temperature pressure sensor, the air compressor and the back pressure valve have faults or not and whether the air pipeline has no falling faults or not, and if so, detecting whether the flow sensor has faults or not; if so, prompting the fault, and replacing the measured flow of the flow sensor with the estimated air intake flow Qe in the subsequent operation until the fault is recovered. The fault monitoring and processing method for the fuel cell intake flow sensor can monitor the working state of the flow sensor in real time and eliminate the potential safety hazard of the fuel cell caused by the fault of the flow sensor.
Description
Technical Field
The invention relates to the technical field of fuel cells, in particular to a fault monitoring and processing method and system for an air inlet flow sensor of a fuel cell and a vehicle.
Background
The fuel cell air system is mainly used for supplying air to the cathode side of a fuel cell, mainly comprises an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, a corresponding air pipeline, a sensor and the like, and is shown in figure 1 in a schematic structural diagram. Generally, the air intake flow required by the control of a Fuel Cell Controller (FCCU) is actually measured from a flow sensor behind an air filter, if the flow sensor fails, the fuel cell cannot operate normally, and if the flow sensor fails, such as signal interruption of the flow sensor, during driving, the power interruption and other major safety hazards are directly caused.
Disclosure of Invention
The invention aims to provide a fault monitoring and processing method and system for a fuel cell intake flow sensor and a vehicle, which can monitor the working state of the flow sensor in real time and eliminate potential safety hazards of the fuel cell caused by faults of the flow sensor.
In order to achieve the purpose, the invention provides a fault monitoring and processing method for an air inlet flow sensor of a fuel cell, which comprises the following steps:
(S1) powering on, and finishing initialization;
(S2) detecting whether the air inlet temperature and pressure sensor, the air compressor and the backpressure valve have no faults or not and whether the air pipeline has no drop faults or not, if so, turning to the execution step (S3);
(S3) detecting whether the flow sensor is malfunctioning; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the operation of the fuel cell and monitoring the measured flow rate Qa of the flow sensor in real time;
(S5) calculating a predicted intake air flow rate Qe,
(S6) judging whether the value of Qa-Qe is smaller than a calibration threshold value, if so, the flow sensor works normally, and the process is ended; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
(S7) prompting a fault, and replacing the measured flow of the flow sensor with the estimated air intake flow Qe in the follow-up operation until the fault is recovered.
Further, in step (S2), if no, the process proceeds to step (S2).
Further, the calculation formula of the estimated intake air flow rate Qe is:
in the formula: qe represents the predicted air intake flow rate; v represents the volume of the air inlet cavity of the pile; p represents the actual measurement empty-in pressure of the empty-in temperature and pressure sensor; ps represents saturated steam pressure at different temperatures and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement idle temperature of the idle temperature pressure sensor; n represents the actually measured air compressor rotating speed; x represents the opening of the backpressure valve measured by the backpressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the backpressure valve, an actual measured value of the humidity inside the galvanic pile is filled into a relative humidity meter, and the relative humidity is obtained through actual measurement of the rotating speed n of the air compressor and the opening x of the backpressure valve to position and then interpolation;
and expressing correction coefficients related to the rotating speed n of the air compressor and the opening x of the backpressure valve, and obtaining the correction coefficients by inquiring a calibrated relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficients.
Further, the calibration step of the relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficient is as follows:
(A1) setting a relation table of air compressor rotating speed-back pressure valve opening degree-correction coefficient, and setting m different air compressor rotating speed values n1、n2、···、ni、···、nmAnd m different back pressure valve opening values x1、x2、···、xj、···、xmM different air compressor rotation speed values and m different back pressure valve opening values form m operating points (n)i,xj) And setting m operating points (n)i,xj) Lower corresponding correction factor
Are all equal to 1;
(A2) selecting a first operating point (n) according to a preset selection sequencei,xj)；
(A3) Acquiring relative humidity H (n, x), recording measured air inlet pressure P, measured air inlet temperature T, measured air compressor rotating speed n, measured air inlet flow Qa and measured backpressure valve opening x, and calculating estimated inlet flow Qe at the working point;
(A4) comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to step (A5);
otherwise, resetting the correction coefficient at the working condition point
Go to step (a 3);
(A5) recording the correction coefficient at the working point
Go to execute step (S6);
(S6) whether the calibration of all the working condition points is finished or not is judged, if yes, the calibration of the relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficient is finished; otherwise, selecting the next working condition point (n) according to the selection sequencei,xj) Go to execute step (a 3).
