WO2024051212A1 - Fuel cell integration system and vehicle - Google Patents

Fuel cell integration system and vehicle Download PDF

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Publication number
WO2024051212A1
WO2024051212A1 PCT/CN2023/095871 CN2023095871W WO2024051212A1 WO 2024051212 A1 WO2024051212 A1 WO 2024051212A1 CN 2023095871 W CN2023095871 W CN 2023095871W WO 2024051212 A1 WO2024051212 A1 WO 2024051212A1
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WO
WIPO (PCT)
Prior art keywords
fuel cell
integrated
stack
air compressor
integrated system
Prior art date
Application number
PCT/CN2023/095871
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French (fr)
Chinese (zh)
Inventor
侯中军
王克勇
贾勇琪
孟维志
涂文特
朱益佳
蔡俊
卢兵兵
Original Assignee
上海捷氢科技股份有限公司
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Publication of WO2024051212A1 publication Critical patent/WO2024051212A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00Electric propulsion with power supplied within the vehicle
    • B60L50/50Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/70Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by fuel cells
    • B60L50/72Constructional details of fuel cells specially adapted for electric vehicles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04007Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
    • H01M8/04029Heat exchange using liquids
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/24Grouping of fuel cells, e.g. stacking of fuel cells
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30Hydrogen technology
    • Y02E60/50Fuel cells

Definitions

  • This application relates to the technical field of fuel cell vehicles and their supporting energy systems, and in particular to a fuel cell integrated system.
  • the application also relates to a vehicle using the fuel cell integrated system.
  • Hydrogen fuel cells have been widely used in the automotive field.
  • fuel cell systems are often supplied in the form of powertrains, that is, the stack and its associated air vapor are The system, hydrogen subsystem, cooling subsystem and control module are pre-integrated and assembled, and then assembled and connected to the entire vehicle.
  • powertrains that is, the stack and its associated air vapor are The system, hydrogen subsystem, cooling subsystem and control module are pre-integrated and assembled, and then assembled and connected to the entire vehicle.
  • Part function integration By merging some parts and reducing the number of parts casings or interfaces between them, the space occupied is reduced, thereby reducing the volume of the entire fuel cell system, such as merging multiple controllers into an all-in-one controller, combining the intercooler and the intensifier Humidifier for direct integration, etc.
  • Partial part integration only eliminates the gaps between several parts without considering the needs of the entire system assembly. Moreover, the integrated component structure is larger than a single part and requires higher layout space. , resulting in a more restricted layout. If the integration structure is unreasonable, it will cause other peripheral parts to take up more space when matching, which is not conducive to improving the integration of the entire system. In addition, the merger of some parts is still limited, and from a system perspective It can also be expanded to a greater extent of parts integration, so this form of integration is insufficient and not combined with the system layout plan.
  • a fuel cell integrated system which includes a reference housing.
  • the reference housing is composed of an upper box and a lower box arranged in sequence from top to bottom, and the upper box is aligned and connected.
  • the top of the box is opened and closed with a top cover, the inner cavity of the upper box is provided with a stack assembly, and the inner cavity of the lower box is provided with an integrated controller assembly;
  • the bottom of the reference housing is provided with an air compressor, a water pump, a heat exchanger, an intercooler, a bypass valve, and a drain valve.
  • the cooling pipe of the integrated controller assembly and the cooling pipe of the air compressor The road is a one-piece structure;
  • the side of the reference housing is provided with an ejector, a hydrogen proportional valve, a thermostat, an anode water separator, a hydrogen discharge valve, an air back pressure valve, a cathode water separator, and an air intake valve.
  • the housing of the air compressor and the lower box body are of an integrated structure.
  • the cooling pipeline of the integrated controller assembly is connected in parallel with the cooling pipeline of the air compressor.
  • the shell of the heat exchanger and the lower box are of an integrated structure.
  • the housing of the intercooler and the lower box are of an integrated structure.
  • the stack assembly includes several stacked stack modules, and the three-cavity interfaces of the stack modules are symmetrically arranged on both sides of the end plate of the stack module.
  • the stack assembly and the integrated controller assembly are electrically connected through a flexible copper bar.
  • the present application also provides a vehicle, including a vehicle body and a fuel cell integrated system.
  • the fuel cell integrated system is the fuel cell integrated system as described in any one of the above.
  • the reference casing formed by the cooperation of the upper box body and the lower box body is used as the structural basis.
  • the stack assembly can be arranged in the upper box body so that it can be easily opened by opening the top box.
  • the controller assembly is arranged in the lower box body, allowing the integrated
  • the controller components of multiple control modules can more easily connect and cooperate with the stack components located in the upper box body and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines, cables and brackets.
  • auxiliary connection structures has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller component and the cooling pipeline of the air compressor are integrated structures, realizing the integrated controller
  • the integrated processing and molding of the components and the corresponding cooling pipelines of the air compressor effectively reduces mold opening and production costs, further simplifies the number of components of the fuel cell integrated system, optimizes the structural layout and integration of the components, and makes all components
  • the fuel cell integrated system forms an integrated high-integration component structure.
  • the housing of the air compressor and the lower box body are of an integrated structure.
  • This integrated structure can further optimize the component structure integration between the air compressor and the lower box body, reduce the assembly space occupied by the shells of each independent component, and improve the assembly space utilization of the fuel cell integrated system, making it The integration of the overall components can be further improved.
  • Figure 1 is a schematic diagram of the assembly structure of a fuel cell integrated system provided by a specific embodiment of the present application
  • Figure 2 is a schematic diagram of the contralateral structure of Figure 1;
  • FIG 3 is a schematic diagram of the overall structure of the integrated controller component in Figure 1;
  • Figure 4 is an exploded view of the internal parts of Figure 3;
  • Figure 5 is an exploded view of the structure of the reference shell in Figure 1;
  • Figure 6 is a schematic diagram of the matching structure between the air compressor and the lower box body in Figure 1;
  • Figure 7 is a schematic diagram of the cooling flow channel layout of the integrated controller and air compressor
  • Figure 8 is a schematic diagram of the layout structure of air heat exchange related components in Figure 1;
  • Figure 9 is a schematic diagram of the layout of each high-voltage connection structure in the fuel cell integrated system.
  • Figure 10 is a schematic structural diagram of the stack assembly in Figure 1;
  • Figure 11 is a schematic diagram of the split assembly structure between the lower box body and the air compressor.
  • the core of this application is to provide a fuel cell integrated system with a good overall structural layout and a high degree of component structural integration; at the same time, it is to provide a vehicle using the above fuel cell integrated system.
  • connection can be a fixed connection
  • connection can also be detachably connected or integrally connected; it can be directly connected or indirectly connected through an intermediate medium; it can be internal communication between two components.
  • connection can also be detachably connected or integrally connected; it can be directly connected or indirectly connected through an intermediate medium; it can be internal communication between two components.
  • a first feature "on” or “below” a second feature may include the first and second features in direct contact, or may include the first and second features. Not in direct contact but through additional characteristic contact between them.
  • the terms “above”, “above” and “above” a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature.
  • the first characteristic is
  • the second features "below”, “below” and “below” include the first feature directly below and diagonally below the second feature, or simply mean that the first feature has a smaller horizontal height than the second feature.
  • the terms “upper”, “lower”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside” etc. indicate The orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation or be configured in a specific orientation. and operation, and therefore cannot be construed as a limitation on this application.
  • the fuel cell integrated system provided by this application includes a reference housing.
  • the reference housing is composed of an upper box 402 and a lower box 403 arranged sequentially from top to bottom and connected in position.
  • the upper box 402 The top opening and closing is provided with a top cover 401, an electric stack assembly 111 is provided in the inner cavity of the upper box body 402, and an integrated controller assembly 110 is provided in the inner cavity of the lower box body 402;
  • the bottom of the reference housing is provided with an air compressor 106, a water pump 107, a heat exchanger 108, an intercooler 109, a bypass valve 115, and a drain valve 116.
