小型燃料电池混合动力车驱动系统构建与控制策略研究
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摘要
本文以小型燃料电池车辆为研究对象，分析风冷氢空燃料电池在小型车辆上应用情况，以求燃料电池在该车上的应用有所突破，代替我国众多的以蓄电池、小型内燃机为动力的小型车辆，更好保护环境。基于这种愿景，研制小型质子交换膜燃料电池（PEMFC）混合动力车，并进行相关的测试试验，主要的研究内容为：
（1）车用PEMFC运行机理分析。分析了PEMFC工作机理，包括燃料电池工作原理、电化学模型和燃料电池主要部件。探讨了双极板、扩散层、催化层和质子膜的材料使用情况，以及反应物在它们内部如何传输。重点分析燃料电池功率衰退的原因，探讨减少其衰退的措施。
（2）小型PEMFC混合动力车辆控制策略分析与建模仿真。小型PEMFC混合动力车辆控制策略是保持车辆正常运行和节省能量消耗必要条件，因此在分析不同控制策略基础上，使用Simulink构建控制策略的仿真图，将仿真图嵌入自主开发的小型PEMFC混合动力车辆仿真模块内，进行仿真，以评价各控制策略的优缺点，找出适合本次研究车辆的控制策略。根据动力学原理预估车辆电机功率为3kW，以燃料最小消耗为原则，通过研发的仿真模块，优化与电机构成驱动链的燃料电池和蓄电池动力参数。另外，基于研发的仿真模块，评估构建的小型PEMFC混合动力车辆的经济性和动力性。
（3）车用风冷PEMFC电堆建模、制造、测试与功率衰退分析。在分析风冷电堆传热机理情况下，建立2kW电堆模型，其尺寸为100mm*60mm*345.68mm。通过仿真模拟，优化燃料电池运行条件和流场形式，为设计风冷电堆做参考。根据风冷电堆特点，建立电堆出口末端均温散热模型，加强电堆散热，以保持电堆内温度分布均匀。依据模拟分析，研制风冷的氢空燃料电池电堆，建立了电堆气管理系统、热管理系统和安全控制系统。通过LABVIEW软件，编写测试程序，在校内试验台架上进行测试分析。同时进行5kW电堆功率衰退试验，以评价小型车辆PEMFC混合动力车辆使用成本。
（4）小型PEMFC混合动力车辆构建与试验分析。依据仿真模拟的结果，构建小型PEMFC混合动力车辆。改装原有的高尔夫球车，拆除其动力系统。选购电机和蓄电池，搭建自制的燃料电池电堆，重建小型PEMFC混合动力车辆的驱动链。根据小型车辆功能的要求，简化车辆总控制器，增加DC/DC转换器控制功能，改进风机控制。最后进行室内测试和道路测试，评价车辆性能及其控制策略。
本论文研究结果表明小型PEMFC混合动力车辆的优势在于设计和制造灵活，便于项目开展。重点是保证电堆能够正常运行，防止过早衰退；车辆控制系统要简单、有效，既要保护电堆，又要减少燃料消耗。良好的仿真能够更好地设计电堆，评价车辆性能，有利于项目的推进。
This paper studies the light vehicle with fuel cell. By analyzing the application ofair-cooled hydrogen-air fuel cell in the light vehicle, we wish to substitute numerous lightvehicles powered by batteries and mini internal combustion engines with the light vehiclepowered by air-cooled hydrogen-air fuel cell so as to better protect the environment. Hence,the light hybrid electric vehicle powered by proton exchange membrane fuel cell (PEMFC) isdeveloped, manufactured and tested. The main studying contents are as follows:
1. Analysis on the PEMFC working mechanism employed in vehicles. The PEMFC workingmechanism analyzed in this paper including fuel cell running mechanism,electrochemistry mode as well as the main components of fuel cell. The paper probed intothe application circumstance of materials including bipolar plate, diffusing layer, catalystlayer and proton membrane and worked out how their reactants transmit inside. Analysisis emphasized on the reasons of fuel cell power recession, probing into the measures oflessening their recession.
