载运工具用燃料电池空气压缩机技术综述

欧凯; 胡皓文; 吴雨衡; 郭轩; 杨新荣; 张前; 马明辉; 王亚雄

doi:10.19818/j.cnki.1671-1637.2025.01.005

载运工具用燃料电池空气压缩机技术综述

doi: 10.19818/j.cnki.1671-1637.2025.01.005

1.
福州大学机械工程及自动化学院，福建福州 350108
2.
河北金士顿科技有限责任公司，河北辛集 052360
3.
中汽研新能源汽车检验中心(天津)有限公司，天津 300300

基金项目:

国家重点研发计划 2022YFB4004200

详细信息

作者简介:
欧凯(1990-)，男，福建南平人，福州大学副教授，工学博士，从事氢燃料电池汽车技术研究

通讯作者:
王亚雄(1988-)，男，湖北宜城人，福州大学教授，工学博士

中图分类号: U469.72
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出版历程
- 收稿日期: 2024-03-21
- 刊出日期: 2025-02-25

Review on technologies of fuel cell air compressors for vehicles

1.
School of Mechanical Engineering and Automation, Fuzhou University, Fuzhou 350108, Fujian, China
2.
Hebei Kingston Technology Co., Ltd., Xinji 052360, Hebei, China
3.
CATARC New Energy Vehicle Test Center (Tianjin) Co., Ltd., Tianjin 300300, China

Funds:

National Key R&D Program of China 2022YFB4004200

More Information

Corresponding author: WANG Ya-xiong(1988-), male, professor, PhD, yxwang@fzu.edu.cn

Article Text (Baidu Translation)

摘要

摘要: 从性能需求与技术现状等角度，综述了载运工具用燃料电池空气压缩机的研究进展，总结了离心式空气压缩机的关键部件参数优化设计、机电耦合控制、加工制造和性能测试等技术，并展望了燃料电池空气压缩机技术未来的发展方向。研究结果表明：燃料电池空气压缩机需满足大流量与快速响应等要求；当前，两级离心式空气压缩机流量与压力等特性可满足5~350 kW燃料电池系统供氧需求，最高转速可达1.0×10⁵ r·min^-1，零转速到怠速的响应时间为秒级；叶轮、扩压器、箔片气体动压轴承等关键部件的参数可采用优化算法进行设计以提高空气压缩机气动性能；为降低驱动电机的转速与转矩波动，离心式空气压缩机机电耦合控制可采用电流环解耦控制和无传感控制等方法以提高空气压缩机的动态响应能力；为保证离心式空气压缩机高速运转下的气动性能和系统稳定性，高精度三元叶轮加工主要通过五轴数控机床铣削实现，箔片气体动压轴承的涂层常采用固体润滑与等离子喷射工艺；燃料电池空气压缩机还需开展流量、压比、效率等特性与启停、寿命等耐久性的指标测试以综合评价其性能；目前，空气压缩机气动性能测试标准与试验方法较为完备，但耐久性相关的测试和评价方法还需进一步完善；未来，随着对可持续交通解决方案需求的不断增长，载运工具用燃料电池空气压缩机技术将朝着集成轻量化与智能化等方向发展。
- 载运工具 /
- 燃料电池 /
- 空气压缩机 /
- 需求分析 /
- 优化设计 /
- 机电耦合控制
Abstract: The research progress of fuel cell air compressors for vehicles was reviewed from the aspects of performance requirements and technology status. The technologies of key components parameter optimization design, electromechanical coupling control, manufacturing and performance testing of centrifugal air compressors were summarized. The future development directions of fuel cell air compressor technologies were prospected. Research results show that fuel cell air compressors need to meet the requirements of large flow rate and fast response. At present, the flow and pressure characteristics of the two-stage centrifugal air compressor can meet the oxygen supply requirements of the 5-350 kW fuel cell system. The maximum speed of the compressor can reach 1.0×10⁵ r·min^-1, and the response time from zero speed to idle speed is seconds. The parameters of key components such as impeller, diffuser and foil gas dynamic pressure bearing can be designed by optimization algorithm to improve the aerodynamic performance of air compressor. In order to reduce the speed and torque fluctuation of drive motor, current loop decoupling control and sensorless control can be used in the electromechanical coupling control of centrifugal air compressor to improve the dynamic response ability of the compressor. In order to ensure the aerodynamic performance and system stability of centrifugal air compressor in high-speed operation, high-precision ternary impeller machining is mainly realized by milling with five-axis computer numerical control machine tool, and the coating of foil gas dynamic pressure bearing usually adopts solid lubrication and plasma injection technology. In order to comprehensively evaluate the performance of fuel cell air compressors, it also need to carry out characteristic test such as flow, pressure ratio and efficiency and durability indicator test such as start-stop and life. At present, the test standards and methods of air compressor aerodynamic performance are relatively complete, but the test and evaluation methods related to durability need to be further improved. In the future, with the growing demand for sustainable transportation solutions, fuel cell air compressor technologies for vehicles will be developed in lightweight and intelligent direction.
- vehicle /
- fuel cell /
- air compressor /
- demand analysis /
- optimization design /
- electromechanical coupling control