  • the cooling pipeline of the integrated controller assembly 110 and the air compressor 106 The cooling pipeline is an integrated structure;
  • the side of the reference housing is provided with an ejector 101, a hydrogen proportional valve 102, a thermostat 103, an anode water separator 104, a hydrogen exhaust valve 105, an air back pressure valve 112, a cathode water separator 113, and an air inlet valve. 114.
  • the stack assembly 111 can be arranged in the upper box body 402 so that it can be installed by opening the top cover 401.
  • the components such as the stack module 901 in the stack assembly 111 are flexibly adjusted and arranged to optimize the operational convenience and efficiency of the stack assembly 111; at the same time, the controller assembly 110 is arranged in the lower box 403 to enable integration
  • the controller assembly 110 with multiple control modules can more conveniently connect and cooperate with the stack assembly 111 located in the upper box 402 and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines.
  • auxiliary connection structures such as cables and brackets has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller assembly 110 and the cooling pipeline of the air compressor 106 are integrated
  • the structure realizes the integrated processing and molding of the integrated controller component 110 and the corresponding cooling pipeline of the air compressor 106, effectively reducing the mold opening and production costs, further simplifying the number of components of the fuel cell integrated system, and optimizing the components.
  • the structural layout and integration degree enable the fuel cell integrated system to form an integrated high-integration component structure.
  • controller assembly 110 all high and low voltage controllers in the fuel cell integrated system are integrated into the controller assembly 110 in the form of control modules, such as DC converters, air compressor controllers, water pump controllers, and fuel cell system controllers. etc., this type of modular integrated design solution has been reflected in relevant patents, and those skilled in the art can use any conventional technical means to help realize the solution. The rest of this article involving conventional assembly and integration of components and conventional functions can be understood and implemented with reference to existing technologies, and will not be described again here.
  • the housing of the air compressor 106 and the lower box 403 have an integrated structure.
  • This integrated structure can further optimize the component structural integration between the air compressor 106 and the lower box 403, reduce the assembly space occupied by the shells of each independent component, and improve the assembly space utilization of the fuel cell integrated system, making it The integration of the overall components can be further improved.
  • the housing and lower box 403 of the air compressor 106 can also be designed as a split structure, that is, a split integrated controller housing 1001 and a split air compressor motor as shown in Figure 11 Shell 1002, and then the two shells are reliably assembled through bolts or other detachable connectors, so that corresponding components can be disassembled and assembled when necessary to meet operational requirements such as component maintenance and replacement.
  • the cooling pipeline of the integrated controller assembly 110 is connected in parallel with the cooling pipeline of the air compressor 106 .
  • the adaptation effect and operating efficiency of the cooling pipeline of the integrated controller assembly 110, the cooling pipeline of the air compressor 106, and related hydraulic devices such as the water pump 107 can be further optimized, and the corresponding number of components and component structure layout can be further streamlined. , thereby correspondingly improving the integration degree of the cooling system components of the fuel cell integrated system.
  • the shell of the heat exchanger 108 and the shell of the intercooler 109 can be integrated with the lower box 403 . Integrating the housings of multiple functionally related and adjacent mating components into an integrated structure can further optimize the related component structures. The integration density is improved, the assembly space utilization is improved, and the shell-related structure is more regular and reliable.
  • the stack assembly 111 includes several stacked stack modules 901 , and the three-cavity interfaces of the stack modules 901 are symmetrically arranged on both sides of the end plates of the stack modules.
  • the stacked arrangement structure allows workers to flexibly adjust the number of stack modules according to working conditions.
  • the three-cavity interface 904 is symmetrically arranged on both sides of the end plate, which can meet actual docking needs through free combination and further optimize the structural integration of the stack assembly 111. High degree and flexible stack expansion and compatibility.
  • the electrical connection between the stack assembly 111 and the integrated controller assembly 110 is achieved through a flexible copper bar.
  • Flexible copper bars are used to directly connect the stack component 111 to the integrated controller component 110 and related high-voltage electrical matching parts. There is no need to arrange connectors and cables accordingly, which greatly reduces the space occupied by the electrical connection structure and integrates the overall structure of the system components. The accuracy can be further improved, making assembly and connection simpler and easier.
  • the positional relationship of the main parts is determined through continuous combination and splicing, preliminary connection of pipelines and wiring harnesses, and the design of structural parts such as brackets are reserved. space, as the basis for the next detailed design.
  • this plan divides the overall layout space into three layers. The top layer is the stack component 111, and the middle layer is the integrated controller component 110. In order to better realize the stack dielectric connection, and the remaining accessories are arranged in 2 areas.
  • the bottom area includes an air compressor 106, a water pump 107, a heat exchanger 108, an intercooler 109, an air bypass valve 115, and an air drain valve 116;
  • the side area includes an ejector 101 , hydrogen proportional valve 102, thermostat 103, anode water separator 104, hydrogen exhaust valve 105, air back pressure valve 112, cathode water separator 113, air inlet valve 114.
  • Setting the integrated controller component 110 in the middle layer is more conducive to the integration of control, structure, thermal management and high-voltage connections to achieve integrated design goals.
  • the layout of each control module inside the controller is designed in the reserved integrated controller component housing 202 to meet the requirements of the controller.
  • the requirements for the position of the high-voltage electrical interface with the controlled device More specifically, there are laminated busbars 301, DCF (distributed coordination function) control driver integrated PCB board 302, and DCF dual-phase integrated SiC module 303 arranged inside the integrated controller component.
  • integrated parallel water channel design 304 integrated parallel water channel design 304, three-in-one motor control drive PCB board 305, air compressor SiC module 306, air compressor three-phase AC filter 307, two-phase magnetic integrated boost power inductor 308, integrated bus DC_Link (DC support) capacitor 309, fuel cell system management controller FCU (fan coil unit) 310, and relay 311, which have the characteristics of reasonable module division, good cooling effect of shared parallel water channels, divided shell structure isolation, and compact structure.
  • the casing of the stack assembly 111, the casing of the integrated controller assembly 110, and the motor casing of the air compressor 106 can be merged to reduce the relative distance and cancel the connection.
  • brackets taking into account the assembly process requirements, the overall structure is assembled through the top cover 401, the upper box body 402 and the lower box body 403.
  • the shell structure When designing the structure, ensure that the high-voltage electrical interface of the integrated controller component designed in the previous step is reserved. At the same time, the installation and connections of the air compressor motor 502, air compressor outlet pump head 501, air compressor inlet pump head 503, etc.
  • the heat exchanger 108 is directly connected to the intercooler 109 and the air compressor 106, eliminating the transition brackets and pipelines between parts, improving system integration and reducing installation and Maintenance costs.
  • a detailed design of thermal management is carried out.
  • a detailed design of the cooling flow channel is carried out inside the casing, and the cooling flow channel 605 of the integrated controller component and the cooling flow channel 604 of the air compressor motor are carried out.
  • Cavity design multiple cooling cavities are connected in sequence through flow channels at the same time. After the coolant enters through the integrated controller component coolant inlet 602, it flows into the integrated controller component 110 and the air compressor motor 502 at the same time, and finally flows through the integrated controller component 110 and the air compressor motor 502 respectively.
  • the coolant outlet 601 of the integrated controller component and the coolant outlet 603 of the air compressor motor flow out, which is more convenient and efficient than the existing dispersed arrangement that requires connecting pipelines and has multiple sets of inlets and outlets.
  • the air efficient utilization area is designed.
  • the external air enters through the air compressor inlet interface 703, is compressed in the air compressor 106 and becomes a high-temperature gas. After that, it enters the heat exchanger 108 and interacts with the low-temperature gas flowing out of the stack air outlet interface 702. The air undergoes heat exchange. After the high-temperature gas further passes through the intercooler 109, it enters the stack assembly for reaction through the stack air inlet interface 701.
  • the low-temperature gas enters the expander end of the air compressor 106 and is discharged through the tail air outlet interface 704.
  • a bypass valve 115 and a drain valve 116 are provided in order to control the gas flow at the expander end of the stack assembly 111 and the air compressor 106. This solution achieves effective utilization of air heat in a highly integrated form and is beneficial to improving expansion. machine energy recovery and improve system efficiency.
