A Fast and Safe Refueling Strategy for On-Board Hydrogen Storage Tanks Considering Average Temperature Ramp Rate Control

TY - JOUR

T1 - A Fast and Safe Refueling Strategy for On-Board Hydrogen Storage Tanks Considering Average Temperature Ramp Rate Control

AU - Yang, Qingqing

AU - Yang, Yaokun

AU - Li, Jianwei

AU - Chen, Lijian

AU - Li, Xutao

AU - Bao, Huanhuan

AU - Ge, Xiaocheng

AU - Wang, Zhao

N1 - Publisher Copyright: © 2025 Elsevier Ltd

PY - 2026/2/1

Y1 - 2026/2/1

N2 - Due to the fast refueling and zero-emission advantages, hydrogen fuel cell vehicles, ships, and trains are research hotspots in the green transformation of the transportation sector. One issue facing this technology is the rapid increase in the internal temperature of the hydrogen storage tanks (HSTs) during the refueling process, which can quickly approach the safety limit, leading to a reduction in the state of charge (SoC) or an extension of the refueling time. Among existing refueling strategies, only the SAE J2601 protocol is capable of coordinating temperature rise and refueling time while meeting SoC requirements. To address this challenge, this paper proposes a refueling strategy based on average temperature ramp rate (ATRR) control. The strategy constructs a natural boundary between hydrogen temperature and refueling time, realizing their joint control. To further enhance operational safety, a dual-ATRR method is introduced, employing a cascade control logic integrating threshold triggering, rate switching, and flow clamping mechanisms for precise mass flow control. The results indicate that, under the specified conditions, the dual-ATRR strategy enables type IV HSTs to complete refueling from 20 % to 95 % SoC within 180 s, while achieving a 17.60 % reduction in hydrogen temperature rise relative to the upper limit of 85 ℃. Within the −40 °C to −30 °C pre-cooling range, the dual-ATRR strategy is still able to complete refueling, although its effectiveness is reduced.

AB - Due to the fast refueling and zero-emission advantages, hydrogen fuel cell vehicles, ships, and trains are research hotspots in the green transformation of the transportation sector. One issue facing this technology is the rapid increase in the internal temperature of the hydrogen storage tanks (HSTs) during the refueling process, which can quickly approach the safety limit, leading to a reduction in the state of charge (SoC) or an extension of the refueling time. Among existing refueling strategies, only the SAE J2601 protocol is capable of coordinating temperature rise and refueling time while meeting SoC requirements. To address this challenge, this paper proposes a refueling strategy based on average temperature ramp rate (ATRR) control. The strategy constructs a natural boundary between hydrogen temperature and refueling time, realizing their joint control. To further enhance operational safety, a dual-ATRR method is introduced, employing a cascade control logic integrating threshold triggering, rate switching, and flow clamping mechanisms for precise mass flow control. The results indicate that, under the specified conditions, the dual-ATRR strategy enables type IV HSTs to complete refueling from 20 % to 95 % SoC within 180 s, while achieving a 17.60 % reduction in hydrogen temperature rise relative to the upper limit of 85 ℃. Within the −40 °C to −30 °C pre-cooling range, the dual-ATRR strategy is still able to complete refueling, although its effectiveness is reduced.

UR - https://www.scopus.com/pages/publications/105013161544

U2 - 10.1016/j.fuel.2025.136516

DO - 10.1016/j.fuel.2025.136516

M3 - Article

AN - SCOPUS:105013161544

SN - 0016-2361

VL - 405

JO - Fuel

JF - Fuel

M1 - 136516

ER -