Numerical analysis and experimental study on the performance optimization of cold storage heat exchanger integrated with evaporator

The ISG (Idle Stop and Go) systems are commonly used in modern automobiles because they are economical and environmental friendly technology. However, when a vehicle stops, the air-conditioning system stops, resulting in thermal discomfort to passengers in the cabin. This paper examines a cold storage heat-exchanger (CSH) integrated with an evaporator. The position of the cold storage parts inside a heat exchanger was analyzed through numerical simulations using FLUENT to create an adequate design for a CSH. The CSH performance was then examined with various airflow volumes and optimized experimentally in terms of the refrigerant flow circuit and fin density in the heat exchanger. Next, an experiment on the coldness release performance of the CSH was conducted in the air-conditioning system. The cold storage system with optimized CSH experiment resulted in lower air discharge temperatures (3.5 °C ~ 4.9 °C) than current air-conditioning systems, and delayed the warm-up by approximately 155 seconds to reach 18 °C temperature of air discharge. For this study, the CSH is an effective solution for the ISG-applied vehicles with less investment by transforming current air-conditioners’ structures more effectively.     

Performance of air conditioners with a gas-liquid separation condenser and one-tank laminated evaporator

In this study, a parallel flow condenser and laminated evaporator for an automotive air-conditioning system were modified to improve performance. Gas-liquid separation type condensers, in which the condenser and receiver drier are integrated, and one-tank laminated type evaporators were developed, and their performances were investigated experimentally using HFC-134a. Heat transfer characteristics in the condenser are examined by means of air temperature, air velocity entering the condenser and inlet pressure of the refrigerant; heat transfer characteristics in the evaporator are examined by means of air temperature, relative humidity, flow rate of air, outlet pressure of refrigerant and superheat. Pressure drops for both evaporator and condenser are also measured, and correlations for pressure drop are derived for the condenser and evaporator, respectively. Air velocity and mass flow rate of the refrigerant have a significant effect on the overall heat transfer coefficient, and flow pass is not significantly influenced by the cooling capacity of the condenser. The overall heat transfer coefficient of the evaporator increases as air flow rate, air temperature and relative humidity increases.     

某重型货车空调系统对乘员舱热舒适性影响的分析与改进

应用计算流体力学软件Fluent对某重型货车空调系统和乘员舱中的气流进行数值仿真,其结果与试验对比,相差在5%以内.采用当量温度Teq,i作为评价指标,对乘员舱的热舒适性进行分析.结果表明,由于各风道风量分配不均匀,乘员舱内部气流组织不合理,致使热舒适性较差.对空调系统进行改进,增加前吹面风道风量比例后,乘员舱的热舒适...     

Thermal anaysis of an electric water pump for internal combustion engine vehicles

An electric water pump for engine cooling system has an advantage which particularly in the cold start, the use of the electric water pump saves fuel and leads to a corresponding reduction in emissions. However, the electric water pump for internal combustion engine generates much more heat loss than that for hybrid electric vehicle or electric vehicle since it is operated by electric power of high current and low voltage. In this study, the fluid flow and thermal characteristics of the canned type electric water pump with an inverter integrated has been investigated under the effects of heat generation. The analysis conditions such as outdoor air temperature of 125°C, water pump speed of 6000 rpm, coolant temperature of 106°C and coolant flow rate of 120 L/min were used as a standard condition. Therefore, the thermal performance of the canned type electric water pump’s motor and inverter was evaluated by comparison with that of mechanical seal type. In the motor, the temperature reduced by over 10°C, and in the inverter, the amount of temperature decrease equaled to the maximum temperature difference, about 18.7°C. Also, canned type electric water pumps of variable materials were compared for the evaluation of thermal transfer performance for variable thermal conductivity of a can. The motor and inverter were cooled lower to 42°C at motor and about 40°C at inverter for reasonable selection of can’s thermal conductivity.     