Further, comparing whether the difference between Qe and Qa is within a preset range, specifically executing the following steps:
and judging whether the value (Qe-Qa)/Qa is smaller than a preset threshold value.
Further, the preset threshold is equal to 3%.
Further, whether the detection air inlet temperature and pressure sensor, the air compressor and the backpressure valve have faults or not and whether the air pipeline has no drop fault or not specifically executes the following steps:
(S01) detecting whether the idle temperature and pressure sensor has no fault, if yes, turning to the step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if yes, turning to the execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the backpressure valve has no fault, if yes, going to the execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no drop fault, if yes, turning to the execution step (S3), otherwise, turning to the execution step (S01).
The invention also provides a fault monitoring and processing system of the fuel cell air inlet flow sensor, which comprises:
the fuel cell air system comprises a galvanic pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the galvanic pile are sequentially connected, the air outlet end of the galvanic pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature pressure sensor is arranged at the air inlet end of the galvanic pile;
the fault detection module is used for detecting and sending whether the air inlet temperature and pressure sensor, the air compressor, the backpressure valve and the air pipeline have faults or not;
the fuel cell controller is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and fault signals and carrying out corresponding calculation and logic processing;
the fault detection module, the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with a fuel cell controller, and the fuel cell inlet flow sensor fault monitoring processing system is configured to execute the steps of the fuel cell inlet flow sensor fault monitoring processing method.
Further the fuel cell air system further includes a humidity sensor coupled to the fuel cell controller.
The invention also provides a vehicle comprising the fault monitoring and processing system of the fuel cell intake air flow sensor.
Compared with the prior art, the invention has the following advantages:
the fault monitoring and processing method and system for the fuel cell intake flow sensor and the vehicle can monitor the working state of the flow sensor in real time based on the redundancy design of the flow sensor, and replace the flow sensor to work until the fault is repaired after the flow sensor has the fault, so that the potential safety hazard of the fuel cell caused by the fault of the flow sensor is eliminated.
Drawings
FIG. 1 is a schematic diagram of a fuel cell air system;
FIG. 2 is a flow chart of a fuel cell inlet flow sensor fault monitoring and processing method in accordance with the present invention;
FIG. 3 shows the correction factor of the present invention
A flow chart of the calibration of (1);
FIG. 4 is a schematic diagram of a fuel cell inlet flow sensor fault monitoring and processing system according to the present invention.
In the figure:
1-fuel cell air system, 2-fault detection module, 3-fuel cell controller.
Detailed Description
The following further describes embodiments of the present invention with reference to the drawings.
Referring to fig. 2, the present embodiment discloses a method for monitoring and processing a fault of an intake air flow sensor of a fuel cell, which includes the steps of:
(S1) powering on, and finishing initialization;
(S2) detecting whether the air inlet temperature and pressure sensor, the air compressor and the backpressure valve have no faults or not and whether the air pipeline has no drop faults or not, if so, turning to the execution step (S3); the air line refers to the line between the air filter to the back pressure valve in fig. 1.
(S3) detecting whether the flow sensor is malfunctioning; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the operation of the fuel cell and monitoring the measured flow rate Qa of the flow sensor in real time;
(S5) calculating a predicted intake air flow rate Qe,
(S6) judging whether the value of Qa-Qe is smaller than a calibration threshold value, if so, the flow sensor works normally, and the process is ended; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
(S7) prompting a fault, and replacing the measured flow of the flow sensor with the estimated air intake flow Qe in the follow-up operation until the fault is recovered. And in subsequent operation, the estimated air inlet flow is adopted as the substitute flow until the fault is repaired, so that the fuel cell can be ensured to continue to operate. The user is reminded of timely checking and maintenance by prompting the fault, the fault prompting can be realized by lightening a fault lamp, and in some embodiments, the fault prompting can also be realized by voice, short messages or other modes or combined prompting.
In the present embodiment, in step (S2), if no, step (S2) is continuously executed. If the air inlet temperature and pressure sensor fails or the air compressor fails or the back pressure valve fails or the air pipeline falls off, the flow sensor monitoring function cannot be performed.
