Research On Thermal Management Of The Direct Methanol Fuel Cell Range Extender Based On Pure Electric SUV

With the increasingly severe world energy crisis and increasing environmental pollution,new energy vehicles are becoming the mainstream in the world’s automotive industry.Among them,extended-range electric vehicles have become a research hotspot due to their lack of mileage anxiety.Many factors need to be considered in the arrangement of the range extender in a vehicle,among which the heat dissipation is one of the important factors that affect the performance and safety of the vehicle.Therefore,in this paper,a mass production pure electric SUV is used as the test vehicle,with the purpose of adding a direct methanol fuel cell range extender on it.By carrying out the thermal management research of the range extender on the test vehicle,a range extender layout scheme with reasonable heat dissipation is obtained to solve the problem that the vehicle cannot work normally because of the heating of the range extender after the range extender is added.Firstly,the feasibility of adding the range extender to the test vehicle is studied.Starting from the structure of the test vehicle,this paper studies the power line layout scheme of connecting the range extender to the power system of the test vehicle,and carries out charging and discharging tests of the power battery based on the selected scheme.The results show that the vehicle control strategy of the test vehicle allows the power battery to supply electric energy to the range extender and to obtain electric energy from the range extender,and the test vehicle can be equipped with range extender.Secondly,the range extender layout scheme is designed based on 3D design software.This paper first conducts a theoretical analysis on the heating of the stack and DC/DC,and determines the goal of the range extender layout design.Then the electrical equipment layout in the test vehicle is adjusted.And the range extender is selected to be arranged in the front compartment based on the available space and heat dissipation effect.A three-dimensional model of the front compartment and range extender components is established with CATIA.Then,based on the goal of the layout design,the model of the range extender components are assembled into the front compartment model in CATIA and the cooling system pipeline is drawn.A complete range extender layout scheme is obtained.Then,the range extender temperature field simulation is carried out and the range extender layout in the front compartment is optimized.Based on the front compartment assembly model,the temperature field of range extender is simulated with FLOEFD at the vehicle speed of 0km/h,30km/h and 60km/h.According to the simulation results,the layout scheme of the range extender is optimized,and the temperature field distribution of the range extender is re-simulated.The simulation results show that the heat generated by the optimized range extender has no effect on the normal operation of the vehicle,and the range extender layout design is reasonable for heat dissipation.Finally,the accuracy of the simulation conclusion is verified through the heating experiment of the range extender in real vehicle.In this paper,the direct methanol fuel cell range extender is arranged in the real vehicle according to the simulation layout scheme and the selected power line layout scheme,and the temperature of the range extender in the steady state is measured,which is compared with the simulation results.The experimental results show that the heat dissipation of the optimized range extender layout scheme is reasonable.The optimized range extender layout scheme can guide the installation of the direct methanol fuel cell range extender on the test vehicle.This paper provides guidance and reference for the application of direct methanol fuel cell range extender in mass-produced passenger vehicles,and will help promote the development of direct methanol fuel cell technology for vehicles.