Optimal design method for fiber winding layup of plastic liner high-pressure hydrogen storage cylinders

Abstract

The present invention belongs to the field of reliability design and calculation of plastic liner high-pressure hydrogen storage cylinders, and specifically discloses a method for optimizing the design of fiber winding layers of plastic liner high-pressure hydrogen storage cylinders. The high-pressure hydrogen storage cylinder is composed of a plastic liner and a composite material layer wound around the outside of the plastic liner, and the composite material layer includes a circumferential winding layer and a spiral winding layer. Based on a full disclosure of the influence of the winding parameters of the composite material layer on the bearing capacity of the cylinder, the present invention adjusts and optimizes the spiral winding angle, the number of spiral winding layers, the number of circumferential winding layers, and the order of spiral winding layers and circumferential winding layers, so that the bearing capacity of the plastic liner high-pressure hydrogen storage cylinder is improved and the fiber usage is reduced, thereby achieving the purpose of optimization and lightweighting, and realizing the improvement of the reliability of the high-pressure hydrogen storage cylinder and the reduction of the manufacturing cost.

Description

Technical Field

[0001] The present invention belongs to the field of reliability design and calculation of plastic liner high-pressure hydrogen storage cylinders, and in particular relates to an optimization design method for fiber winding layers of plastic liner high-pressure hydrogen storage cylinders. Background Art

[0002] Since the Paris Agreement, countries have developed long-term low-carbon development strategies. The transportation sector has shown strong demand for a shift to more environmentally friendly vehicles, leading to strategies to adopt hydrogen fuel cell electric vehicles. General Motors, Toyota, Hyundai, Daimler, BMW, and other companies have invested in hydrogen fuel cell technology. Hydrogen can complement electricity, biofuels, and synthetic liquid fuels. It is one of the few energy carriers with the potential to provide a major share of the world's transportation energy needs, with near-zero greenhouse gas and air pollutant emissions. Hydrogen is increasingly viewed as a versatile future energy carrier that can fill diverse roles in the energy system. However, due to its gaseous nature, hydrogen faces challenging storage challenges. This storage issue may be the greatest obstacle to the success of the hydrogen economy. Therefore, resolving this issue is a key to the development of hydrogen energy.

[0003] Compared to metal hydrogen cylinders, plastic-lined composite high-pressure hydrogen storage cylinders offer advantages such as light weight, long lifespan, and low cost, making them a key focus and hotspot in the current development and manufacturing of gas cylinders. Currently, domestic research on plastic-lined composite high-pressure hydrogen storage cylinders is still in its infancy, plagued by lagging design experience, a lack of relevant theory, and immature composite layup optimization and lightweight design methods. Therefore, optimizing and lightweighting composite layup based on understanding the influence of composite layup parameters on the cylinder's load-bearing capacity has important practical significance and engineering application value. Summary of the Invention

[0004] The purpose of the present invention is to provide an optimization design method for fiber winding plies of plastic liner high-pressure hydrogen storage cylinders, which effectively solves the problem of immature domestic optimization design and lightweight design methods of composite material plies of plastic liner composite material high-pressure hydrogen storage cylinders.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0006] A method for optimizing the fiber winding layup of a plastic liner high-pressure hydrogen storage cylinder is disclosed. The method is applied to the high-pressure hydrogen storage cylinder. The high-pressure hydrogen storage cylinder comprises a plastic liner and a composite material layup wound around the plastic liner. The composite material layup comprises a hoop winding layer and a spiral winding layer. The method comprises the following steps:

[0007] S1. Study on the influence of the number of circumferential winding layers on the load-bearing capacity of high-pressure hydrogen storage cylinders.

[0008] ABAQUS software was used to model the hoop winding layer, and i groups of models were designed. The number of hoop winding layers in each group of models was i·n.

[0009] Add periodic boundary conditions and apply fixed constraints at the ends of the model to prevent rigid displacements.

[0010] The maximum stress in the fiber direction of the hoop winding layer and the maximum stress in the direction perpendicular to the fiber of each group of models were calculated and output, and the changing patterns of the maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber as the number of hoop winding layers increased were analyzed.

[0011] S2. Study on the influence of the number of spiral winding layers on the carrying capacity of high-pressure hydrogen storage cylinders.

[0012] ABAQUS software was used to model the plastic liner and spiral winding layers. A certain spiral winding angle θ was set, and k groups of models were designed. The number of spiral winding layers in each group of models was k·l.