  • the stack component 111 connects the high-voltage output positive and negative electrode copper bars 802 and 805 goes deep into the integrated controller component 110. In order to facilitate assembly and connection, it is connected to the positive relay 803 and the negative relay 804 in the integrated controller component through two flexible transfer copper bars 801 and 806. The connection relationship is completely realized inside the shell. , without cables and connectors.
  • the three-phase high-voltage connection structure of the air compressor 106, the water pump 107 and the integrated controller assembly 110 is similar to this. Only the positions are different and will not be described again.
  • the layout plan of other components in the system is refined to further optimize the connection form and fully utilize the space, further reduce the system volume and improve the integration level.
  • the stack is first integrated into a standard stack module 901 according to space constraints. Its length and width are designed according to the layout space structure restrictions.
  • the three-cavity interfaces 904 are distributed on both sides of the end plate.
  • this solution adopts the form of two standard stack modules 901 stacked one above the other.
  • the anode current collector plate 902 and cathode current collector plate 903 of the two stack modules 901 are connected in series through the stack connection busbar 905.
  • the integrated form of the stack component avoids the impact of a large number of high-power stack sections and large size, and the system is compact, highly integrated, and the stack has flexible scalability.
  • the vehicle provided by this application includes a vehicle body and a fuel cell integrated system, and the fuel cell integrated system is specifically the fuel cell integrated system as described above.
  • the reference housing formed by the cooperation of the upper box body and the lower box body is used as the structural foundation, and the stack components can be arranged in the upper box body.
  • the stack modules and other components in the stack assembly can be flexibly adjusted and arranged, optimizing the operational convenience and efficiency of the stack assembly; at the same time, the controller assembly is arranged in the lower box , so that the controller component integrated with multiple control modules can more conveniently connect and cooperate with the stack component located in the upper box body and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines
  • the application of auxiliary connection structures such as cables and brackets has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller component and the cooling pipeline of the air compressor are integrated structures, achieving The integrated controller component and the corresponding cooling pipeline of the air compressor are processed and formed in an integrated manner, which effectively reduces the mold opening and production costs, further simplifies the
  • the vehicle provided by this application using the above-mentioned fuel cell integrated system has a better overall structural layout of the fuel cell integrated system, which can correspondingly improve the overall performance of the vehicle.

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  • Sustainable Development (AREA)
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Abstract

The present application discloses a fuel cell integration system, comprising a reference housing. The reference housing is formed by aligning and connecting an upper box and a lower box which are sequentially arranged from top to bottom; a top cover is provided at the top of the upper box in such a manner that the top cover can be opened and closed; a cell stack assembly is provided in an inner cavity of the upper box; an integrated controller assembly is provided in an inner cavity of the lower box; an air compressor, a water pump, a heat exchanger, an intercooler, a bypass valve and a relief valve are provided at the bottom of the reference housing; a cooling pipeline of the integrated controller assembly and a cooling pipeline of the air compressor are of an integrated structure; an ejector, a hydrogen proportional valve, a thermostat, an anode water separator, a hydrogen discharge valve, an air back pressure valve, a cathode water separator, and an air inlet valve are provided on the side of the reference housing. The present application further discloses a vehicle using the fuel cell integration system.

Description

燃料电池集成系统及车辆Fuel cell integrated systems and vehicles 技术领域Technical field
本申请涉及燃料电池汽车及其配套能源系统技术领域,特别涉及一种燃料电池集成系统。本申请还涉及一种应用该燃料电池集成系统的车辆。This application relates to the technical field of fuel cell vehicles and their supporting energy systems, and in particular to a fuel cell integrated system. The application also relates to a vehicle using the fuel cell integrated system.
背景技术Background technique
氢燃料电池目前已被广泛应用于汽车领域,为降低整车布置设计和装配维护的复杂度,燃料电池系统往往采用动力总成的形式供货,即,将电堆及其相关联的空气子系统、氢气子系统、冷却子系统和控制模块等进行预先集成组装,之后再与整车进行装配连接。但由于不同车型内部空间及车身结构部件的差异性,同时也受限于零部件体积大、集成度偏低等现状,导致同一燃料电池设计方案难以在不同车型兼容。为此,本领域内的现有技术方案从如下两个方面进行了探索和应用:Hydrogen fuel cells have been widely used in the automotive field. In order to reduce the complexity of vehicle layout design, assembly and maintenance, fuel cell systems are often supplied in the form of powertrains, that is, the stack and its associated air vapor are The system, hydrogen subsystem, cooling subsystem and control module are pre-integrated and assembled, and then assembled and connected to the entire vehicle. However, due to the differences in the internal space and body structure components of different models, as well as the large volume and low integration of components, it is difficult for the same fuel cell design to be compatible with different models. To this end, existing technical solutions in this field have been explored and applied from the following two aspects:
1、优化系统集成方案。通过分区分层布置、设置集成框架连接、以电堆为中心环绕形布置、合理设置接口、模块化集成布置等方式,实现空间有效利用、缩小系统体积、提高装配便利性等设计目标;1. Optimize the system integration solution. Through partitioning and hierarchical layout, setting up integrated frame connections, surrounding layout with the stack as the center, rationally setting interfaces, modular integrated layout, etc., we can achieve design goals such as effective use of space, reduction of system volume, and improvement of assembly convenience;
2、零件功能集成。通过将部分零件合并,减少零件外壳或相互间接口的连接,以缩小空间占用,进而缩小整个燃料电池系统体积,如将多个控制器合并为一个多合一控制器、将中冷器与增湿器进行直接集成等。2. Part function integration. By merging some parts and reducing the number of parts casings or interfaces between them, the space occupied is reduced, thereby reducing the volume of the entire fuel cell system, such as merging multiple controllers into an all-in-one controller, combining the intercooler and the intensifier Humidifier for direct integration, etc.
然而,如上所述的现有技术方案仍存在如下问题:However, the existing technical solutions described above still have the following problems:
1、优化系统集成方案的问题:系统内部仍然由多个零件组合,各个零件外形接口存在差异难以最大限度利用布置空间,零件之间仍需预留合理间隙,且各个零件组合连接需必要的支架、管路、线束,优化布置没有进行有效且合理的集成处理,只能缩短路径或简化结构,不能减少零件数量,也无法消除空间占用等,因此其对提高空间利用率的效果是有限的,而且会带来成本高、装配复杂、系统效率低、可靠性差等问题。1. Problems in optimizing system integration solutions: The system is still composed of multiple parts. The shape interfaces of each part are different, making it difficult to maximize the use of the layout space. Reasonable gaps still need to be reserved between parts, and necessary brackets are needed to connect each part combination. , pipelines, wire harnesses, optimized layout without effective and reasonable integration processing, can only shorten the path or simplify the structure, cannot reduce the number of parts, nor eliminate space occupation, etc., so its effect on improving space utilization is limited. Moreover, it will bring problems such as high cost, complex assembly, low system efficiency, and poor reliability.
2、零件功能集成的问题:局部零件集成只消除了若干零件之间的空隙,没有从整个系统总成需求角度出发,且集成后的组件结构相比单个零件体积更大,布置空间要求更高,导致布置更为受限,如果集成结构不合理会导致其他周边件匹配时占用更大空间,反而不利于整个系统的集成度提升,此外部分零件的合并仍是有限范围的,而在系统角度还可拓展更大限度的零件集成,因此该形式的集成是不充分的,没有结合系统布置方案进行。2. Problems with part function integration: Partial part integration only eliminates the gaps between several parts without considering the needs of the entire system assembly. Moreover, the integrated component structure is larger than a single part and requires higher layout space. , resulting in a more restricted layout. If the integration structure is unreasonable, it will cause other peripheral parts to take up more space when matching, which is not conducive to improving the integration of the entire system. In addition, the merger of some parts is still limited, and from a system perspective It can also be expanded to a greater extent of parts integration, so this form of integration is insufficient and not combined with the system layout plan.
因此,如何优化燃料电池系统的结构布局,提高其组件结构集成度是本领域技术人 员目前需要解决的重要技术问题。Therefore, how to optimize the structural layout of the fuel cell system and improve the structural integration of its components is a matter for those skilled in the art. Important technical issues that members currently need to solve.