二氧化碳汽车空调系统的动态仿真

文章建立了跨临界CO2汽车空调系统的动态仿真模型。利用移动边界法和平均空泡系数法对蒸发器建立了集总参数模型;利用移动边界法对气冷器和中间换热器分别建立了集总参数模型;由于压缩机和节流阀的热惯性较小,利用经验公式对其建立了稳态模型。计算结果同实验数据的比较表明,该动态模型比较准确地体现系统实际的动态性能。     

基于响应面模型的智能台架供风系统开发

为解决瞬态工况下,汽车主动进气格栅（AGS）开度及风扇转速实时调整,换热器进风量时刻改变,热管理测试台架风机无法实时为换热器提供精准瞬态供风这一问题,应用计算流体力学（CFD）仿真技术,分析了换热器进风量与车速、AGS开度及风扇转速之间的关系,并构建了数学模型,模型预测误差小于6.6%。将该模型置于CANOE设备中,与VN1640设备及风机系统连接,可实时采集车速、AGS开度及风扇转速CAN信号,计算换热器进风量,从而控制风机输出相应风量,实现了台架风机为换热器提供精准、实时供风这一目标。     

Powertrain design and experiment research of a parallel hybrid electric vehicle

The powertrain of an ultra-capacitor-based parallel hybrid electric vehicle (HEV) was developed. Innovations, such as the engine management system, floating ISG (Integrated Starter and Generator), electronic-controlled double-clutch system and dual-driven air conditioning system were realized. Hybrid control strategies to improve the fuel economy and reduce emissions were analyzed briefly. In order to ensure the vehicle emission performance, the engine management system calibration was performed. The vehicle emission test was also conducted, showing that the vehicle emission satisfied the EURO III standard and has great potential for improvement. The hybrid start test was introduced in detail. We realized the hybrid function and start parameter optimization of the engine and ISG.     

Dynamic model of supercritical Organic Rankine Cycle waste heat recovery system for internal combustion engine

The supercritical Organic Rankine Cycle (ORC) for the Waste Heat Recovery (WHR) from Internal Combustion (IC) engines has been a growing research area in recent years, driven by the aim to enhance the thermal efficiency of the ORC and engine. Simulation of a supercritical ORC-WHR system before a real-time application is important as high pressure in the system may lead to concerns about safety and availability of components. In the ORC-WHR system, the evaporator is the main contributor to thermal inertia of the system and is considered to be the critical component since the heat transfer of this device influences the efficiency of the system. Since the thermo-physical properties of the fluid at supercritical pressures are dependent on temperature, it is necessary to consider the variations in properties of the working fluid. The wellknown Finite Volume (FV) discretization method is generally used to take those property changes into account. However, a FV model of the evaporator in steady state condition cannot be used to predict the thermal inertia of the cycle when it is subjected to transient heat sources. In this paper, a dynamic FV model of the evaporator has been developed and integrated with other components in the ORC-WHR system. The stability and transient responses along with the performance of the ORC-WHR system for the transient heat source are investigated and are also included in this paper.     

Decoupled self-tuning PI controller for an idling stop system applied to scooters

This paper is aimed to propose a decoupled self-tuning proportional plus integral (PI) controller with simple law for an idling stop system applied to scooters. An integrated starter generator (ISG) of the idling stop system is designed with a high efficiency permanent magnet synchronous motor (PMSM). The PMSM used as an ISG must have a high torque characteristic to ensure that the engine can be accelerated up to firing speed. A conventional and useful control algorithm named PI control is unable to handle motor current very well for dynamic load, parametric variation, and external disturbance, especially in a vehicle application. Therefore, a robust algorithm for current control in an ISG is proposed. The decoupled selftuning PI controller based on the Lyapunov stability theorem is utilized to guarantee the control performance. Numerical simulations demonstrate the effectiveness of the proposed control algorithm. Experimental results show that the engine of a 150 cm3 scooter can be cranked to reach firing speed by a ISG within 0.1?0.2 second. The proposed method is simple, robust, as well as stable for idling stop system, and can be effectively implemented.     