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图 1 燃料电池系统用空压机流量与压力计算流程

Figure 1. Calculation process of flow and pressure of fuel cell system used air compressor

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图 2 港口物流用燃料电池重卡运行工况

Figure 2. Operation condition of fuel cell heavy truck for port logistics

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图 3 瑞典Södertälje-Norrköping高速公路燃料电池重卡运行工况

Figure 3. Operation condition of fuel cell heavy truck on Södertälje-Norrköping Highway in Sweden

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图 4 郑州市公交车运行工况

Figure 4. Operation condition of bus in Zhengzhou City

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图 5 中国重型商用车辆行驶工况

Figure 5. China heavy-duty test cycles

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图 6 不同CHTC下动力系统功率需求

Figure 6. Power requirements of power system under different CHTCs

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图 7 城市道路循环工况

Figure 7. Urban dynamometer driving schedule

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图 8 印度城际客运列车运行工况

Figure 8. Operation condition of India intercity passenger trains

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图 9 船舶典型运行工况

Figure 9. Typical operation condition of ships

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图 10 不同CHTC下燃料电池系统用空压机流量和压比

Figure 10. Flows and pressure ratios of fuel cell system used air compressor under different CHTCs

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图 11 22 kW两级离心式空压机流量和压比

Figure 11. Flows and pressure ratios of 22 kW two-stage centrifugal air compressor

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图 12 空压机分类

Figure 12. Classification of air compressors

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图 13 离心式空压机气动零部件结构

Figure 13. Structures of aerodynamic components of centrifugal air compressor

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图 14 两级离心式空压机结构

Figure 14. Structure of two-stage centrifugal air compressor

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图 15 透平离心式空压机结构

Figure 15. Structure of turbine centrifugal air compressor

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图 16 离心式空压机关键部件设计参数

Figure 16. Design parameters of key components of centrifugal air compressor

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图 17 离心式空压机扩压器

Figure 17. Diffuser of centrifugal air compressor

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图 18 箔片气体动压轴承

Figure 18. Foil gas dynamic pressure bearings

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图 19 离心式空压机的叶轮参数多目标优化流程

Figure 19. Multi-objective optimization flow of impeller parameters of centrifugal air compressor

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图 20 离心式空压机的叶轮数值模拟流程

Figure 20. Numerical simulation flow of centrifugal air compressor impeller

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图 21 典型电压源逆变器电路拓扑

Figure 21. Typical voltage source inverter circuit topology

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图 22 多电平电压源逆变器电路拓扑

Figure 22. Multilevel voltage source inverter circuit topology

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图 23 PAM控制原理

Figure 23. PAM control principle

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图 24 模型参考自适应系统

Figure 24. Model reference adaptive system

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图 25 等离子喷涂工艺工作原理

Figure 25. Working principle of plasma spraying process

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图 26 氢燃料电池离心式空压机启停性能测试工况

Figure 26. Start-stop performance test condition of centrifugal compressor in hydrogen fuel cell