[0013] The outer surface of the plastic liner is bound to the inner surface of the spirally wound layer, periodic boundary conditions are added, and fixed constraints are applied at the ends of the model to prevent rigid displacement. A certain internal pressure value p is applied for calculation, and the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction of the spirally wound layer of each group of models are calculated and output. The variation patterns of the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction with the increase of the number of spirally wound layers are analyzed respectively.

[0014] S3. Study on the influence of spiral winding angle on the carrying capacity of high-pressure hydrogen storage cylinders.

[0015] ABAQUS software was used to model the plastic liner and spiral winding layer. m spiral winding layers were set, and t groups of models with varying spiral winding angles were set. The spiral winding angle of each group of models was t·α.

[0016] The outer surface of the plastic liner is bound to the inner surface of the spirally wound layer, periodic boundary conditions are added, and fixed constraints are applied at the ends of the model to prevent rigid displacement. A certain internal pressure value p is applied for calculation, and the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction of each group of models are calculated and output. The variation patterns of the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction with the increase of the spiral winding angle are analyzed respectively.

[0017] S4. Study on the influence of the winding sequence of the circumferential winding layer and the spiral winding layer on the load-bearing capacity of the high-pressure hydrogen storage cylinder.

[0018] ABAQUS software was used to model the high-pressure hydrogen storage cylinder and set the spiral winding angle θ.

[0019] There are three winding modes: x layers of spiral winding + y layers of hoop winding, y layers of hoop winding + x layers of spiral winding, and layer + hoop winding layer y layer + spiral winding layer layer.

[0020] The outer surface of the plastic liner is bound to the inner surface of the winding layer, periodic boundary conditions are added, and fixed constraints are applied to the ends of the model to prevent rigid displacement. A certain internal pressure value p is applied for calculation, and the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction of each group of models are calculated and output. The magnitude and position of the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction are analyzed respectively.

[0021] S5. Preliminary design of composite material layup.

[0022] According to the design pressure of the high-pressure hydrogen storage cylinder, the number of circumferential winding layers, the number of spiral winding layers and the spiral winding angle of the composite material are preliminarily designed.

[0023] S6. Optimal design of composite material layup.

[0024] The spiral winding angle is further designed to change layer by layer so that the thickness of the composite material layer near the pole holes at both ends of the high-pressure hydrogen storage cylinder is continuous.

[0025] S7. Lightweight design of composite material layup.

[0026] Based on the winding parameter influence results of steps S1, S2, S3 and S4, the optimal winding layer distribution range, the optimal spiral winding angle and the appropriate winding sequence are obtained, and the number of circumferential winding layers, the number of spiral winding layers, the spiral winding angle and the winding sequence of the circumferential winding layers and the spiral winding layers are further optimized.

[0027] Furthermore, in step S1, a 1 / 4 model is used for modeling.

[0028] Furthermore, in steps S2, S3 and S4, a 1 / 36 model is used for modeling.

[0029] The beneficial technical effects of the present invention are:

[0030] (1) The present invention reduces the total number of winding layers by optimizing the number of circumferential winding layers, the number of spiral winding layers, the spiral winding angle, and the winding sequence of the circumferential winding layers and the spiral winding layers, thereby achieving the purpose of lightweighting the high-pressure hydrogen storage cylinder, reducing the number of composite material layup layers, and thus reducing costs.

[0031] (2) The present invention clarifies the influence of the winding parameters of the composite material layer on the load-bearing capacity of the high-pressure hydrogen storage cylinder, making the optimization design process of the high-pressure hydrogen storage cylinder more convenient, easier to understand, and easy to fine-tune the winding parameters, thereby improving the reliability of the high-pressure hydrogen storage cylinder.

[0032] (3) The present invention has clear steps and simple operation, which is convenient for engineers to operate. In addition, the present invention is not limited to high-pressure hydrogen storage cylinders of a specific volume and size and has universal applicability.

[0033] (4) The present invention only relies on one finite element calculation software and does not require excessive software support, which is convenient for application. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0035] Figure 1 The grid and boundary conditions of the 1 / 4 finite element model of the 10-layer hoop-wound layer of the high-pressure hydrogen storage cylinder of the present invention;

[0036] Figure 2 The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction change curves with the increase of the number of circumferential winding layers;

[0037] Figure 3 The grid and boundary conditions of the 1 / 36 high-pressure hydrogen storage cylinder finite element model of the present invention;

[0038] Figure 4 The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction change curves with the increase of the number of spiral winding layers;

[0039] Figure 5 The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction change curves with the increase of the spiral winding angle, where (a) is the 7-layer winding model, (b) is the 14-layer winding model, (c) is the 21-layer winding model, (d) is the 28-layer winding model, and (e) is the 35-layer winding model.

