Four-layer full-stack hydrogen storage control system architecture
Plain Text | MeCa X hydrogen calibration │ | SimCar hydrogen-storage system HIL │ | SimCore hydrogen simulation | Bus recorder │ | EOL production-line test equipment │ ├─────────────────────────────────────────────────────────┤ | Integrated cylinder temperature-pressure monitoring│ | Multi-stage pressure relief control | Pipeline flow control │ | Hydrogen leak diagnostics │ | Multi-cylinder balancing & coordination logic │ | Hydrogen safety interlock protection │ | Low-temperature adaptation strategy │ | Fault-tolerant degradation system│ | U34 full-domain hydrogen coordination controller │ | High-precision high/low-pressure acquisition │ | Temperature/flow signal sampling interface │ | High-frequency solenoid valve drive │ | CAN FD communication │ | Automotive-grade explosion-proof wide-temperature hardware design │ ├─────────────────────────────────────────────────────────┤ | Steady constant-pressure gas supply │ | Abnormal pressure relief safety protection │ | Multi-cylinder coordinated gas supply │ | Full-domain hydrogen safety monitoring │ | Extreme-condition interlock protection │ └─────────────────────────────────────────────────────────┘ |
System interconnection logic
Hydrogen tank-group temperature/pressure sensors, pipeline pressure / flow sensors, refueling port sensors and inlet/outlet solenoid valve groups → hydrogen storage control unit (status calculation, refueling closed loop, valve regulation, safety judgment) → cross-domain interlock coordination with the fuel cell FCU, vehicle central domain and thermal management domain. The upper-computer toolchain completes the full closed loop of hydrogen storage strategy modeling, automatic code generation, hydrogen storage system HIL simulation, vehicle hydrogen calibration, production flashing and fault diagnostics.
1. High-precision all-domain tank-group temperature/pressure monitoring
Supporting synchronized high-frequency acquisition of pressure and temperature across multiple hydrogen storage tank groups, it monitors in-tank hydrogen status, pressure change rate and temperature fluctuation range in real time, accurately identifying hidden hazards such as over-pressure, over-temperature, low-temperature anomalies and sudden pressure changes, achieving dynamic full-lifecycle monitoring of tank groups and eliminating high-pressure hydrogen storage safety risks.
2. Intelligent closed-loop hydrogen refueling control
Compatible with the national hydrogen refueling protocol, it dynamically matches refueling flow and pressure temperature-rise rates, adopting a segmented refueling strategy to precisely control the refueling pressure ramp curve and suppress refueling over-temperature and over-pressure, balancing refueling speed and storage safety and effectively improving storage fill rate and refueling consistency.
3. Multi-level pressure relief and safety interlock protection
Equipped with three-level protection logic — normal regulated pressure relief, abnormal over-limit pressure relief and emergency fault pressure relief — it triggers tiered interlock protection for high-pressure excursions, pipeline blockage, abnormal pressure fluctuation and leakage faults, automatically closing inlet valves and opening relief circuits to provide a safety fallback for the hydrogen system.
4. Multi-tank balanced coordinated gas supply control
For multi-tank storage architectures, it achieves tank-group pressure balancing, rotating gas supply and adaptive pressure-difference regulation, solving the uneven supply pressure, excessive single-tank wear and supply fluctuation of multi-tank systems, ensuring stable input pressure for the downstream fuel cell system and improving vehicle power generation smoothness.
5. All-condition pipeline fault diagnostics and protection
Real-time monitoring of hydrogen pipeline flow, pressure difference and sealing status accurately identifies faults such as micro-leaks, blockages, valve sticking and signal failure, with fusion judgment using temperature and ambient hydrogen concentration data, achieving early fault warning and tiered handling, comprehensively improving on-board hydrogen system safety.
6. Model-based development and full-scenario simulation
Refueling control, tank-group management, pressure-relief interlock and fault diagnostics strategies are quickly built on Simulink, and ECUCoder generates automotive-grade production code with one click. The dedicated hydrogen storage HIL simulation bench simulates extreme scenarios such as high/low-temperature refueling, high-pressure shock, pipeline leakage and valve faults for strategy iteration and reliability validation.
1. Comprehensive upgrade of hydrogen storage safety level
Building a five-layer protection system of monitoring, prediction, regulation, interlock and pressure relief, it thoroughly solves industry safety pain points of high-pressure hydrogen storage such as over-pressure, over-temperature, leakage and pipeline anomalies, greatly reducing on-board hydrogen system operating risks and meeting stringent on-board high-pressure hydrogen safety standards.
2. Self-controlled upstream hydrogen energy core technology
Hydrogen storage and refueling strategies, tank-group coordination algorithms, pressure-relief interlock logic and fault safety protection are all developed in-house; the full toolchain has no overseas licensing binding, with fully open low-level code, completing the upstream hydrogen storage electronic control core IP and achieving self-control across the whole hydrogen technology chain.
3. High development efficiency adaptable to multiple hydrogen platforms
With reusable same-source software and hardware and full upfront MIL/SIL/HIL verification, a large amount of refueling conditions, fault scenarios and tank-group matching is completed on virtual benches, greatly shortening hydrogen storage system calibration and vehicle adaptation cycles and rapidly delivering various hydrogen vehicle projects.
4. Strong full-scenario condition adaptability
Targeted optimization of complex conditions such as severe-cold low-temperature refueling, high-temperature storage, heavy-load continuous supply and ultra-fast refueling solves inaccurate low-temperature pressure, restricted high-temperature refueling and pressure fluctuation on condition switching, greatly improving the all-weather operation capability of hydrogen vehicles.
5. Front-back-end coordination improving vehicle hydrogen stability
Deeply linked with the downstream fuel cell FCU, it dynamically matches hydrogen supply pressure to load demand, suppressing pressure fluctuation under generation conditions and solving the unstable power following and generation jitter of fuel cells, comprehensively improving vehicle power smoothness and system durability.
6. Fully meeting automotive-grade mass production standards
Strictly following the IATF 16949 automotive quality system and ISO 26262 functional safety development process, it supports the full set of DV/PV high/low temperature, vibration, high-pressure endurance, explosion-proof and fault-injection tests for the hydrogen storage system, directly satisfying OEM mass-production audit standards for hydrogen models.