Portable Refueling Device

Abstract

The present invention provides a portable refueler for storing a quantity of gaseous fuel, optionally hydrogen, for refueling an end-user vehicle, comprising: a plurality of storage tanks, each storage tank comprising at least one cylinder which is horizontally arranged within an enclosure, wherein the enclosure is configured to be carried by a vehicle, and, a refueling nozzle for discharging a quantity of the gaseous fuel to the end-user vehicle during refueling.

Claims

1. A portable refueler for storing a quantity of gaseous fuel, optionally hydrogen, for refueling an end-user vehicle, comprising: a plurality of storage tanks, each storage tank comprising at least one cylinder which is horizontally arranged within an enclosure, wherein the enclosure is configured to be carried by a vehicle, and, a refueling nozzle for discharging a quantity of the gaseous fuel to the end-user vehicle during refueling.

2. The refueler of claim 1, wherein the vehicle is an off-highway work-machine.

3. The refueler of claim 1, wherein enclosure comprises a pair of sleeves for receiving a pair fork lift forks for loading the storage device on to the vehicle.

4. The refueler of claim 1, wherein a wall of the enclosure comprises a plurality of user access panels for providing access to one or more controls or displays.

5. The refueler of claim 4, comprising a first user access panel which conceals an electrical interface, and a second access panel which conceals a gas interface.

6. The refueler of claim 5, wherein the electrical interface is intrinsically sealed with respect to the storage tanks.

7. The refueler of claim 6, wherein the electrical interface comprises a power source and a controller for controlling discharging of the storage tanks during refueling of an end-user vehicle.

8. The refueler of claim 1, wherein the enclosure comprises a plurality of separately constructed discrete sections which are subsequently assembled to provide the enclosure.

9. The refueler of claim 8, wherein the discrete sections comprise a base which is configured to receive a first plurality of storage tanks, and an upper section which is configured to enclose a second plurality of storage tanks located on the first plurality of storage tanks.

10. The refueler of claim 1, wherein each storage tank may comprise a tank valve for discharging the respective tank, wherein, optionally, the tank valves are electrically operated.

11. The refueler of claim 10, wherein the tank valves are independently controlled.

12. The refueler of claim 10, wherein each storage tank comprises corresponding first and second ends, wherein the tank valves are mounted to the respective first ends.

13. The refueler of claim 12, comprising a first user access panel which conceals an electrical interface, and a second access panel which conceals a gas interface, wherein the tank valves are located behind the wall which comprises the access panels.

14. The refueler of claim 1, wherein the plurality of tanks is arranged in four banks, wherein each of the four banks is configured to be individually controlled for discharge.

15. The refueler of claim 1, further comprising an electronic control unit configured to control the charging and discharging of the plurality of storage tanks.

16. The refueler of claim 10, wherein the tank valves comprise at least one sensor for measuring a tank pressure and/or temperature.

17. The refueler of claim 1, wherein each of the plurality of storage tanks comprises a thermal pressure response device, TPRD, configured to vent the gaseous fuel when the temperature rises to beyond a predetermined value.

18. The refueler of claim 17, wherein the TPRD are mounted directly to the tank.

19. A vehicle comprising the portable refueler of claim 1, wherein the vehicle is an off-highway vehicle, optionally, a tractor.

20. The vehicle of claim 19, wherein the vehicle comprises an operator cab, wherein the portable storage device has a maximum height approximately in line with the height of the operator cab.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Embodiments are now disclosed by way of example only with reference to the drawings, in which:

[0049] FIG. 1 shows a vehicle comprising a portable refueler mounted thereon;

[0050] FIG. 2 shows the portable refueler of shown in FIG. 1 dismounted from the vehicle;

[0051] FIG. 3 shows the internal structure of the portable refueler of FIG. 2;

[0052] FIG. 4 shows portable refueler including a plurality of storage tanks;

[0053] FIG. 5 shows an external view of the refueler and the user interface panels;

[0054] FIG. 6 shows a plurality of storage tanks;

[0055] FIG. 7 shows a schematic layout of the fluid system of the refueler;

[0056] FIG. 8 shows an alternative refueler layout; and,

[0057] FIG. 9 shows a schematic representation of a controller.