In this embodiment, the calculation formula of the estimated intake air flow rate Qe is:
in the formula: qe representsPre-estimating the air inlet flow; v represents the volume of the air inlet cavity of the pile; p represents the actual measurement empty-in pressure of the empty-in temperature and pressure sensor; ps represents saturated steam pressure at different temperatures and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement idle temperature of the idle temperature pressure sensor; n represents the actually measured air compressor rotating speed; x represents the opening of the backpressure valve measured by the backpressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the backpressure valve, an actual measured value of the humidity inside the galvanic pile is filled into a relative humidity meter, and the relative humidity is obtained through actual measurement of the rotating speed n of the air compressor and the opening x of the backpressure valve to position and then interpolation;
and expressing correction coefficients related to the rotating speed n of the air compressor and the opening x of the backpressure valve, and obtaining the correction coefficients by inquiring a calibrated relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficients.
The temperature-saturated steam pressure relation table is a standard table, can be directly obtained on the network and needs to be recorded into FCCU software, and the FCCU software can obtain saturated steam pressures at different temperatures by looking up the table according to different temperatures during operation.
The humidity sensor is used for measuring the humidity of the inlet position of the fuel cell stack, and the humidity inside the stack can not be measured by the sensor, so that the humidity inside the stack is represented by the humidity at the inlet of the stack.
The humidity sensor is a sensor additionally arranged on the rack, the measured value of the humidity inside the galvanic pile is measured in the rack and is input into the FCCU software relative humidity meter for interpolation, the meter is related to the rotating speed of the air compressor and the opening degree of the backpressure valve, and the FCCU can position through the rotating speed and the opening degree during operation and then interpolate to obtain the relative humidity.
Referring to fig. 3, the calibration steps of the air compressor rotation speed-back pressure valve opening-correction coefficient relation table are as follows:
(A1) setting the rotation speed-back pressure valve opening of the air compressor-a correction factor relation table for setting m different compressor speed values n1、n2、···、ni、···、nmAnd m different back pressure valve opening values x1、x2、···、xj、···、xmM different air compressor rotation speed values and m different back pressure valve opening values form m operating points (n)i,xj) And setting m operating points (n)i,xj) Lower corresponding correction factor
Are all equal to 1;
the air compressor rotation speed-back pressure valve opening degree-correction coefficient relation table is a two-dimensional table related to the air compressor rotation speed and the back pressure valve opening degree, for example, as shown in table 1, the air compressor rotation speed is x-axis, the back pressure valve opening degree is y-axis, and z is correction coefficient
TABLE 1
(A2) Selecting a first operating point (n) according to a preset selection sequencei,xj) (ii) a E.g. the first operating point (n)i,xj) Is composed of
(n1，x1) N in the above table1＝20000，x1＝10；
(A3) Acquiring relative humidity H (n, x), recording measured air inlet pressure P, measured air inlet temperature T, measured air compressor rotating speed n, measured air inlet flow Qa and measured backpressure valve opening x, and calculating estimated inlet flow Qe at the working point;
(A4) comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to step (A5);
otherwise, resetting the correction coefficient at the working condition point
Go to step (a 3); for example, it is currently the operating point (n)1，x1) Then will (n)1，x1) The correction factor 1 is adjusted to 0.9.
(A5) Recording the correction coefficient at the working point
Go to execute step (S6);
(S6) whether the calibration of all the working condition points is finished or not is judged, if yes, the calibration of the relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficient is finished; otherwise, selecting the next working condition point (n) according to the selection sequencei,xj) Go to execute step (a 3). For example, the previous operating point is (n)1，x1) Selecting the next operating point according to the selection sequence (n)1，x2) I.e. n as in the table above1＝20000，x2Repeating steps (A3) and (a4) for a 20 operating point until all operating point calibrations are completed; and after the calibration is finished, recording the recorded correction coefficient of each working condition point into the FCCU.
In this embodiment, the comparing step of comparing whether the difference between Qe and Qa is within a preset range specifically includes the following steps: and judging whether the value (Qe-Qa)/Qa is smaller than a preset threshold value. In this embodiment, the preset threshold is equal to 3%. In some embodiments, other values may be taken and are not limited herein.