2. Analysis on the light PEMFC hybrid vehicle control strategy and modeling simulation.Control strategies of the light PEMFC hybrid vehicle are necessary conditions to keep thevehicle work normally and save energy, therefore, based on different control strategiesanalysis, Simulink is applied to build simulation diagram of control strategy, to simulateby inserting the simulation diagram into a self-development light PEMFC hybrid vehiclesimulation model, it aims to estimate the advantages and disadvantages of all the controlstrategies and to find out the optimal development of the vehicle control strategies.According to dynamics principles, the motor power is estimated to be3kW, which setsthe minimum consumption of the fuel as its principle, optimizing the fuel cell andbatteries dynamic parameters. In addition, the economic efficiency and powerperformance of the established light PEMFC hybrid vehicle are estimated based on thedeveloped simulation model.
3. Analysis on the PEMFC stacks model establishment, manufacture, test and powerrecession employed in vehicles. A2kW stack model is established with a size of100mm *60mm*345.68mm according to analysis on air-cooled stack heat transfer mechanism.The working conditions and flow distributions of the fuel cell are optimized throughsimulation so as to make the reference to designing air-cooled stack. An equal heatdiffusing model is built at the end of the stack exit and the stack heat diffusing isreinforced so as to maintain the equal temperature distribution in the stack according tothe air-cooled stack features. Based on the simulation, an air-cooled hydrogen-air fuel cellstack is developed, manufactured, where the stack gas management system, heatmanagement system as well as security control system are established. Test analysis isconducted in the university bench through LABVIEW which compiles the test procedure.Meanwhile, a5kW stack power recession is tested to estimate the using cost of lightvehicle with PEMFC hybrid power.
4. The rebuilding and test analysis of light PEMFC hybrid vehicle. A light PEMFC hybridvehicle is built according to simulation results. The original golf cart is adapted and itspower system is removed. The motor and batteries are selected and purchased, aself-made fuel cell stack is built and the driving chains of light PEMFC hybrid vehicle arerebuilt. According to the requirements of the light vehicle features, simplifying thevehicle main controller, adding DC/DC converter control function, improving fan controlfunction. Finally, bench test and road test are conducted to estimate the vehicleperformance as well as its control strategies.
The researching result indicates the advantages of light PEMFC hybrid vehicle lie in thedesign and manufacture flexibility, which is convenient for the project to carry on. Theemphasis is to validate the normal working of the stack, preventing its fast recession; thevehicle control system is supposed to be simple and effective, which is to protect the stackand to reduce fuel consumption. A better simulation can better design the stack and estimatethe vehicle performance, which is benefit for the project development.
（1）车用PEMFC运行机理分析。分析了PEMFC工作机理，包括燃料电池工作原理、电化学模型和燃料电池主要部件。探讨了双极板、扩散层、催化层和质子膜的材料使用情况，以及反应物在它们内部如何传输。重点分析燃料电池功率衰退的原因，探讨减少其衰退的措施。
（2）小型PEMFC混合动力车辆控制策略分析与建模仿真。小型PEMFC混合动力车辆控制策略是保持车辆正常运行和节省能量消耗必要条件，因此在分析不同控制策略基础上，使用Simulink构建控制策略的仿真图，将仿真图嵌入自主开发的小型PEMFC混合动力车辆仿真模块内，进行仿真，以评价各控制策略的优缺点，找出适合本次研究车辆的控制策略。根据动力学原理预估车辆电机功率为3kW，以燃料最小消耗为原则，通过研发的仿真模块，优化与电机构成驱动链的燃料电池和蓄电池动力参数。另外，基于研发的仿真模块，评估构建的小型PEMFC混合动力车辆的经济性和动力性。
（3）车用风冷PEMFC电堆建模、制造、测试与功率衰退分析。在分析风冷电堆传热机理情况下，建立2kW电堆模型，其尺寸为100mm*60mm*345.68mm。通过仿真模拟，优化燃料电池运行条件和流场形式，为设计风冷电堆做参考。根据风冷电堆特点，建立电堆出口末端均温散热模型，加强电堆散热，以保持电堆内温度分布均匀。依据模拟分析，研制风冷的氢空燃料电池电堆，建立了电堆气管理系统、热管理系统和安全控制系统。通过LABVIEW软件，编写测试程序，在校内试验台架上进行测试分析。同时进行5kW电堆功率衰退试验，以评价小型车辆PEMFC混合动力车辆使用成本。
（4）小型PEMFC混合动力车辆构建与试验分析。依据仿真模拟的结果，构建小型PEMFC混合动力车辆。改装原有的高尔夫球车，拆除其动力系统。选购电机和蓄电池，搭建自制的燃料电池电堆，重建小型PEMFC混合动力车辆的驱动链。根据小型车辆功能的要求，简化车辆总控制器，增加DC/DC转换器控制功能，改进风机控制。最后进行室内测试和道路测试，评价车辆性能及其控制策略。
本论文研究结果表明小型PEMFC混合动力车辆的优势在于设计和制造灵活，便于项目开展。重点是保证电堆能够正常运行，防止过早衰退；车辆控制系统要简单、有效，既要保护电堆，又要减少燃料消耗。良好的仿真能够更好地设计电堆，评价车辆性能，有利于项目的推进。