发明内容Contents of the invention
本申请的目的是提供一种燃料电池集成系统,该燃料电池集成系统的整体结构布局较好,组件结构集成度较高。本申请的另一目的是提供一种应用上述燃料电池集成系统的车辆。The purpose of this application is to provide a fuel cell integrated system that has a better overall structural layout and a higher degree of component structural integration. Another object of the present application is to provide a vehicle using the above fuel cell integrated system.
为解决上述技术问题,本申请提供一种燃料电池集成系统,包括基准壳体,所述基准壳体由自上而下依次布置的上盒体与下盒体对位连接而成,所述上盒体的顶部开合设置有顶盖,所述上盒体的内腔中设置有电堆组件,所述下盒体的内腔中设置有集成控制器组件;In order to solve the above technical problems, the present application provides a fuel cell integrated system, which includes a reference housing. The reference housing is composed of an upper box and a lower box arranged in sequence from top to bottom, and the upper box is aligned and connected. The top of the box is opened and closed with a top cover, the inner cavity of the upper box is provided with a stack assembly, and the inner cavity of the lower box is provided with an integrated controller assembly;
所述基准壳体的底部设置有空压机、水泵、换热器、中冷器、旁路阀、泄流阀,所述集成控制器组件的冷却管路与所述空压机的冷却管路为一体式结构;The bottom of the reference housing is provided with an air compressor, a water pump, a heat exchanger, an intercooler, a bypass valve, and a drain valve. The cooling pipe of the integrated controller assembly and the cooling pipe of the air compressor The road is a one-piece structure;
所述基准壳体的侧部设置有引射器、氢气比例阀、节温器、阳极分水器、排氢阀、空气背压阀、阴极分水器、空气进气阀。The side of the reference housing is provided with an ejector, a hydrogen proportional valve, a thermostat, an anode water separator, a hydrogen discharge valve, an air back pressure valve, a cathode water separator, and an air intake valve.
可选地,所述空压机的壳体与所述下盒体为一体式结构。Optionally, the housing of the air compressor and the lower box body are of an integrated structure.
可选地,所述集成控制器组件的冷却管路与所述空压机的冷却管路相并联。Optionally, the cooling pipeline of the integrated controller assembly is connected in parallel with the cooling pipeline of the air compressor.
可选地,所述换热器的壳体与所述下盒体为一体式结构。Optionally, the shell of the heat exchanger and the lower box are of an integrated structure.
可选地,所述中冷器的壳体与所述下盒体为一体式结构。Optionally, the housing of the intercooler and the lower box are of an integrated structure.
可选地,所述电堆组件包括若干堆叠设置的电堆模块,且所述电堆模块的三腔接口对称布置于所述电堆模块的端板的两侧。Optionally, the stack assembly includes several stacked stack modules, and the three-cavity interfaces of the stack modules are symmetrically arranged on both sides of the end plate of the stack module.
可选地,所述电堆组件与所述集成控制器组件之间通过柔性铜排实现电连接。Optionally, the stack assembly and the integrated controller assembly are electrically connected through a flexible copper bar.
本申请还提供一种车辆,包括车体和燃料电池集成系统,所述燃料电池集成系统为如上述任一项所述的燃料电池集成系统。The present application also provides a vehicle, including a vehicle body and a fuel cell integrated system. The fuel cell integrated system is the fuel cell integrated system as described in any one of the above.
本申请所提供的燃料电池集成系统,其装配应用时,由于采用了上盒体与下盒体配合形成的基准壳体作为结构基础,能够将电堆组件布置于上盒体内,以便通过打开顶盖,即可对电堆组件中的电堆模块等部件进行灵活调整和布置,优化了电堆组件的操作便利性和操作效率;同时,将控制器组件布置于下盒体中,使得集成有多个控制模块的控制器组件能够更加便捷地与位于上盒体内的电堆组件以及位于基准壳体下方和侧部的各功能部件相互连接配合,有效减少了相关的管路、线缆及支架等辅助连接结构的应用,大幅提高了所述燃料电池集成系统的组件结构集成度;此外,集成控制器组件的冷却管路与空压机的冷却管路为一体式结构,实现了集成控制器组件和空压机的相应冷却管路的一体式加工成型,有效降低了开模和生产成本,并进一步精简了所述燃料电池集成系统的组件数量,优化了组件结构布局和集成度,使得所述燃料电池集成系统形成一体式高集成度组件结构。 When the fuel cell integrated system provided by this application is assembled and applied, the reference casing formed by the cooperation of the upper box body and the lower box body is used as the structural basis. The stack assembly can be arranged in the upper box body so that it can be easily opened by opening the top box. With the cover, the stack modules and other components in the stack assembly can be flexibly adjusted and arranged, optimizing the operational convenience and efficiency of the stack assembly; at the same time, the controller assembly is arranged in the lower box body, allowing the integrated The controller components of multiple control modules can more easily connect and cooperate with the stack components located in the upper box body and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines, cables and brackets. The application of other auxiliary connection structures has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller component and the cooling pipeline of the air compressor are integrated structures, realizing the integrated controller The integrated processing and molding of the components and the corresponding cooling pipelines of the air compressor effectively reduces mold opening and production costs, further simplifies the number of components of the fuel cell integrated system, optimizes the structural layout and integration of the components, and makes all components The fuel cell integrated system forms an integrated high-integration component structure.
在本申请的另一可选方案中,所述空压机的壳体与所述下盒体为一体式结构。该一体式结构能够进一步优化空压机与下盒体之间的组件结构集成度,减少各独立部件的壳体所占用的装配空间,提高所述燃料电池集成系统的装配空间利用率,使其整体组件一体化集成度得以进一步提高。In another optional solution of this application, the housing of the air compressor and the lower box body are of an integrated structure. This integrated structure can further optimize the component structure integration between the air compressor and the lower box body, reduce the assembly space occupied by the shells of each independent component, and improve the assembly space utilization of the fuel cell integrated system, making it The integration of the overall components can be further improved.
附图说明Description of the drawings
为了更清楚地说明本申请实施例的技术方案,下面将对实施例中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本申请的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings without exerting creative efforts.
图1为本申请一种具体实施方式所提供的燃料电池集成系统的装配结构示意图;Figure 1 is a schematic diagram of the assembly structure of a fuel cell integrated system provided by a specific embodiment of the present application;
图2为图1的对侧结构示意图;Figure 2 is a schematic diagram of the contralateral structure of Figure 1;
图3为图1中集成控制器组件的整体结构示意图;Figure 3 is a schematic diagram of the overall structure of the integrated controller component in Figure 1;
图4为图3的内部零件爆炸图;Figure 4 is an exploded view of the internal parts of Figure 3;
图5为图1中基准壳体的结构爆炸图;Figure 5 is an exploded view of the structure of the reference shell in Figure 1;
图6为图1中空压机与下盒体之间的配合结构示意图;Figure 6 is a schematic diagram of the matching structure between the air compressor and the lower box body in Figure 1;
图7为集成控制器和空压机的冷却流道布局示意图;Figure 7 is a schematic diagram of the cooling flow channel layout of the integrated controller and air compressor;
图8为图1中空气换热相关组件的布局结构示意图;Figure 8 is a schematic diagram of the layout structure of air heat exchange related components in Figure 1;
图9为燃料电池集成系统内各高压连接结构布局示意图;Figure 9 is a schematic diagram of the layout of each high-voltage connection structure in the fuel cell integrated system;
图10为图1中电堆组件的结构示意图;Figure 10 is a schematic structural diagram of the stack assembly in Figure 1;
图11为下盒体与空压机之间的分体式组装结构示意图。Figure 11 is a schematic diagram of the split assembly structure between the lower box body and the air compressor.