In this embodiment, the following steps are specifically executed to detect whether the air inlet temperature and pressure sensor, the air compressor and the backpressure valve have no fault, and whether the air pipeline has no drop fault:
(S01) detecting whether the idle temperature and pressure sensor has no fault, if yes, turning to the step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if yes, turning to the execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the backpressure valve has no fault, if yes, going to the execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no drop fault, if yes, turning to the execution step (S3), otherwise, turning to the execution step (S01).
Referring to fig. 4, the present embodiment discloses a fault monitoring and processing system for an intake air flow sensor of a fuel cell, comprising:
the fuel cell air system 1 comprises a galvanic pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the galvanic pile are sequentially connected, the air outlet end of the galvanic pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature pressure sensor is arranged at the air inlet end of the galvanic pile;
the fault detection module 2 is used for detecting and sending whether the air inlet temperature and pressure sensor, the air compressor, the backpressure valve and the air pipeline have faults or not;
the fuel cell controller 3 is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and fault signals, and carrying out corresponding calculation and logic processing;
the fault detection module 2, the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with the fuel cell controller 3, and the fault monitoring and processing system of the fuel cell inlet flow sensor is configured to be capable of executing the steps of the fault monitoring and processing method of the fuel cell inlet flow sensor.
In this embodiment, the fuel cell air system further comprises a humidity sensor coupled to the fuel cell controller.
The embodiment also discloses a vehicle which comprises the fault monitoring and processing system for the fuel cell intake air flow sensor.
The fault monitoring and processing method and system for the fuel cell intake flow sensor and the vehicle can monitor the working state of the flow sensor in real time based on the redundancy design of the flow sensor, and replace the flow sensor to work until the fault is repaired after the flow sensor has the fault, so that the potential safety hazard of the fuel cell caused by the fault of the flow sensor is eliminated.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. A fault monitoring and processing method for a fuel cell intake flow sensor is characterized by comprising the following steps:
(S1) powering on, and finishing initialization;
(S2) detecting whether the air inlet temperature and pressure sensor, the air compressor and the backpressure valve have no faults or not and whether the air pipeline has no drop faults or not, if so, turning to the execution step (S3);
(S3) detecting whether the flow sensor has a failure; if yes, go to execute step (S7); otherwise, go to execute step (S4);
(S4) starting the operation of the fuel cell and monitoring the measured flow rate Qa of the flow sensor in real time;
(S5) calculating a predicted intake air flow rate Qe;
(S6) judging whether the value of Qa-Qe is smaller than a calibration threshold value, if so, the flow sensor works normally, and the process is ended; otherwise, the measurement error of the flow sensor is overlarge, and the step (S7) is executed;
(S7) prompting a fault, and replacing the measured flow of the flow sensor with the estimated air intake flow Qe in the follow-up operation until the fault is recovered.
2. The fuel cell intake air flow sensor malfunction monitoring processing method according to claim 1, wherein in step (S2), if not, step (S2) is continued.
3. The fuel cell intake air flow sensor malfunction monitoring processing method according to claim 1 or 2, characterized in that the calculation formula of the estimated intake air flow rate Qe is:
in the formula: qe represents the predicted air intake flow rate; v represents the volume of the air inlet cavity of the pile; p represents the actual measurement empty-in pressure of the empty-in temperature and pressure sensor; ps represents saturated steam pressure at different temperatures and is obtained by inquiring a temperature-saturated steam pressure relation table; r represents a gas constant; ma represents the molar mass of dry air; t represents the actual measurement idle temperature of the idle temperature pressure sensor; n represents the actually measured air compressor rotating speed; x represents the opening of the backpressure valve measured by the backpressure valve position sensor; h (n, x) represents relative humidity related to the rotating speed n of the air compressor and the opening x of the backpressure valve, an actual measured value of the humidity inside the galvanic pile is filled into a relative humidity meter, and the relative humidity is obtained through actual measurement of the rotating speed n of the air compressor and the opening x of the backpressure valve to position and then interpolation;
and expressing correction coefficients related to the actually measured rotating speed n of the air compressor and the actually measured opening x of the backpressure valve, and obtaining the correction coefficients by inquiring a calibrated relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficients.
