Failure Simulation and Mechanism Research of On-board Hydrogen System

Hydrogen Fuel Cell Vehicles（HFCVs） are important carriers for energy conservation and emission reduction in the transport industry. Studying the failure mechanism of HFCV’s on-board hydrogen system is of great significance for the expanding application and safety improvement of HFCVs. In this paper, the on-board hydrogen system and its components of commercial vehicles are taken as the research object, and the failure model of the on-board hydrogen system is constructed through dynamic simulation, and the failure behavior of the hydrogen system under different working conditions is simulated. The results show that the relative displacement of the hydrogen storage bottle and the strap of the hydrogen system is 6.816 mm, and the hydrogen storage bottle and the strap are easy to detach and cause impact failure. In a high-pressure environment, hydrogen storage cylinders and bottle valves bear large stress, and the stress concentration in some positions is prone to structural failure. Finally, it is revealed that the main reason for the failure of the hydrogen system is that when it is subjected to vibration shock or overpressure inside the component, the stress of the structure is too large and the long-term stress is concentrated, which exceeds the yield limit of the material and then causes failure. The research results can provide data support and theoretical guidance for the structural design and safety research of on-board hydrogen systems.