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表 1 近年来国内代表性燃料电池商用车

Table 1. Domestic representative fuel cell commercial vehicles in recent years

类型	车辆名称	制造商	动力系统
燃料电池重卡	FSQ4250SFFCEV型燃料电池半挂牵引车	佛山市飞驰汽车科技有限公司	质子交换膜燃料电池+ 锰酸锂电池；驱动电机峰值功率为355 kW，额定功率为198 kW
	ZKH3310P6FCEV1型燃料电池自卸汽车	郑州宇通集团有限公司	质子交换膜燃料电池+ 锰酸锂蓄电池；驱动电机额定功率为200 kW，峰值功率为400 kW
	BJ4189FCEVPH型燃料电池半挂牵引车	北汽福田汽车股份有限公司	氢燃料电池+磷酸铁锂电池；驱动电机额定功率为220 kW，峰值功率为360 kW
	CA3310P66L4T4FCEV型燃料电池自卸汽车	中国第一汽车集团有限公司	质子交换膜电池+磷酸铁锂电池；驱动电机峰值功率为360 kW
燃料电池客车	BJ6126FCEVUH-N1型燃料电池客车	北京福田欧辉新能源汽车有限公司	氢燃料电池系统+磷酸铁锂电池；额定功率为110 kW
	XML6855JFCEVJ0CL型燃料电池城市客车	厦门金龙旅行车有限公司	质子交换膜燃料电池系统+磷酸铁锂电池；驱动电机额定功率为90 kW，峰值功率为188 kW
	LCK6106FCEVGF1型燃料电池低入口城市客车	中通客车股份有限公司	质子交换膜燃料电池+ 磷酸铁锂蓄电池；驱动电机峰值功率为200 kW

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表 2 某型号12 t重型卡车主要参数

Table 2. Main parameters of a 12 t heavy truck

整备质量/kg	旋转部件等效质量/kg	滚动阻力系数	迎风面积/m²	空气阻力系数
12 000	1 200	0.012	6.06	0.7

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表 3 商用离心式空压机气动性能水平

Table 3. Aerodynamic performance levels of commercial centrifugal air compressors

类型	公司	型号	最高压缩比	额定流量/(g·s^-1)	电机功率/kW
单级	金通灵	FC150-20+	3.0	150	21.0
单级	施宾德斯	S26	3.5	200	25.6
两级	金士顿	TCC120	3.8	140	23.0
	势加透博	XT-FCC400	3.6	144	22.0
	海德韦尔	HEC15	3.5	160	20.0
	毅合捷	ELD-FCC3010001	3.4	180	26.0
	优社动力	YF30	3.2	180	30.0
透平	金士顿	TMC-120	3.0	140	16.2
	势加透博	XT-FCTC500	4.0	200	22.5
	海德韦尔	VSEC15	3.1	220	20.0
	优社动力	YF30T	2.6	150	30.0
	蜂巢蔚领	VF20(T)	3.5		20.0

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表 4 商用离心式空压机动态响应水平

Table 4. Dynamic response levels of commercial centrifugal air compressors

公司	型号	适用燃料电池功率/kW	响应时间/s
东德实业	DK系列	5~230	静止到怠速为1.0
毅合捷	ELD-FCB0104001	2	静止到怠速小于0.9；怠速到额定点小于3.0
	ELD-FCC0410001	13~20	0→3.0×10⁴ r·min^-1小于1.0；3.0×10⁴→0 r·min^-1小于1.0；3.0×10⁴→1.0×10⁵ r·min^-1小于1.0；1.0×10⁵→3.0×10⁴ r·min^-1小于1.0
	ELD-FCC3010001	100~150	0→3.0×10⁴ r·min^-1小于1.0；3.0×10⁴→0 r·min^-1小于0.6；3.0×10⁴→1.0×10⁵ r·min^-1小于1.5；1.0×10⁵→3.0×10⁴ r·min^-1小于1.4
	ELD-FCC4510001	150~260
蜂巢蔚领	VF系列	5~350	静止到怠速小于0.5；怠速到95%转速最快0.7

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表 5 无传感器控制算法对比

Table 5. Comparison of sensorless control algorithms

方法	优点	缺点
模型参考自适应	简单，易于实现，稳定性好	可调的自适应模型难以建立
滑模观测器	快速响应，鲁棒性强	对系统模型准确性要求较高，滑模面设计困难

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表 6 叶轮加工制造方案

Table 6. Processing and manufacturing schemes of impeller

类型	方法	原理	优势	劣势
减材制造	五轴数控机床铣削	联动控制五个坐标轴的运动，实现对工件在多个角度和方向上的切削	复杂曲面加工，加工柔性高，精度高，可靠性高且加工过程稳定	高成本，加工周期长，材料浪费多，存在干涉风险
	数控电火花	通过脉冲放电击穿电极和工件绝缘介质生产火花放电，去除零件多余材料	复杂形状加工，高精度加工，适合于导电材料	加工效率低，表面质量差，材料选择局限
	电解加工	通过极间电场的作用实现阳极金属材料溶解或氧化	无宏观切削力，复杂形状加工，加工精度高	加工过程复杂，阴极设计难度大，加工速度慢
增材制造	精密焊接	将焊接能量集中到小尺寸的焊接区域，以实现高精度的连接	速度快，高精度，适用多种材料	成本高，接头可视性差，难以处理大尺寸工件
增材制造	3D打印	将三维模型按其截面形状进行分层，通过逐层增加材料实现零件制造	加工柔性高，不受零件形状，工装夹具等的限制，材料利用率高	受零件尺寸限制，成形精度差，产品强度不足