其中:
101-引射器;102-氢气比例阀;103-节温器;104-阳极分水器;105-排氢阀;106-空
压机;107-水泵;108-换热器;109-中冷器;110-集成控制器组件;111-电堆组件;112-空气背压阀;113-阴极分水器;114-空气进气阀;115-旁路阀;116-泄流阀;202-集成控制器壳体;301-叠层母排;302-DCF控制驱动集成PCB板;303-DCF双相集成SiC模组;304-集成式并联水道设计;305-三合一电机控制驱动PCB板;306-空压机SiC模组;307-空压机三相交流滤波器;308-双相磁集成升压功率电感;309-集成式母线DC_Link电容;310-燃料电池系统管理控制器FCU;311-继电器;401-顶盖;402-上盒体;403-下盒体;501-空压机出口泵头;502-空压机电机;503-空压机入口泵头;601-集成控制器冷却液出口;602-集成控制器冷却液入口;603-空压机电机冷却液出口;604-空压机电机冷 却流道;605-集成控制器冷却流道;701-电堆空气入口接口;702-电堆空气出口接口;703-空压机空气入口;704-尾排空气出口接口;801-电堆正极转接柔性铜排;802-电堆正极输出铜排;803-正极继电器;804-负极继电器;805-电堆负极输出铜排;806-电堆负极转接柔性铜排;901-电堆模块;902:阳极集流板;903-阴极集流板;904-电堆模块三腔接口;905-电堆连接母排;1001-分体式集成控制器壳体;1002-分体式空压机电机壳体。
in:
101-ejector; 102-hydrogen proportional valve; 103-thermostat; 104-anode water separator; 105-hydrogen exhaust valve; 106-air compressor; 107-water pump; 108-heat exchanger; 109-medium Cooler; 110-Integrated controller component; 111-Pack component; 112-Air back pressure valve; 113-Cathode water separator; 114-Air intake valve; 115-Bypass valve; 116-Drain valve; 202 -Integrated controller housing; 301-laminated busbar; 302-DCF control drive integrated PCB board; 303-DCF dual-phase integrated SiC module; 304-integrated parallel water channel design; 305-three-in-one motor control drive PCB Board; 306-Air compressor SiC module; 307-Air compressor three-phase AC filter; 308-Dual-phase magnetic integrated boost power inductor; 309-Integrated bus DC_Link capacitor; 310-Fuel cell system management controller FCU ; 311-relay; 401-top cover; 402-upper box body; 403-lower box body; 501-air compressor outlet pump head; 502-air compressor motor; 503-air compressor inlet pump head; 601-integrated Controller coolant outlet; 602-Integrated controller coolant inlet; 603-Air compressor motor coolant outlet; 604-Air compressor motor cooling Cooling runner; 605-Integrated controller cooling runner; 701-Stack air inlet interface; 702-Stack air outlet interface; 703-Air compressor air inlet; 704-Tail exhaust air outlet interface; 801-Stack positive electrode Adapter to flexible copper bar; 802-Pile positive output copper bar; 803-Positive relay; 804-Negative relay; 805-Pack negative output copper bar; 806-Pack negative electrode to flexible copper bar; 901-Pack module ; 902: Anode current collector plate; 903-Cathode current collector plate; 904-Stack module three-cavity interface; 905-Stack connection busbar; 1001-Split integrated controller housing; 1002-Split air compressor motor case.
具体实施方式Detailed ways
本申请的核心是提供一种燃料电池集成系统,该燃料电池集成系统的整体结构布局较好,组件结构集成度较高;同时,提供一种应用上述燃料电池集成系统的车辆。The core of this application is to provide a fuel cell integrated system with a good overall structural layout and a high degree of component structural integration; at the same time, it is to provide a vehicle using the above fuel cell integrated system.
为了使本技术领域的人员更好地理解本申请方案,下面结合附图和具体实施方式对本申请作进一步的详细说明。In order to enable those skilled in the art to better understand the solution of the present application, the present application will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.
需要提前说明的是,在本申请中,除非另有明确的规定和限定,术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本申请中的具体含义。It should be noted in advance that in this application, unless otherwise clearly stated and limited, the terms "installation", "connection", "connection", "fixing" and other terms should be understood in a broad sense. For example, it can be a fixed connection, It can also be detachably connected or integrally connected; it can be directly connected or indirectly connected through an intermediate medium; it can be internal communication between two components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.
此外,在本申请中,除非另有明确的规定和限定,第一特征在第二特征“上”或“下”可以包括第一和第二特征直接接触,也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且,第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方,或仅仅表示第一特征水平高度高于第二特征。第一特征在In addition, in this application, unless otherwise expressly stated and limited, a first feature "on" or "below" a second feature may include the first and second features in direct contact, or may include the first and second features. Not in direct contact but through additional characteristic contact between them. Furthermore, the terms "above", "above" and "above" a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature. The first characteristic is
第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方,或仅仅表示第一特征水平高度小于第二特征。术语“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本申请和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本申请的限制。The second features "below", "below" and "below" include the first feature directly below and diagonally below the second feature, or simply mean that the first feature has a smaller horizontal height than the second feature. The terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" etc. indicate The orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation or be configured in a specific orientation. and operation, and therefore cannot be construed as a limitation on this application.
下面参考本申请的图1-9对本申请的燃料电池系统进行具体描述。The fuel cell system of the present application will be described in detail below with reference to Figures 1-9 of the present application.
在实施方式中,本申请所提供的燃料电池集成系统,包括基准壳体,基准壳体由自上而下依次布置的上盒体402与下盒体403对位连接而成,上盒体402的顶部开合设置有顶盖401,上盒体402的内腔中设置有电堆组件111,下盒体402的内腔中设置有集成控制器组件110;In an embodiment, the fuel cell integrated system provided by this application includes a reference housing. The reference housing is composed of an upper box 402 and a lower box 403 arranged sequentially from top to bottom and connected in position. The upper box 402 The top opening and closing is provided with a top cover 401, an electric stack assembly 111 is provided in the inner cavity of the upper box body 402, and an integrated controller assembly 110 is provided in the inner cavity of the lower box body 402;
基准壳体的底部设置有空压机106、水泵107、换热器108、中冷器109、旁路阀115、泄流阀116,集成控制器组件110的冷却管路与空压机106的冷却管路为一体式结构; The bottom of the reference housing is provided with an air compressor 106, a water pump 107, a heat exchanger 108, an intercooler 109, a bypass valve 115, and a drain valve 116. The cooling pipeline of the integrated controller assembly 110 and the air compressor 106 The cooling pipeline is an integrated structure;
基准壳体的侧部设置有引射器101、氢气比例阀102、节温器103、阳极分水器104、排氢阀105、空气背压阀112、阴极分水器113、空气进气阀114。The side of the reference housing is provided with an ejector 101, a hydrogen proportional valve 102, a thermostat 103, an anode water separator 104, a hydrogen exhaust valve 105, an air back pressure valve 112, a cathode water separator 113, and an air inlet valve. 114.
其装配应用时,由于采用了上盒体402与下盒体403配合形成的基准壳体作为结构基础,能够将电堆组件111布置于上盒体402内,以便通过打开顶盖401,即可对电堆组件111中的电堆模块901等部件进行灵活调整和布置,优化了电堆组件111的操作便利性和操作效率;同时,将控制器组件110布置于下盒体403中,使得集成有多个控制模块的控制器组件110能够更加便捷地与位于上盒体402内的电堆组件111以及位于基准壳体下方和侧部的各功能部件相互连接配合,有效减少了相关的管路、线缆及支架等辅助连接结构的应用,大幅提高了所述燃料电池集成系统的组件结构集成度;此外,集成控制器组件110的冷却管路与空压机106的冷却管路为一体式结构,实现了集成控制器组件110和空压机106的相应冷却管路的一体式加工成型,有效降低了开模和生产成本,进一步精简了所述燃料电池集成系统的组件数量,优化了组件结构布局和集成度,使得所述燃料电池集成系统形成一体式高集成度组件结构。During its assembly and application, since the reference shell formed by the upper box body 402 and the lower box body 403 is used as the structural basis, the stack assembly 111 can be arranged in the upper box body 402 so that it can be installed by opening the top cover 401. The components such as the stack module 901 in the stack assembly 111 are flexibly adjusted and arranged to optimize the operational convenience and efficiency of the stack assembly 111; at the same time, the controller assembly 110 is arranged in the lower box 403 to enable integration The controller assembly 110 with multiple control modules can more conveniently connect and cooperate with the stack assembly 111 located in the upper box 402 and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines. The application of auxiliary connection structures such as cables and brackets has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller assembly 110 and the cooling pipeline of the air compressor 106 are integrated The structure realizes the integrated processing and molding of the integrated controller component 110 and the corresponding cooling pipeline of the air compressor 106, effectively reducing the mold opening and production costs, further simplifying the number of components of the fuel cell integrated system, and optimizing the components. The structural layout and integration degree enable the fuel cell integrated system to form an integrated high-integration component structure.