DETAILED DESCRIPTION OF EMBODIMENT(S)

[0058] Referring firstly to FIGS. 1 and 2, there is shown a portable refueling device 10 located on a transportation vehicle 12. The transportation vehicle 12 may be an off-highway vehicle, such as a tractor, which is suited to delivering the portable refueling device 10 to a place of use, i.e. a refueling location. The portable refueling device 10 is sized and shaped to be received on a flatbed carrying platform of the vehicle 12 which may incorporate one more locating features which engage with the portable refueling device 10 to prevent movement during transportation. It will be appreciated that, although a flatbed platform is provided in the example shown in FIG. 1, this is not a limitation and other carrying platforms and/or attachments are possible.

[0059] The use of an off-highway vehicle 12 for transportation allows the refueling device 10 to be provided at a point of use of the end user vehicle 14 (shown in FIG. 5). This can be particularly advantageous as it minimizes the distance to be travelled by the end user vehicle 14 when refueling is required. For example, when the end user vehicle 14 is an off-highway work-machine, it may be time consuming and energy inefficient to travel from a point of work to a refueler location. This is particularly so in large construction or agricultural settings where the separation between a central base or some other central location may be up to 30 minutes travel for more remotely located work-machines. Hence, providing a refueler on a vehicle 12 which can be deployed to a work-machine 10 in accordance with a predetermined schedule or on demand, has the potential to save significant resource, both in terms of time and fuel. Additionally, or alternatively, the use of a portable refueler 10 allows an optimum refueling location to be provided flexibly, thereby allowing an improved refueling strategy for work-machines located in work locations which may vary during the course of a day or week, for example.

[0060] The portable refueling device 10 (which may be simply referred to as refueler) is for refueling of a gaseous fuel such as hydrogen, but other gas based fuels may be used.

[0061] The portable refueling device 10 may comprise a plurality of storage tanks 16a-h comprised within an enclosure 18. The tanks 16a-h may be arranged horizontally such that the overall height of the refueler 10 is kept to a minimum whilst maximizing the storage capacity. In the example shown, the reduced height may allow the upper surface of the enclosure 18 to be provided at a level similar to the operator cab 20 height, thereby reducing the likelihood of impact from overhead objects. Further, providing the tanks 16a-h horizontally allows the center of gravity to be as low as possible thereby aiding the stability of the transporting vehicle 12, which may be particularly useful in an off-highway scenario.

[0062] The storage tanks 16a-h may be elongate cylinders as known in the art. In the arrangement shown, the longitudinal axes of the tanks 16a-h are parallel to one another and to the principal axis 22 of the vehicle chassis 24, although this is not a limitation and the longitudinal axes may traverse the vehicle chassis 24, that is, extended side-to-side in some embodiments.

[0063] The enclosure 18 may comprise a base 26, an upper section 28, and an optional mid-section 30. The base 26 provides a structural element which is configured to support the mid-section/upper section and provide a load bearing surface on which refueling device 10 resides, in use.

[0064] The refueling device 10 is configured to be portable in that it is possible to be loaded on to the transporting vehicle 12, travel to a refueling location, refuel an end-user work-machine 14 at least once whilst the refueler remains on the transporting vehicle 12 and then travel to an alternative location. The alternative location may be a second refueling location for a second end-user machine for example, or a refilling location at which the storage tanks can be refilled. The transporting vehicle 12 may comprise a vehicle which is configured to travel on and/or off-highway and may be, as per FIG. 1, a tractor.

[0065] In order to allow the refueler 10 to be loaded and unloaded from the transporting vehicle 12, the base 26 may comprise a pair of sleeves 32 which are sized and spaced to receive the forks of a forklift truck or telehandler, for example. As such the refueler 10 can be lifted and maneuvered relatively easily for loading and unloading from the back of the vehicle 12.

[0066] Additionally, or alternatively, the enclosure 18 may comprise one or more other lifting features such as the eyelets 34 located at each corner and configured to enable the device 10 to be lifted by a suitable crane or other lifting device using cables or straps.

[0067] The upper section 30 of the enclosure 18 provides a lid configured to mechanically enclose the tanks 16a-h to prevent the ingress of foreign objects such as tree branches, stones, earth, tools, people or other hazards which may be present at the point of use. Although generally enclosed, it can be seen that the upper section 30 also includes vented panels to help prevent the entrapment of gas within the enclosure which may be present due to a leak or purposeful discharge during decommissioning or some other event.

[0068] The mid-section 28 comprises sidewalls of the enclosure 18 which extend between the upper 30 and lower 26 sections.