4. The method for monitoring and processing the fault of the fuel cell intake air flow sensor as claimed in claim 3, wherein the calibration step of the air compressor rotation speed-back pressure valve opening-correction coefficient relation table is as follows:
(A1) setting a relation table of air compressor rotating speed-back pressure valve opening degree-correction coefficient, and setting m different air compressor rotating speed values n1、n2、···、ni、···、nmAnd m different back pressuresValve opening value x1、x2、···、xj、···、xmM different air compressor rotation speed values and m different back pressure valve opening values form m operating points (n)i,xj) And setting m operating points (n)i,xj) Lower corresponding correction factor
Are all equal to 1;
(A2) selecting a first operating point (n) according to a preset selection sequencei,xj)；
(A3) Acquiring relative humidity H (n, x), recording measured air inlet pressure P, measured air inlet temperature T, measured air compressor rotating speed n, measured air inlet flow Qa and measured backpressure valve opening x, and calculating estimated inlet flow Qe at the working point;
(A4) comparing whether the difference between Qe and Qa is within a preset range;
if yes, go to step (A5);
otherwise, resetting the correction coefficient at the working condition point
Go to step (a 3);
(A5) recording the correction coefficient at the working point
Go to execute step (S6);
(S6) whether the calibration of all the working condition points is finished or not is judged, if yes, the calibration of the relation table of the rotating speed of the air compressor, the opening of the backpressure valve and the correction coefficient is finished; otherwise, selecting the next working condition point (n) according to the selection sequencei,xj) Go to execute step (a 3).
5. The fuel cell intake air flow sensor failure monitoring processing method according to claim 4, wherein the comparing of whether the difference between Qe and Qa is within a preset range specifically performs the steps of:
and judging whether the value (Qe-Qa)/Qa is smaller than a preset threshold value.
6. The fuel cell intake air flow sensor failure monitoring processing method according to claim 5, wherein the preset threshold value is equal to 3%.
7. The fuel cell intake air flow sensor fault monitoring processing method according to claim 1, 2, 4, 5 or 6, wherein the detecting whether there is no fault in any of the air intake temperature pressure sensor, the air compressor and the back pressure valve, and whether there is no drop-off fault in the air line, specifically performs the following steps:
(S01) detecting whether the idle temperature and pressure sensor has no fault, if yes, turning to the step (S02); otherwise, continuing to execute the step (S01);
(S02) detecting whether the air compressor has no fault, if yes, turning to the execution step (S03); otherwise, go to execute step (S01);
(S03) detecting whether the backpressure valve has no fault, if yes, going to the execution step (S04); otherwise, go to execute step (S01);
(S04) detecting whether the air pipeline has no drop fault, if yes, turning to the execution step (S3), otherwise, turning to the execution step (S01).
8. A fuel cell intake air flow sensor fault monitoring processing system is characterized by comprising:
the fuel cell air system (1) comprises a galvanic pile, an air filter, an air compressor, an intercooler, a humidifier, a back pressure valve, an air inlet temperature and pressure sensor and a flow sensor, wherein the air filter, the air compressor, the intercooler, the humidifier and the air inlet end of the galvanic pile are sequentially connected, the air outlet end of the galvanic pile, the humidifier and the back pressure valve are sequentially connected, the flow sensor is arranged on a pipeline between the air filter and the air compressor, and the air inlet temperature and pressure sensor is arranged at the air inlet end of the galvanic pile;
the fault detection module (2) is used for detecting and sending whether the air inlet temperature and pressure sensor, the air compressor, the backpressure valve and the air pipeline have faults or not;
the fuel cell controller (3) is used for receiving the actually measured air inlet pressure and temperature, the rotating speed of the air compressor, the air inlet flow, the opening degree of the back pressure valve and fault signals and carrying out corresponding calculation and logic processing;
the fault detection module (2), the air compressor, the back pressure valve, the air inlet temperature and pressure sensor and the flow sensor are all connected with a fuel cell controller (3), and the fuel cell inlet air flow sensor fault monitoring processing system is configured to be capable of executing the steps of the fuel cell inlet air flow sensor fault monitoring processing method according to any one of claims 1 to 7.
9. The fuel cell intake air flow sensor fault monitoring processing system of claim 8, further comprising a humidity sensor connected to a fuel cell controller.
10. A vehicle characterized by comprising the fuel cell intake air flow sensor failure monitoring processing system according to claim 8 or 9.
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