应当理解的是,将燃料电池集成系统内所有高低压控制器以控制模块的形式合并集成于控制器组件110内,如直流变换器、空压机控制器、水泵控制器、燃料电池系统控制器等,该类模块式集成设计方案已有相关专利体现,本领域技术人员可以采用任何常规技术手段以帮助该方案实现。本文中其余部分涉及部件常规组装集成和常规功能的内容均可参照现有技术对应理解和实现,在此不做赘述。It should be understood that all high and low voltage controllers in the fuel cell integrated system are integrated into the controller assembly 110 in the form of control modules, such as DC converters, air compressor controllers, water pump controllers, and fuel cell system controllers. etc., this type of modular integrated design solution has been reflected in relevant patents, and those skilled in the art can use any conventional technical means to help realize the solution. The rest of this article involving conventional assembly and integration of components and conventional functions can be understood and implemented with reference to existing technologies, and will not be described again here.
进一步地,空压机106的壳体与下盒体403为一体式结构。该一体式结构能够进一步优化空压机106与下盒体403之间的组件结构集成度,减少各独立部件的壳体所占用的装配空间,提高燃料电池集成系统的装配空间利用率,使其整体组件一体化集成度得以进一步提高。Further, the housing of the air compressor 106 and the lower box 403 have an integrated structure. This integrated structure can further optimize the component structural integration between the air compressor 106 and the lower box 403, reduce the assembly space occupied by the shells of each independent component, and improve the assembly space utilization of the fuel cell integrated system, making it The integration of the overall components can be further improved.
参考图11,实际应用中,空压机106的壳体与下盒体403也可以为分体式结构设计,即如图11所示的分体式集成控制器壳体1001和分体式空压机电机壳体1002,再将二者的壳体通过螺栓或其他可拆装的连接件实现可靠组装,以便在必要时进行相应的组件拆装,满足部件维护和更换等作业需求。Referring to Figure 11, in actual applications, the housing and lower box 403 of the air compressor 106 can also be designed as a split structure, that is, a split integrated controller housing 1001 and a split air compressor motor as shown in Figure 11 Shell 1002, and then the two shells are reliably assembled through bolts or other detachable connectors, so that corresponding components can be disassembled and assembled when necessary to meet operational requirements such as component maintenance and replacement.
更进一步地,集成控制器组件110的冷却管路与空压机106的冷却管路相并联。如此,可以进一步优化集成控制器组件110的冷却管路与空压机106的冷却管路与相关的水泵107等液压装置的适配效果和运行效率,并进一步精简相应的部件数量和组件结构布局,以此使所述燃料电池集成系统的冷却系统组件集成度相应提高。Furthermore, the cooling pipeline of the integrated controller assembly 110 is connected in parallel with the cooling pipeline of the air compressor 106 . In this way, the adaptation effect and operating efficiency of the cooling pipeline of the integrated controller assembly 110, the cooling pipeline of the air compressor 106, and related hydraulic devices such as the water pump 107 can be further optimized, and the corresponding number of components and component structure layout can be further streamlined. , thereby correspondingly improving the integration degree of the cooling system components of the fuel cell integrated system.
此外,换热器108的壳体、中冷器109的壳体均可以与下盒体403为一体式结构。将多个功能关联且位置相邻的配合部件的壳体集成为一体式结构,能够进一步优化相关的组件结 构集成度,提高装配空间利用率,并使其壳体相关结构更加规整可靠。In addition, the shell of the heat exchanger 108 and the shell of the intercooler 109 can be integrated with the lower box 403 . Integrating the housings of multiple functionally related and adjacent mating components into an integrated structure can further optimize the related component structures. The integration density is improved, the assembly space utilization is improved, and the shell-related structure is more regular and reliable.
另一方面,电堆组件111包括若干堆叠设置的电堆模块901,且电堆模块901的三腔接口对称布置于电堆模块的端板的两侧。堆叠布置结构便于工作人员依据工况需求灵活调整电堆模块的数量,而将三腔接口904对称布置于端板两侧,能够通过自由组合满足实际对接需求,进一步优化电堆组件111的结构集成度和灵活的电堆扩展及兼容。On the other hand, the stack assembly 111 includes several stacked stack modules 901 , and the three-cavity interfaces of the stack modules 901 are symmetrically arranged on both sides of the end plates of the stack modules. The stacked arrangement structure allows workers to flexibly adjust the number of stack modules according to working conditions. The three-cavity interface 904 is symmetrically arranged on both sides of the end plate, which can meet actual docking needs through free combination and further optimize the structural integration of the stack assembly 111. High degree and flexible stack expansion and compatibility.
另外,电堆组件111与集成控制器组件110之间通过柔性铜排实现电连接。采用柔性铜排将电堆组件111与集成控制器组件110及相关各高压电气配合件直连,无需对应布置连接器和电缆,大幅降低了电连接结构的空间占用,使得系统组件的整体结构集成度得以进一步提高,装配连接更加简便易行。In addition, the electrical connection between the stack assembly 111 and the integrated controller assembly 110 is achieved through a flexible copper bar. Flexible copper bars are used to directly connect the stack component 111 to the integrated controller component 110 and related high-voltage electrical matching parts. There is no need to arrange connectors and cables accordingly, which greatly reduces the space occupied by the electrical connection structure and integrates the overall structure of the system components. The accuracy can be further improved, making assembly and connection simpler and easier.
为便于理解本方案,下面结合具体的组件布局对本申请中燃料电池集成系统的具体结构设计加以说明。In order to facilitate understanding of this solution, the specific structural design of the fuel cell integrated system in this application will be described below in conjunction with the specific component layout.
根据整车应用环境对燃料电池系统的外形和接口限制要求,同时综合考虑系统架构和零部件组成,通过不断组合拼接确定主要零件位置关系,初步连接管路和线束,预留支架等结构件设计空间,作为下一步详细设计的基础,本方案为保证深度集成形式,将整体布置空间分为三层,顶层为电堆组件111,中层为集成控制器组件110,为更好地实现电堆介质连接,其余附件布置在2个区域,底层区域包括空压机106、水泵107、换热器108、中冷器109、空气旁路阀115、空气泄流阀116;侧面区域包括引射器101、氢气比例阀102、节温器103、阳极分水器104、排氢阀105、空气背压阀112、阴极分水器113、空气进气阀114。集成控制器组件110设置在中间层更有利于实现控制、结构、热管理和高压连接的集成实现,达到一体化的设计目标。According to the shape and interface restrictions of the fuel cell system in the vehicle application environment, while comprehensively considering the system architecture and component composition, the positional relationship of the main parts is determined through continuous combination and splicing, preliminary connection of pipelines and wiring harnesses, and the design of structural parts such as brackets are reserved. space, as the basis for the next detailed design. In order to ensure deep integration, this plan divides the overall layout space into three layers. The top layer is the stack component 111, and the middle layer is the integrated controller component 110. In order to better realize the stack dielectric connection, and the remaining accessories are arranged in 2 areas. The bottom area includes an air compressor 106, a water pump 107, a heat exchanger 108, an intercooler 109, an air bypass valve 115, and an air drain valve 116; the side area includes an ejector 101 , hydrogen proportional valve 102, thermostat 103, anode water separator 104, hydrogen exhaust valve 105, air back pressure valve 112, cathode water separator 113, air inlet valve 114. Setting the integrated controller component 110 in the middle layer is more conducive to the integration of control, structure, thermal management and high-voltage connections to achieve integrated design goals.