[0069] The upper and lower edges of the enclosure 18 may comprise chamfered regions in which the joint between any of the walls and lid, any of the walls and base, or any two walls is provided with a short intermediate wall section to provide a chamfered edge. The provision of a chamfer may improve the structural rigidity of the device and/or may be provided for aesthetic reasons.

[0070] The refueling device 10 may comprise an electrical interface 36 and a gas interface 38 with which a user may engage to control or receive information relating to the status or operating state of the refueler 10. The electrical 36 and gas 38 user interfaces may be accessed through respective access panels 36′, 38′ which are provided in a side wall of the of the enclosure 18, as shown in FIG. 5. Hence, the access panels 36′, 38′ may be provided to allow a user to access any controls and/or displays which are provided on the interfaces and which may be needed to operate the refueler and/or determine its current operating status.

[0071] The electrical interface 36 may form part of an electrical enclosure which is provided to electrically isolate the electrical systems from the gas systems of the refueler 10, thereby providing an intrinsically safe system. As such, an electrical interface enclosure may be partitioned by one or more bulkheads, which in the present embodiment is provided by the interface panel, or other walls, with any cables passing through suitably gas tight fittings into the regions in which the gas systems are provided. The electrical interface enclosure may comprise one or more display devices 40, controllers 42 and/or power sources 44 required to provide the necessary electrical control. The gas systems may include the storage tanks and any associated pipework, valves or sensors or the like.

[0072] The gas interface may comprise a refueling device, such as a nozzle 46, which is provided on a suitable hose (shown in FIG. 5), and which is connectable to the end-user vehicle 14 which is to be refueled; one or more inlets (shown) which are configured to receive a refill nozzle from an appropriate source of fuel such as a mains tank or a refueling tanker; one or more display devices 48 for providing information in relation to the individual storage tanks 16a- h such as a fill levels or tank pressures; and, one or more controls 50 which are required for charging and discharging of the storage tanks 16a-h. The gas interface 38 may also comprise one or more valves for isolating the output line of the tanks during on-road transportation. In some embodiments, the isolating valve may be provided behind a separate access panel 52, as may other service related valves which are not generally required by a refueling operator.

[0073] The particular arrangement of the controls and display devices of the electrical and gas enclosures can be any suitable and are not limited to this disclosure. Hence, further details are not provided.

[0074] The access panels 36′, 38′ may be provided by hinged doors which include suitable latching or locking mechanisms to provide protection and convenient suitably authorized access. In FIG. 2, the gas interface is distinguishable by having a plurality of vent apertures located towards the top and bottom of the door. The doors are both shown as being hinged peripherally so that both open from the inner edge located towards the mid-region of the side wall to increase user convenience but this is not a limitation.

[0075] As shown in FIG. 5, the doors may be located at the rear of the vehicle when mounted for convenience, but this is not a limitation and access panels 36′, 38′ may be provided on a side surface where desired.

[0076] As noted above, in addition to the electrical interface access panel 36′ and the gas interface access panel 38′, the enclosure 18 may comprise one or more additional access panels 52 to provide access to other elements. As an example of this, there is shown an auxiliary panel on the side adjacent the main access panels which houses an isolation valve for closing off the output from the tanks thereby ensuring no escape of gas is possible should one of the tank valves fail.

[0077] FIGS. 3 and 4 show the internal structural framework of the enclosure 18 and the storage tanks 16a-h located therein. The tanks 16a-h may be arranged in a parallel horizontal arrangement and may comprise two rows of four cylinders with one stacked above the other. However, the number of tanks, both in total and per each row, may be varied and the described example should not be taken to be a limitation of the present disclosure. The rows of the cylinders may be provided in banks which are movable as a single unit.

[0078] The structural framework may comprise a plurality of sections which correspond to the different sections are separately constructed and subsequently attached to one another during assembly of the storage device. A first section may comprise a lower section or base 26 and provide the contacting surface on which the device resides in use. The base 26 may comprise a lower portion which provides the contacting surface and one or more internal members onto which the first plurality of storage tanks 16e-h is loaded and supported. The base 26 may also include the fork sleeves 32 which extend transversely (relative to the direction of the storage tanks) across the device 10 side-to-side. The sleeves 32 are shown as being full tubular sleeves which extend fully across the width of the enclosure so as to allow lifting from either side, but this is not a limitation.

[0079] Although not shown, it will be appreciated that the base 26 may comprise one more attachment features or cradles for receiving and locating the lower storage tanks.

