EVS28KINTEX, Korea, May 3-6, 2015
Centrifugal Air Compressor for Fuel Cell Electric Vehicle
Kyungseok Cho1, Hyunsup Yang2 , Chiyong Park3
Changha Lee4·Chi Myung Kim51,2,3Halla Visteon Climate Control Corp., 95, Sinilseo-ro, Daedeok-gu, Daejeon, Korea
4,5 Hyundai Motor Group,17-5Mabuk-ro #240, Giheung-gu, Yongin-si,Gyeonggi-do, 446-716, Korea
Contents
I. Introduction1. Balance of Plant & Air Compressor 2. Selection of Air Compressor Type
II. Low Noise & High Performance Air Compressor1. Structure of Centrifugal Air Compressor2. Design Process of Air Compressor2. Design Process of Air Compressor3. Surge Margin improvement using CFD4. Rotor dynamic optimization techniques 5. Improvement of Structure Resonance6. Significant improvement in NVH performance
III. Conclusion
2
ExhaustExhaust
Air intakeAir intake
Air Provide SystemAir Provide System
Humidifier
Balance of Plant & Air Compressor
3
Water Pump
Thermal managementThermal managementRadiator
3-way Valve
H2 Tank
ExhaustExhaust
HydrogenHydrogenHydrogen SupplyHydrogen Supply
Fuel Cell Stack
Selection of Air Compressor Type
Ø Decision making - No oil mist*/High efficiency/Low noise & vibration/Low cost/Compact size
Type CentrifugalCentrifugal Displacement
Shape
* Oil mist contamination is a major cause of fuel cell degradation
4
Shape
Oil mist X O O
Efficiency High Even Low
Cost/Size Good Bad Bad
Vibration/Noise Good Bad Bad
BLDC Motor-Rotor
BLDC Motor-Stator
Centrifugal compressor- Impeller
Structure of Centrifugal Air Compressor
5
Inlet Duct
Centrifugal compressor- Volute
• Centrifugal compressor – compresses and pressurizes air, as per vehicle require• Brushless DC motor – converts electric energy into axial power for the compressor
Design Process of Air Compressor
[Aerodynamic Design] [Motor Design] [Power Electronics Simulation]
6
[Rotor Dynamic Analysis] [Mechanical Design & Structure Analysis] [Test Performance & Nosie]
Surge Margin improvement using CFD
[CFD Modeling & Analysis]
DecreaseAir flow loss
Inlet Air flowLoss
7
Stall
DecreasedUnstable air flow
[CFD Modeling & Analysis]
[Meridian Plane]
[Blade to Blade (span 0.9)]
Proto Sample
Improved Sample
Rotor dynamic optimization techniques
[Analysis Model]
Rigid 2nd mode
Rigid 1st mode
766Hz(46,000RPM)
8
[Critical Speed of Air Compressor]
[Rotor Structure]
ü Weight Reductionü Length Reductionü Increase Shaft Stiffness
Prototype Improved1st Mode 41,012RPM 45,672RPM
2nd Mode 89,000RPM 115,496RPM
[Critical Speed Map]
Improvement of Structure Resonance
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[Vibration Characteristic at Volute]
[Impact Test Result at Rear Support]
Significant improvement in NVH performance
1X
3X
[Proto Sample Noise]
StructureResonance
10
[Test Bench & Setup for Noise Measurement][Improved Sample Noise]
[DER Noise Level in Vehicle][Noise Test in vehicle]
Conclusion
u Centrifugal type Air Compressor has advantage in- High Efficiency - Low Noise level
u Surge Margin improvement using CFD- Impeller Angle - Volute Development Angle
To meet MHG’s NVH level specifications, HVCC conduct
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u To meet MHG’s NVH level specifications, HVCC conduct- High Speed Motor Electro-magnetic field optimization - Rotor dynamic optimization techniques - Improvement of Structure Resonance
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