根据集成控制器组件110与电堆组件111、空压机106、水泵107的相对位置关系,在预留集成控制器组件壳体202中进行控制器内部各控制模块的布置方案设计,满足控制器与被控件的高压电气接口位置要求,更具体的,在集成控制器组件内部布置有叠层母排301、DCF(分布式协调功能)控制驱动集成PCB板302、DCF双相集成SiC模组303、集成式并联水道设计304、三合一电机控制驱动PCB板305、空压机SiC模组306、空压机三相交流滤波器307、双相磁集成升压功率电感308、集成式母线DC_Link(直流支撑)电容309、燃料电池系统管理控制器FCU(风机盘管)310、继电器311,具有模块划分合理、共用并联水道冷却效果好、壳体结构划分隔离、结构紧凑等特点。According to the relative positional relationship between the integrated controller component 110, the stack component 111, the air compressor 106, and the water pump 107, the layout of each control module inside the controller is designed in the reserved integrated controller component housing 202 to meet the requirements of the controller. The requirements for the position of the high-voltage electrical interface with the controlled device. More specifically, there are laminated busbars 301, DCF (distributed coordination function) control driver integrated PCB board 302, and DCF dual-phase integrated SiC module 303 arranged inside the integrated controller component. , integrated parallel water channel design 304, three-in-one motor control drive PCB board 305, air compressor SiC module 306, air compressor three-phase AC filter 307, two-phase magnetic integrated boost power inductor 308, integrated bus DC_Link (DC support) capacitor 309, fuel cell system management controller FCU (fan coil unit) 310, and relay 311, which have the characteristics of reasonable module division, good cooling effect of shared parallel water channels, divided shell structure isolation, and compact structure.
控制器完成设计之后,零件间相对位置已基本确定,可将电堆组件111的壳体、集成控制器组件110的壳体、空压机106电机壳体进行合并,缩小相对距离,取消连接用支架,在兼顾装配工艺需求下,整体结构通过顶盖401、上盒体402和下盒体403拼装组成,壳体结 构设计时保证上一步已设计的集成控制器组件高压电气接口预留,同时也需兼顾空压机电机502、空压机出口泵头501、空压机入口泵头503等的安装连接,保证加工和装配的可行性等;此外将换热器108与中冷器109、空压机106进行了直连,取消了零件间的过渡支架和管路,提高了系统集成度,降低了安装与维护成本。After the controller is designed and the relative positions of the parts have been basically determined, the casing of the stack assembly 111, the casing of the integrated controller assembly 110, and the motor casing of the air compressor 106 can be merged to reduce the relative distance and cancel the connection. Using brackets, taking into account the assembly process requirements, the overall structure is assembled through the top cover 401, the upper box body 402 and the lower box body 403. The shell structure When designing the structure, ensure that the high-voltage electrical interface of the integrated controller component designed in the previous step is reserved. At the same time, the installation and connections of the air compressor motor 502, air compressor outlet pump head 501, air compressor inlet pump head 503, etc. need to be taken into consideration to ensure The feasibility of processing and assembly, etc.; in addition, the heat exchanger 108 is directly connected to the intercooler 109 and the air compressor 106, eliminating the transition brackets and pipelines between parts, improving system integration and reducing installation and Maintenance costs.
在一体化机械结构的基础上,进行热管理细化设计,首先在壳体内部进行冷却流道的细化设计,对集成控制器组件冷却流道605和空压机电机冷却流道604内部进行腔体设计,同时通过流道将多个冷却腔体按顺序连接起来,冷却液通过集成控制器组件冷却液入口602进入后,同时流入集成控制器组件110和空压机电机502,最后分别由集成控制器组件冷却液出口601和空压机电机冷却液出口603流出,相比于现有的分散布置需要连接管路且有多组进出口的形式更为便捷和高效。其次进行空气高效利用区域设计,外接空气经空压机入口接口703进入,在空压机106中被压缩后变为高温气体,此后进入换热器108,与电堆空气出口接口702流出的低温空气进行换热,高温气体进一步经过中冷器109后,通过电堆空气入口接口701进入电堆组件内反应,低温气体进入空压机106的膨胀机端后经尾排空气出口接口704排出,此外为控制电堆组件111和空压机106膨胀机端气体流量,设置了旁路阀115和泄流阀116,该方案以高集成度的形式实现了空气热量的有效利用,有利于改善膨胀机的能量回收以及提高系统效率。On the basis of the integrated mechanical structure, a detailed design of thermal management is carried out. First, a detailed design of the cooling flow channel is carried out inside the casing, and the cooling flow channel 605 of the integrated controller component and the cooling flow channel 604 of the air compressor motor are carried out. Cavity design, multiple cooling cavities are connected in sequence through flow channels at the same time. After the coolant enters through the integrated controller component coolant inlet 602, it flows into the integrated controller component 110 and the air compressor motor 502 at the same time, and finally flows through the integrated controller component 110 and the air compressor motor 502 respectively. The coolant outlet 601 of the integrated controller component and the coolant outlet 603 of the air compressor motor flow out, which is more convenient and efficient than the existing dispersed arrangement that requires connecting pipelines and has multiple sets of inlets and outlets. Next, the air efficient utilization area is designed. The external air enters through the air compressor inlet interface 703, is compressed in the air compressor 106 and becomes a high-temperature gas. After that, it enters the heat exchanger 108 and interacts with the low-temperature gas flowing out of the stack air outlet interface 702. The air undergoes heat exchange. After the high-temperature gas further passes through the intercooler 109, it enters the stack assembly for reaction through the stack air inlet interface 701. The low-temperature gas enters the expander end of the air compressor 106 and is discharged through the tail air outlet interface 704. In addition, in order to control the gas flow at the expander end of the stack assembly 111 and the air compressor 106, a bypass valve 115 and a drain valve 116 are provided. This solution achieves effective utilization of air heat in a highly integrated form and is beneficial to improving expansion. machine energy recovery and improve system efficiency.
之后进行高压电气连接细化设计,以电堆组件111与集成控制器组件110连接为例,整个连接关系完全在一体化框架结构内部实现,电堆组件111将高压输出正负极铜排802和805深入到集成控制器组件110内部,为便于装配连接,通过两块柔性转接铜排801和806连接至集成控制器组件内的正极继电器803和负极继电器804,连接关系完全在壳体内部实现,无电缆和连接器。空压机106、水泵107与集成控制器组件110的三相高压连接结构形式与此类似,仅位置不同,不再赘述。After that, a detailed design of the high-voltage electrical connection is carried out. Taking the connection between the stack component 111 and the integrated controller component 110 as an example, the entire connection relationship is completely realized inside the integrated frame structure. The stack component 111 connects the high-voltage output positive and negative electrode copper bars 802 and 805 goes deep into the integrated controller component 110. In order to facilitate assembly and connection, it is connected to the positive relay 803 and the negative relay 804 in the integrated controller component through two flexible transfer copper bars 801 and 806. The connection relationship is completely realized inside the shell. , without cables and connectors. The three-phase high-voltage connection structure of the air compressor 106, the water pump 107 and the integrated controller assembly 110 is similar to this. Only the positions are different and will not be described again.
最后对系统内其他组成件进行布置方案细化,进一步优化连接形式和充分利用空间,进一步缩小系统体积,提高集成度。具体到电堆组件的内部布置方案,先根据空间限制将电堆集成为标准的电堆模块901,其长宽尺寸按照布置空间结构限制设计,三腔接口904分布在端板两侧,对接时根据外部对接关系进行了选择与组合。此外,本方案中采用了两个标准电堆模块901上下叠放的形式,两个电堆模块901的阳极集流板902和阴极集流板903通过电堆连接母排905进行串联。该电堆组件的集成形式避免了大功率电堆节数较多尺寸较大的影响,且系统紧凑、集成度高、电堆具备灵活的可拓展性。Finally, the layout plan of other components in the system is refined to further optimize the connection form and fully utilize the space, further reduce the system volume and improve the integration level. Specific to the internal layout plan of the stack assembly, the stack is first integrated into a standard stack module 901 according to space constraints. Its length and width are designed according to the layout space structure restrictions. The three-cavity interfaces 904 are distributed on both sides of the end plate. When docking, according to External docking relationships are selected and combined. In addition, this solution adopts the form of two standard stack modules 901 stacked one above the other. The anode current collector plate 902 and cathode current collector plate 903 of the two stack modules 901 are connected in series through the stack connection busbar 905. The integrated form of the stack component avoids the impact of a large number of high-power stack sections and large size, and the system is compact, highly integrated, and the stack has flexible scalability.