[0080] The base 26 may additionally comprise one or more side walls which extend upwardly from the lower section of the base 26. The side walls define the main enclosure in which the first plurality of storage tanks 16e-h are located.

[0081] An upper section 30 of the structural framework comprises the supporting structure of the lid of the enclosure 18 and may include one more side walls which extend downwardly to meet the side walls of the base 26. These may be attached to one another using suitable fixings such as bolted connections or by welding for example.

[0082] It will be appreciated that the sidewalls of the enclosure 18 may be provided separately from the base 26 and/or upper section 30 and may comprise an independent mid-section 28, which is shown in FIG. 3 and described further below.

[0083] The storage tanks 16a-h each comprise a tank valve 54a-h (best seen in FIG. 6) for charging and discharging purposes which may be provided at the same respective end of the tanks 16a-h. The side wall, or a portion of the side wall, which faces the valves 54a-h may be advantageously attachable once the storage tanks 16a-h have been loaded into the main enclosure. This allows some or all of the connections to each of the respective tank valves (and any other parts) to be made prior to that side wall (or a portion thereof) being attached. In the example described herein, access to the tank valves 54a-h and associated pipework etc. is provided by removing the gas and/or electrical interface panels. Doing so provides relatively easy access for maintenance purposes.

[0084] The (internal) sidewall which is adjacent to the valves and pipework may be provided with one or more webs, plates or flanges to allow the mounting of the any control devices or display devices. There may also be appropriately sized apertures 360, 380 to provide access to the tanks 16a-h and internal pipework during assembly once the interface panels have been removed as shown in FIG. 4.

[0085] It will be appreciated that the internal structural framework, as well as providing an enclosure of the storage tanks 16a-h also provides a scaffold onto which external cladding can be attached, including the aforementioned venting ducts provided on an upper surface.

[0086] In FIG. 6, there is shown an example of a plurality of storage tanks 16a-h with the interconnecting pipework and tank valves 54a-h to enable charging and discharging of the storage tanks 16a-h. FIG. 7 shows a schematic layout for the arrangement of FIG. 6.

[0087] As can best be seen in FIG. 7, the arrangement may comprise a plurality of storage tanks 16a-h, a control valve or tank valve 54a-h, for each storage tank 16a-h, a refilling manifold 60 and a dispensing (or refueling) manifold 58. The manifolds 58, 60 may be referred to as common connection points.

[0088] Respective fluid lines 60a-h, 58a-h connect each of the tank valves 54a-h and the manifolds in parallel such that each tank can be charged (refilled) and discharged (to refuel a vehicle) simultaneously upon control of the valves. Also shown is a charging inlet 62 which connects to the charging manifold 60 via an inlet fluid line 64, and a discharging outlet 66 which is connected to the discharge manifold 58 via an outlet fluid line 68. Each of the inlet fluid line 64 and outlet fluid line 68 may comprise various gauges and valves to enable to the system to be discharged during a pressure surge or decommissioning. The outlet may comprise primary and secondary pressure gauges to provide redundancy.

[0089] Each of the inlet fluid lines 60a-h may comprise a one-way valve (which may be referred to as a check valve) which is shown as being integrated with the manifolds 60 in the described example, although this is not a limitation. The check valves operate as pressure responsive valves through which, during the filling of the tanks, the flow from the inlet 62 is only permitted to each tank when the inlet pressure is equal to or greater than the existing tank pressure 16a-h associated with the check-valve. Hence, in the case where the existing tank pressure varies between tanks to provide a “staircase” or “cascade” of distributed pressures due to operating a cascade filling (which is likely to be the case), the inlet pressure can be increased from below the lowest tank pressure with none of the check valves opening due to the tank pressure being greater. As the inlet pressure is increased, the check valves will sequentially open as the respective tank pressures are overcome, thereby equalizing the pressures across the tanks to flatten the cascaded pressures. It will be appreciated that the outlet line is closed during charging.

[0090] The check valves in the discharge manifold 58 are arranged to allow a flow from the tanks 16a-h to the outlet 66. As each tank line has an independent check valve, it is not possible to get a back flow from a discharging tank to another tank at a lower pressure. It will be appreciated that the outlet check valves and inlet check valves operate independently of one another and it is not required to include both in working system.

[0091] Also shown in FIG. 7 is a master isolation valve, TPED, which isolates the discharge line thereby preventing any accidental discharge should any of the tank valves fail.