[0040] Figure 6 It is a structural schematic diagram of the high-pressure hydrogen storage cylinder of the present invention. DETAILED DESCRIPTION

[0041] A method for optimizing the fiber winding layup of a plastic liner high-pressure hydrogen storage cylinder is disclosed. The method is applied to the high-pressure hydrogen storage cylinder. The high-pressure hydrogen storage cylinder comprises a plastic liner and a composite material layup wound around the plastic liner. The composite material layup comprises a hoop winding layer and a spiral winding layer. The method comprises the following steps:

[0042] S1. Study on the influence of the number of circumferential winding layers on the load-bearing capacity of high-pressure hydrogen storage cylinders.

[0043] Since the influence of the inner liner on the stress of the hoop winding layer can be ignored, only the hoop winding layer is established for simulation. The hoop winding layer is modeled using ABAQUS software. Since the structure is a rotationally symmetric model, a 1 / 4 model is used for convenience of calculation.

[0044] Set the number of circumferential winding layers to 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 and 80 layers, a total of 16 groups; add periodic boundary conditions, and apply fixed constraints at the ends of the model to prevent rigid displacement, such as Figure 1 shown.

[0045] The maximum stress S11 in the fiber direction of the hoop winding layer and the maximum stress S22 in the perpendicular fiber direction of each model are calculated and output; the variation of the maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction with the increase of the number of hoop winding layers are analyzed respectively, such as Figure 2 As shown in the figure, with the increase of the number of circumferential winding layers, the maximum stress in the fiber direction and the perpendicular fiber direction gradually decreases. In the early stage of increasing the number of winding layers, the stress decreases significantly. When the number of winding layers reaches 30, the stress decreases more gradually with the increase of the number of layers.

[0046] S2. Study on the influence of the number of spiral winding layers on the carrying capacity of high-pressure hydrogen storage cylinders.

[0047] The plastic liner and spiral winding layer are modeled using ABAQUS software. Since the structure is a rotationally symmetrical model, a 1 / 36 model is used for ease of calculation. Figure 3 shown.

[0048] Set a certain spiral winding angle θ, such as 10°; set the number of spiral winding layers to 7, 14, 21, 28, 35, 42, and 50 layers, totaling 7 groups; set the internal pressure to 20 MPa; bind the outer surface of the plastic liner to the inner surface of the spiral winding layer; add periodic boundary conditions, and apply fixed constraints at the ends of the model to prevent rigid displacement.

[0049] The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction of the spiral winding layer of each group of models are calculated and output; the variation of the maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction with the increase of the number of spiral winding layers are analyzed respectively, such as Figure 4 It is found that with the increase of the number of spiral winding layers, the maximum stress in the fiber direction and the perpendicular fiber direction gradually decreases. In the early stage of increasing the number of winding layers, the stress decreases significantly. When the number of winding layers reaches 35, the stress decreases more slowly with the increase of the number of layers.

[0050] S3. Study on the influence of spiral winding angle on the carrying capacity of high-pressure hydrogen storage cylinders.

[0051] ABAQUS software was used to model the plastic liner and spiral winding layer. Since the structure is a rotationally symmetric model, a 1 / 36 model was used for modeling for the convenience of calculation. Five models were set with 7, 14, 21, 28 and 35 spiral winding layers respectively. For each model, the spiral winding angles were set to 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75° and 80°, totaling 15 groups of angle settings. The internal pressure was set to 20 MPa. The outer surface of the plastic liner was bound to the inner surface of the spiral winding layer. Periodic boundary conditions were added, and fixed constraints were applied at the ends of the model to prevent rigid displacement.

[0052] The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction of each group of models are calculated and output; the variation of the maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction with the increase of the spiral winding angle are analyzed respectively, as shown in FIG. Figure 5 As shown in the figure, it was found that as the winding angle increases, the maximum stress in the fiber direction and perpendicular to the fiber direction changes in a basically consistent manner at different winding layers. Therefore, taking 28 layers of spiral winding as an example to illustrate the influence of the law, as the winding angle increases, the maximum stress in the fiber direction S11 first decreases and then increases. The maximum stress in the perpendicular to the fiber direction S22 is basically stable before the winding angle reaches 60°, and then gradually increases after 60° with a large fluctuation range.

[0053] S4. Study on the influence of the winding sequence of the circumferential winding layer and the spiral winding layer on the load-bearing capacity of the high-pressure hydrogen storage cylinder.