柴油机冷起动过程喷油系统的控制模式

冷起动性能是柴油机重要的使用特性之一。与机械式喷油泵相比，电控喷油系统可使柴油机冷起动过程自动化和冷起动混合气状态最佳化。从柴油机冷起动过程及其影响因素、冷起动燃烧过程和喷油系统的最佳控制模式等方面，论述了最佳冷起动过程的电控喷油模式。设计了冷起动控制器，使柴油机能自动地与变化的起动条件相适应。     

ISG混合动力汽车整车控制器的设计

根据ISG用于带增压柴油机的混合动力汽车的特点,设计了基于CAN总线的ISG混合动力汽车的整车控制器,包括硬件的模块化设计、CAN总线的应用设计及针对废气涡轮增压柴油机的ISG混合动力汽车控制策略设计,并且详细介绍了其硬件设计方法以及部分主要模块和算法的程序流程图.实验结果表明,该控制器功能强大、性能可靠,能准确实现带增压柴油机的ISG混合动力汽车的整车控制策略.     

基于天然气发动机排气余热回收系统的非共沸混合工质性能分析

针对一台车用天然气发动机排气能量的变化规律,建立了带回热器有机朗肯循环系统,对比分析了采用纯工质R245fa和非共沸混合工质R416A时,带回热器有机朗肯循环系统的净输出功率、热效率、效率和单位工质能量输出密度。结果表明,采用非共沸混合工质R416A时上述各项性能指标均优于采用纯工质R245fa。最后,构建了天然气发动机-带回热器有机朗肯循环联合系统,采用非共沸混合工质R416A,分析了联合系统的热效率。结果表明,加装带回热器有机朗肯循环系统后,发动机热效率最大可提高7%。     

纯电动汽车主动进气格栅策略开发及能耗贡献量研究

介绍了一套完整的主动进气格栅整车热管理控制策略平台架构和开发流程,基于多款纯电动汽车试验验证,充分利用大数据研究、理论分析、高低温环境舱试验匹配等手段,完成了对主动进气格栅整车热管理控制策略的正向开发,并结合纯电动车型热泵空调系统完成了整车能耗贡献量对比试验分析。研究表明,新开发的主动进气格栅整车热管理策略在常温、低温环境下均有较好的节能收益,高温环境下可及时响应整车热管理系统的散热需求,同时具备平台化应用的可行性。     

混合动力发动机与动力电池冷却余热双向循环预热

为了提高并联式混合动力汽车发动机和动力电池低温生存能力,探索发动机与电池冷却余热资源的利用新途径,提出了一种基于余热再利用的发动机和动力电池双向循环低温预热的新方法。建立发动机和动力电池余热数值模型,定量分析和研究余热系统的温升特点与温度分布状况,揭示了发动机与动力电池余热的传热规律,设计了基于相变材料的自动双向热控装置并进行了低温试验。结果表明:该方法实现了发动机与动力电池吸热冷却和发热加热的一体化应用,可将发动机冷却余热经热换器预热动力电池并使电池内部温度保持在29℃,又将动力电池冷却余热反向循环传输至发动机机体,使发动机内部冷却液温度预热至51℃,能够明显提高发动机和动力电池低温运行能力,节约了能量,验证了所提方法的优越性。     

冷热冲击工况下发动机冷却水套传热分析

通过模拟整车在上下坡过程中发动机工作状况,建立了冷却水套非稳态工作环境,利用CFX流体分析软件对非稳态工况下的冷却水套流动传热状况进行仿真分析,得到了冷却液流场和温度场,通过流固耦合分析得出了发动机缸体缸盖热负荷的分布情况。对发动机进行了实际的变工况试验验证,证明了仿真分析的正确性,验证了冷热冲击试验可以为冷却水套换热分析提供准确的工况环境。     

纯电动汽车热泵空调系统布置设计分析

空调系统是整车重要的组成部分和能耗部件。纯电动汽车在低温环境下续驶里程大幅缩减,热泵空调系可提升整车电能利用效率,但热泵空调系统相对复杂,增加了布置难度。文章通过热泵系统关键零部件及管路走向布置、静态及动态间隙校核、装配工艺性分析和美观性等多个维度,结合具体整车系统案例,总结了热泵空调系统总布置设计时的注意因素和遵循原则,为热泵空调系统开发提供参考依据,降低开发周期。     