[0092] The tank valves 54a-h which are operable to charge or discharge the tanks 16a-h may be any suitable valves controllable either hydraulically or electrically. In the example shown, the valves 54a-h are on-tank valves which are mounted directly to the tank outlet opening, for example, by a threaded boss provided on the tank. Each of the tank valves 54a-h may be operated independently of the other tank valves 54a-h. The tank valves 54a-h may be electrical operated and, as such, include an electrical solenoid for example. The tank valves 54a-h may be configured to be normally closed and switchable to be fully open.

[0093] In addition to providing the basic switching operation, the tank valves 54a-h may also comprise one or more additional functions. In some embodiments, the tank valves 54a-h may comprise one or more sensors to monitor the status of the tanks. For example, each of the tank valves 54a-h may comprise one or more from the group comprising a pressure sensor, a temperature sensor, and a thermal pressure relief device, TPRD, which is configured to open if a locally sensed temperature exceeds a predetermined threshold. The tank valves 54a-h may also include a filter, for example.

[0094] Each tank 16a-h may comprise TPRD valves at each end of the tank to enable the temperature local to the front and the rear of each storage tank to be measured and the tank discharged if the pressure increases beyond the safe operating limit. The TPRDs may be tank mounted as shown in FIG. 7, or, as shown in FIG. 6, may be connected by one or more fluid lines 70 which extend from the front (operating end) of the tank and carried on a suitable support member to the rear of the tank. It can be seen from FIG. 6 that each pair of tanks includes a single support member for the TPRD, but this is not a limitation.

[0095] To assemble the storage device 10 of the present disclosure, the base 26 may first be provided prior to locating the first plurality of storage tanks 16e-h therein using a suitable lifting device such as a hoist. The first plurality of storage tanks 16e-h may be attached together to provide a raft, or may be individually loaded.

[0096] Once the first plurality of tanks 16e-h are in place, select pipework, including the manifolds, valves, sensors or display devices (e.g. a gauge) may be attached. This is convenient as it allows any pipe work which is required to pass to the rear of the tanks (such as the TPRD lines), can be laid prior to locating the second plurality of tanks 16a-d.

[0097] Following the locating of the first plurality of tanks 16a-d (and optionally the connection of the various components), a mid-section 28 which provides support for the second plurality of tanks 16a-d may be positioned and attached to the base 26. As can be seen, the mid-section 26 comprises a plurality of members 72 which span the gap between the side members to provide the necessary support.

[0098] Once the mid-section 28 is in place, the second plurality of tanks 16a-d may be located and secured to it and the pipework associated with the second plurality of tanks 16a-d installed. Following the securing of the mid-section 28, the upper section 30 may be located and attached to the mid-section 28.

[0099] Once the main structural members of the enclosure are in place, the remaining lines, control devices and display devices together with the electrical interface enclosure bulkhead/panel and control panels, may be installed, prior to the external cladding and panel doors being mounted. Where the electrical interface comprises the bulkhead, it will be appreciated that the electrical components will be installed following the installation of the bulkhead.

[0100] It will be appreciated that the above assembly is an example and the order of the assembly/installation of the various parts may differ.

[0101] FIG. 8 shows an alternative example of the storage refueler fluid layout which does not include the manifold connections 58, 60 or the tank valves 54a-h with the integrated sensors or filters. Hence, there is shown separate check valves for each of the charging and discharging tank lines and separate pressure and temperature sensors for the lines. Other aspects of the system shown in FIG. 8 may be the same as those shown in FIG. 7 and are not repeated here for brevity.

[0102] It will be appreciated that the arrangement of FIG. 7 is preferable over that shown in FIG. 8 as it reduces the number of connections and lines required.

[0103] FIG. 9 shows a control system 90 which may be utilized with the portable refueler 10. The control system may comprise a controller, a plurality of tank valves, an output device, an input device, and a power source. The controller may be an electronic control unit (which may be referred to as an electronic control module) and may comprise a microcontroller and/or a microprocessor, memory and various input and outport interfaces for connecting to the tank valves and/or any other sensors or actuators associated with the refueler’s operation. The output device may comprise any device which provides a user with information relating to the refueler status or operating state and may comprise one or more of a display, one or more lights, or an audio output device. The input device may comprise any user input device such as one or more push buttons or touch screens. The tank valves may be any disclosed herein. The power source may be any suitable power source such as a battery or fuel cell. The operating voltage of the controller and electrical equipment, e.g. valves, sensors etc., may be 12v, 24v or 36v.