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表 7 箔片气体动压轴承涂层性能对比

Table 7. Comparison of coating properties of foil gas dynamic pressure bearing

涂层	区域	喷涂法	优势	劣势
PS系列	转子表面	等离子喷涂	高温减摩性好	室温摩擦性能差
类金刚石膜		磁控溅射	高硬度，低摩擦因数，热稳定性好	附着性限制，成本高
Korolon TM系列	顶箔表面	空气喷涂法	低摩擦因数，耐磨损	制备复杂，成本高

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表 8 离心式空压机测试规范与标准

Table 8. Test specifications and standards of centrifugal air compressor

序号	适用方法	发布单位	内容
1	《透平压缩机性能试验规程》(GB/T 25630—2010)	中华人民共和国国家质量监督检验检疫总局与中国国家标准化管理委员会	规定了所有型式的透平压缩机进行流量、功率、功耗、压力、温度等性能指标试验时的准备、过程与评定
2	《氢燃料电池发动机用离心式空气压缩机性能试验方法》(T/CSAE 187—2021)	中国汽车工程学会	规定了氢燃料电池电动汽车使用的工作特性试验装置要求、一般性能、工作特性、安全性、环境适应性、噪声、耐久等性能试验方法
3	《燃料电池发动机用空气压缩机》(QC/T 1207—2024)	中华人民共和国工业和信息化部	规定了燃料电池空压机的技术要求、环境适应性与耐久性试验方法
4	《燃料电池电动汽车用空气压缩机试验方法》(T/CAAMTB 13—2020)	中国汽车工业协会	规定了燃料电池电动汽车用空压机的气动性能、环境适应性与耐久性试验方法
5	《氢燃料电池用离心式空压机》(T/CSTE 0076—2020)	中国技术经济学会	规定了氢燃料电池用离心式空压机的一般要求、性能要求、安全性、环境适应性与耐久等性能试验方法
6	Acoustics—Noise Test Code for Compressors and Vacuum Pumps—Engineering Method (Grade 2)(ISO 2151: 2004 EN)	国际标准化组织	规定了便携式与固定式压缩机及真空泵噪声排放的测量、计算和声明方法和测量的安装、负载和工作条件
7	《往复式内燃机声压法声功率级的测定第3部分：半消声室精密法》(GB/T 1895.3—2015)	中华人民共和国国家质量监督检验检疫总局与中国国家标准化管理委员会	规定了往复式内燃机声压法声功率级的测定方法——半消声室精密法
8	Compressed Air—Part 1: Contaminants and Purity Classes (ISO 8573-1: 2010 EN)	国际标准化组织	规定了压缩空气相对于颗粒、水和油的纯度等级，与规定或测量空气的压缩空气系统的位置无关
9	Compressed Air Contaminant Measurement—Part 2: Oil Aerosol Content (ISO 8573-2: 2018 EN)	国际标准化组织	规定了通常存在于压缩空气中的液体油和油气溶胶的取样和定量分析的试验方法
10	Compressed Air—Part 5: Test Methods for Oil Vapour and Organic Solvent Content (ISO 8573-5: 2001 EN)	国际标准化组织	规定了用于测定压缩空气中油蒸气(6个及以上碳原子的碳氢化合物)含量的气相色谱测试方法

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表 9 商用离心式空压机启停性能

Table 9. Start-stop performances of commercial centrifugal air compressors

类型	公司	型号	电堆功率/kW	启停次数/10⁴
单级	金通灵	FC150	150	10
两级	海德韦尔	HEC ©	120	20
	势加透博	FCC300	150	10
	蜂巢蔚领	VF60	200~300	30
	优社动力	YF50	150~210	15
	毅合捷	ELD-FCTC3010001	120~200	20
透平	蜂巢蔚领	VF25(T)	80~120	30
	蜂巢蔚领	VF50(T)	140~220	30
	优社动力	YF30T	90~150	15

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表 10 离心式空压机耐久性能

Table 10. Durabilities of centrifugal air compressors

类型	公司	型号	电堆功率/kW	工况	寿命/h
两级	优社动力	YF50	150~210	交变	>20 000
两级	势加透博	FCC	30~140	NEDC	>12 000
透平	海德韦尔	VSEC30	80~300		>5 760
透平	蜂巢蔚领	VF50(T)	140~220		>20 000

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