This paper studies the light vehicle with fuel cell. By analyzing the application ofair-cooled hydrogen-air fuel cell in the light vehicle, we wish to substitute numerous lightvehicles powered by batteries and mini internal combustion engines with the light vehiclepowered by air-cooled hydrogen-air fuel cell so as to better protect the environment. Hence,the light hybrid electric vehicle powered by proton exchange membrane fuel cell (PEMFC) isdeveloped, manufactured and tested. The main studying contents are as follows:
1. Analysis on the PEMFC working mechanism employed in vehicles. The PEMFC workingmechanism analyzed in this paper including fuel cell running mechanism,electrochemistry mode as well as the main components of fuel cell. The paper probed intothe application circumstance of materials including bipolar plate, diffusing layer, catalystlayer and proton membrane and worked out how their reactants transmit inside. Analysisis emphasized on the reasons of fuel cell power recession, probing into the measures oflessening their recession.
2. Analysis on the light PEMFC hybrid vehicle control strategy and modeling simulation.Control strategies of the light PEMFC hybrid vehicle are necessary conditions to keep thevehicle work normally and save energy, therefore, based on different control strategiesanalysis, Simulink is applied to build simulation diagram of control strategy, to simulateby inserting the simulation diagram into a self-development light PEMFC hybrid vehiclesimulation model, it aims to estimate the advantages and disadvantages of all the controlstrategies and to find out the optimal development of the vehicle control strategies.According to dynamics principles, the motor power is estimated to be3kW, which setsthe minimum consumption of the fuel as its principle, optimizing the fuel cell andbatteries dynamic parameters. In addition, the economic efficiency and powerperformance of the established light PEMFC hybrid vehicle are estimated based on thedeveloped simulation model.
3. Analysis on the PEMFC stacks model establishment, manufacture, test and powerrecession employed in vehicles. A2kW stack model is established with a size of100mm *60mm*345.68mm according to analysis on air-cooled stack heat transfer mechanism.The working conditions and flow distributions of the fuel cell are optimized throughsimulation so as to make the reference to designing air-cooled stack. An equal heatdiffusing model is built at the end of the stack exit and the stack heat diffusing isreinforced so as to maintain the equal temperature distribution in the stack according tothe air-cooled stack features. Based on the simulation, an air-cooled hydrogen-air fuel cellstack is developed, manufactured, where the stack gas management system, heatmanagement system as well as security control system are established. Test analysis isconducted in the university bench through LABVIEW which compiles the test procedure.Meanwhile, a5kW stack power recession is tested to estimate the using cost of lightvehicle with PEMFC hybrid power.
4. The rebuilding and test analysis of light PEMFC hybrid vehicle. A light PEMFC hybridvehicle is built according to simulation results. The original golf cart is adapted and itspower system is removed. The motor and batteries are selected and purchased, aself-made fuel cell stack is built and the driving chains of light PEMFC hybrid vehicle arerebuilt. According to the requirements of the light vehicle features, simplifying thevehicle main controller, adding DC/DC converter control function, improving fan controlfunction. Finally, bench test and road test are conducted to estimate the vehicleperformance as well as its control strategies.
The researching result indicates the advantages of light PEMFC hybrid vehicle lie in thedesign and manufacture flexibility, which is convenient for the project to carry on. Theemphasis is to validate the normal working of the stack, preventing its fast recession; thevehicle control system is supposed to be simple and effective, which is to protect the stackand to reduce fuel consumption. A better simulation can better design the stack and estimatethe vehicle performance, which is benefit for the project development.
引文
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