A New Hydrogen Filling Method Based on the Analytical Solutions of Final Filling Time and Hydrogen Temperature

To fill hydrogen fuel cell vehicles quickly and safely, the SAE J2601 protocol has published the MC method, which includes control of the filling speed and pressure target. The filling speed depends on the final filling time, the formula for which is obtained by fitting simulated data. The pressure target depends on the final hydrogen temperature, whose analytical solution is derived from a thermodynamic tank model. This article derives new analytical solutions of the final filling time and hydrogen temperature based on an established lumped-parameter model of the storage tank. Based on the original MC method’s control logic, a new filling method that directly uses the analytical solutions of the final filling time and hydrogen temperature was proposed. The simulation results of the new filling method and the validated model (zone-dimensional gas and a one-dimensional tank wall, 0D1D) are compared. Under the ambient temperature conditions of the 0–20 °C and precooling temperature conditions of −20–0 °C set in this article, results show that the new filling method achieves maximum errors of 4.3 °C in its final hydrogen temperature and 0.9% in a state of charge (SOC) compared to the 0D1D model. Parameter sensitivity analysis reveals that initial pressure has the most significant impact on computational accuracy, followed by ambient and precooling temperatures. Future work may further improve prediction accuracy by incorporating correction factors for initial pressure and ambient temperature. Moreover, since the analytical solution of the final hydrogen temperature inherently includes the precooling temperature parameter, the new filling method can automatically adapt to precooling temperature variations.