Experimental study of performance and emission characteristics of DEE-assisted minimally processed ethanol fuelled HCCI engine

The homogeneous charge compression ignition (HCCI) is an alternative combustion concept for reciprocating engines. This study investigates an HCCI engine fuelled with Diethyl ether (DEE) ignition assisted wet ethanol (ethanol with 20% water content). The direct use of wet ethanol could reduce the associated energy required for distillation and dehydration of ethanol. The HCCI engine offers significant benefits in terms of its high efficiency and ultra low emissions. The experiment is conducted with various DEE flow rates and at different air-fuel ratios, for which stable HCCI combustion is achieved. Incylinder pressure, heat release analysis and exhaust emissions were observed. In this study, the effect of DEE on combustion parameters, thermal efficiency and emissions is analysed and discussed in detail. The experimental results indicate that the DEE flow rates have a significant effect on the maximum in-cylinder pressure and its position, thermal efficiency, maximum rate of pressure rise and the heat release rate. Results show that for all stable operating points, brake thermal efficiency is higher than reference mode at lower loads and almost same at higher loads. The emission parameters such as NO, HC and CO are lower than the dual fuel mode which is considered as a reference model for this experiment.     

Performance characteristics of a supplementary stack-cooling system for fuel-cell vehicles using a carbon dioxide air-conditioning unit

In fuel-cell-powered vehicles, the fuel-cell system requires a thermal-management subsystem to dissipate heat released during the reaction of hydrogen with oxygen. When the stack generates power at a high rate, a large amount of heat is also generated. If cooling by the radiator is insufficient, a supplementary stack-cooling system is needed to maintain a safe operating temperature. In this study, the performance of a CO₂ air-conditioning unit for stack cooling was investigated under various conditions, and the relationship between cabin cooling and stack cooling was also studied. The coefficient of performance (COP) increased from 1.9 to 2.4, with an increase in cabin-air inlet flow rate from 0 to 8 m³/min. When the air-conditioning unit was turned off, the cooling capacity of the stack cooler was increased; correspondingly, as the cabin-cooling capacity was increased, that of the stack cooler decreased. With an increase in ambient-air inlet temperature from 38°C to 45°C, the COP decreased by 24%. Additionally, both the stack-cooling capacity and cabin-cooling capacity were decreased by about 12% and 16%, respectively, due to reduced heat transfer in the gas cooler as the ambient air inlet temperature was increased. It is expected that the experimental results can serve as a resource in designing a stack-cooling system using a CO₂ air-conditioning unit to enhance stack power generation and efficiency.     

柴油机后处理系统一维数值模拟

以准稳态流动的压力损失方程与传热方程为计算依据,将过滤体看成是一维单通道流动管道的集合,建立了DPF一维流动模型,模拟过滤体;以BJ493ZQ3发动机为试验用发动机,建立发动机模型,将DPF模型连接在发动机排气管尾端,集合为系统整体模型,模拟系统排气阻力。计算与试验结果都表明,固定转速,低负荷时,系统排气阻力与负荷近似呈线性关系,高负荷时,二者近似呈二次曲线关系。计算给出了柴油机加装壁流式碳化硅DPF在实际不同运行条件下的排气背压MAP图,用来标定控制器,同时为DPF的再生控制策略提供了依据。     

基于有机朗肯循环的车用柴油机排气余热回收系统性能分析

利用设计的有机朗肯循环系统回收某重型车用柴油机的排气能量,通过台架试验,获得了变工况下柴油机排气余热能分布特性。分析了有机工质蒸发压力、过热度以及柴油机工况变化对有机朗肯循环系统性能的影响,以系统净输出功率和热效率为优化目标,确定了适用于有机朗肯循环系统的最佳蒸发压力。研究结果表明,当有机工质蒸发压力为1.8 MPa时,有机朗肯循环系统的净输出功率最大可以达到12.69kW,热效率可以达到11.19%;将有机工质加热至过热状态并不能明显提高有机朗肯循环系统的净输出功率。