通过以上设计方案,最终实现深度集成下的一体化燃料电池集成系统设计方案,达到系统设备体积小,成本低、可靠性高、应用便捷的设计目标,以高集成度方案兼容不同车型的 布置需求。Through the above design scheme, an integrated fuel cell integrated system design scheme under deep integration is finally realized, achieving the design goals of small system equipment, low cost, high reliability and convenient application, and a highly integrated scheme compatible with different models of vehicles. Arrangement requirements.
在具体实施方式中,本申请所提供的车辆,包括车体和燃料电池集成系统,所述燃料电池集成系统具体为如上文所述的燃料电池集成系统。In a specific embodiment, the vehicle provided by this application includes a vehicle body and a fuel cell integrated system, and the fuel cell integrated system is specifically the fuel cell integrated system as described above.
综上可知,本申请中提供的燃料电池集成系统,其装配应用时,由于采用了上盒体与下盒体配合形成的基准壳体作为结构基础,能够将电堆组件布置于上盒体内,以便通过打开顶盖,即可对电堆组件中的电堆模块等部件进行灵活调整和布置,优化了电堆组件的操作便利性和操作效率;同时,将控制器组件布置于下盒体中,使得集成有多个控制模块的控制器组件能够更加便捷地与位于上盒体内的电堆组件以及位于基准壳体下方和侧部的各功能部件相互连接配合,有效减少了相关的管路、线缆及支架等辅助连接结构的应用,大幅提高了所述燃料电池集成系统的组件结构集成度;此外,集成控制器组件的冷却管路与空压机的冷却管路为一体式结构,实现了集成控制器组件和空压机的相应冷却管路的一体式加工成型,有效降低了开模和生产成本,并进一步精简了所述燃料电池集成系统的组件数量,优化了组件结构布局和集成度,使得所述燃料电池集成系统形成一体式高集成度组件结构。In summary, it can be seen that when the fuel cell integrated system provided in this application is assembled and applied, the reference housing formed by the cooperation of the upper box body and the lower box body is used as the structural foundation, and the stack components can be arranged in the upper box body. By opening the top cover, the stack modules and other components in the stack assembly can be flexibly adjusted and arranged, optimizing the operational convenience and efficiency of the stack assembly; at the same time, the controller assembly is arranged in the lower box , so that the controller component integrated with multiple control modules can more conveniently connect and cooperate with the stack component located in the upper box body and the functional components located below and on the side of the reference housing, effectively reducing the related pipelines, The application of auxiliary connection structures such as cables and brackets has greatly improved the component structural integration of the fuel cell integrated system; in addition, the cooling pipeline of the integrated controller component and the cooling pipeline of the air compressor are integrated structures, achieving The integrated controller component and the corresponding cooling pipeline of the air compressor are processed and formed in an integrated manner, which effectively reduces the mold opening and production costs, further simplifies the number of components of the fuel cell integrated system, and optimizes the component structure layout and integration. degree, so that the fuel cell integrated system forms an integrated high-integration component structure.
此外,本申请所提供的应用上述燃料电池集成系统的车辆,其燃料电池集成系统的整体结构布局较好,能够使所述车辆的整体性能得以相应提高。In addition, the vehicle provided by this application using the above-mentioned fuel cell integrated system has a better overall structural layout of the fuel cell integrated system, which can correspondingly improve the overall performance of the vehicle.
以上对本申请所提供的燃料电池集成系统以及应用该燃料电池集成系统的车辆进行了详细介绍。本文中应用了具体个例对本申请的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本申请的方法及其核心思想。应当指出,对于本技术领域的普通技术人员来说,在不脱离本申请原理的前提下,还可以对本申请进行若干改进和修饰,这些改进和修饰也落入本申请权利要求的保护范围内。 The fuel cell integrated system provided by this application and the vehicle using the fuel cell integrated system have been introduced in detail above. This article uses specific examples to illustrate the principles and implementation methods of this application. The description of the above embodiments is only used to help understand the method and its core idea of this application. It should be noted that for those of ordinary skill in the art, several improvements and modifications can be made to the present application without departing from the principles of the present application, and these improvements and modifications also fall within the protection scope of the claims of the present application.

Claims (8)

  1. 一种燃料电池集成系统,包括基准壳体,所述基准壳体由自上而下依次布置的上盒体与下盒体对位连接而成,所述上盒体的顶部开合设置有顶盖,所述上盒体的内腔中设置有电堆组件,所述下盒体的内腔中设置有集成控制器组件;A fuel cell integrated system includes a reference housing. The reference housing is composed of an upper box and a lower box arranged in sequence from top to bottom and connected in position. The top of the upper box is opened and closed with a top. Cover, the inner cavity of the upper box body is provided with a stack assembly, and the inner cavity of the lower box body is provided with an integrated controller assembly;
    所述基准壳体的底部设置有空压机、水泵、换热器、中冷器、旁路阀、泄流阀,所述集成控制器组件的冷却管路与所述空压机的冷却管路为一体式结构;The bottom of the reference housing is provided with an air compressor, a water pump, a heat exchanger, an intercooler, a bypass valve, and a drain valve. The cooling pipe of the integrated controller assembly and the cooling pipe of the air compressor The road is a one-piece structure;
    所述基准壳体的侧部设置有引射器、氢气比例阀、节温器、阳极分水器、排氢阀、空气背压阀、阴极分水器、空气进气阀。The side of the reference housing is provided with an ejector, a hydrogen proportional valve, a thermostat, an anode water separator, a hydrogen discharge valve, an air back pressure valve, a cathode water separator, and an air intake valve.
  2. 如权利要求1所述的燃料电池集成系统,其中所述空压机的壳体与所述下盒体为一体式结构。The fuel cell integrated system according to claim 1, wherein the housing of the air compressor and the lower box body are of an integrated structure.
  3. 如权利要求2所述的燃料电池集成系统,其中所述集成控制器组件的冷却管路与所述空压机的冷却管路相并联。The fuel cell integrated system of claim 2, wherein the cooling pipeline of the integrated controller assembly is connected in parallel with the cooling pipeline of the air compressor.
  4. 如权利要求2所述的燃料电池集成系统,其中所述换热器的壳体与所述下盒体为一体式结构。The fuel cell integrated system according to claim 2, wherein the housing of the heat exchanger and the lower box body are of an integrated structure.
  5. 如权利要求2所述的燃料电池集成系统,其中所述中冷器的壳体与所述下盒体为一体式结构。The fuel cell integrated system according to claim 2, wherein the housing of the intercooler and the lower box are of an integrated structure.
  6. 如权利要求1至5中任一项所述的燃料电池集成系统,其中所述电堆组件包括多个堆叠设置的电堆模块,且所述电堆模块的三腔接口对称布置于所述电堆模块的端板的两侧。The fuel cell integrated system according to any one of claims 1 to 5, wherein the stack assembly includes a plurality of stacked stack modules, and the three-chamber interface of the stack module is symmetrically arranged on the stack. Stack the modules on both sides of the end plates.
  7. 如权利要求1至6中任一项所述的燃料电池集成系统,其中所述电堆组件与所述集成控制器组件之间通过柔性铜排实现电连接。The fuel cell integrated system according to any one of claims 1 to 6, wherein the electrical connection between the stack assembly and the integrated controller assembly is achieved through a flexible copper bar.
  8. 一种车辆,包括车体和燃料电池集成系统,其中所述燃料电池集成系统为如权利要求1至7中任一项所述的燃料电池集成系统。 A vehicle includes a vehicle body and a fuel cell integrated system, wherein the fuel cell integrated system is the fuel cell integrated system according to any one of claims 1 to 7.
PCT/CN2023/095871 2022-09-08 2023-05-23 Fuel cell integration system and vehicle WO2024051212A1 (en)

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