Research on the Diaphragm Movement Characteristics and Cavity Profile Optimization of a Dual-Stage Diaphragm Compressor for Hydrogen Refueling Applications

The large-scale utilization of hydrogen energy is currently hindered by challenges in lowcost production, storage, and transportation. This study focused on investigating the impact of the diaphragm cavity profile on the movement behavior and stress distribution of a dual-stage diaphragm compressor. Firstly, an experimental platform was established to test the gas mass flowrate and fluid pressures under various preset conditions. Secondly, a simulation path integrating the finite element method simulation, theoretical stress model, and movement model was developed and experimentally validated to analyze the diaphragm stress distribution and deformation characteristics. Finally, comparative optimization analyses were conducted on different types of diaphragm cavity profiles. The results indicated that the driving pressure differences at the top dead center position reached 85.58 kPa for the first-stage diaphragm and 75.49 kPa for the second-stage diaphragm. Under experimental conditions of 1.6 MPa suction pressure, 8 MPa second-stage discharge pressure, and 200 rpm rotational speed, the first-stage and second-stage diaphragms reached the maximum center deflections of 4.14 mm and 2.53 mm, respectively, at the bottom dead center position. Moreover, the cavity profile optimization analysis indicated that the double-arc profile (DAP) achieved better cavity volume and diaphragm stress characteristics. The first-stage diaphragm within the optimized DAP-type cavity exhibited 173.95 MPa maximum principal stress with a swept volume of 0.001129 m3 , whereas the second-stage optimized configuration reached 172.57 MPa stress with a swept volume of 0.0003835 m3 . This research offers valuable insights for enhancing the reliability and performance of diaphragm compressors.