[0054] ABAQUS software is used to model the high-pressure hydrogen storage cylinder. Since the structure is a rotationally symmetric model, a 1 / 36 model is used for convenience of calculation.

[0055] Select a spiral winding angle of 50°; set three winding methods, namely 14 spiral winding layers + 21 circumferential winding layers, 21 circumferential winding layers + 14 spiral winding layers, and 7 spiral winding layers + 21 circumferential winding layers + 7 spiral winding layers; set the internal pressure to 20 MPa; bind the outer surface of the plastic liner to the inner surface of the winding layer; add periodic boundary conditions, and apply fixed constraints at the ends of the model to prevent rigid displacement.

[0056] The maximum stress S11 in the fiber direction and the maximum stress S22 in the perpendicular fiber direction of each model were calculated and output; the magnitude and position of the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction were analyzed respectively, as shown in Table 1 and Table 2. It was found that the maximum S11 of the three winding sequences all appeared at the transition point of the head 1 cylinder, and the maximum S22 all appeared in the middle of the head 1. Among them, the winding method of 21 layers of circumferential winding layer + 14 layers of spiral winding layer had the smallest maximum S11 and maximum S22 values. The position of the head 1 is shown in Figure 6 .

[0057] Table 1 Stress distribution results of spiral winding layers of different winding sequence models

[0058]

[0059] Table 2 Stress distribution results of the hoop winding layer of different winding sequence models

[0060]

[0061] S5. Preliminary design of composite material layup;

[0062] Based on the stress of the high-pressure hydrogen storage cylinder, the number of circumferential winding layers, the single spiral winding angle, and the number of spiral winding layers of the composite material were preliminarily designed, as shown in Table 3.

[0063] Table 3 Preliminary design of composite material layup

[0064]

[0065] S6. Optimal design of composite material layup;

[0066] The angle of the spiral winding layer is gradually changed, and the angle of the spiral winding at different levels is designed to make the thickness of the composite material layer near the pole hole 2 at both ends of the high-pressure hydrogen storage cylinder continuous, avoiding the accumulation of layers and local excessive thickness. The winding method is shown in Table 4. The position of the pole hole 2 is shown in Table 4. Figure 6 .

[0067] Table 4 Optimization design of composite material layup

[0068]

[0069] S7. Lightweight design of composite material layup.

[0070] Based on the results of the winding parameter impact in steps S1, S2, S3, and S4, we further optimized the number of circumferential and spiral winding layers, the number of spiral winding layers, the spiral winding angle, and the winding sequence of the circumferential and spiral winding layers. The load-bearing capacity and total number of winding layers of each solution were compared, and the final winding solution is shown in Table 5. This approach achieved a lightweight design for the high-pressure hydrogen storage cylinder, reduced the number of composite layups, and thus lowered costs.

[0071] Table 5 The best optimization scheme for reducing the total number of winding layers

[0072]

[0073]

[0074] Based on a full disclosure of the influence of the winding parameters of the composite material plies on the load-bearing capacity of the high-pressure hydrogen storage cylinder, the present invention adjusts and optimizes the spiral winding angle, the number of spiral winding layers, the number of circumferential winding layers, and the sequence of spiral winding layers and circumferential winding layers, so as to achieve the purpose of optimization and lightweighting, and realize the improvement of the reliability of the hydrogen storage cylinder and the reduction of the manufacturing cost.

[0075] Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions or substitutions made by technicians in this technical field within the essential scope of the present invention should also fall within the scope of protection of the present invention.

Claims

1. A method for optimizing the fiber winding layer of a plastic liner high-pressure hydrogen storage cylinder, applied to a high-pressure hydrogen storage cylinder, wherein the high-pressure hydrogen storage cylinder comprises a plastic liner and a composite material layer wound around the plastic liner, wherein the composite material layer comprises a hoop winding layer and a spiral winding layer, and wherein: The following steps are involved: S1. Study on the influence of the number of hoop winding layers on the load-bearing capacity of high-pressure hydrogen storage cylinders; ABAQUS software was used to model the hoop winding layer, and i groups of models were designed. The number of hoop winding layers in each group of models was i·n. Add periodic boundary conditions and apply fixed constraints at the ends of the model to prevent rigid displacement; The maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction of each model group are calculated and output, and the variation patterns of the maximum stress in the fiber direction and the maximum stress in the perpendicular fiber direction with the increase of the number of hoop winding layers are analyzed respectively. S2. Study on the influence of the number of spiral winding layers on the carrying capacity of high-pressure hydrogen storage cylinders; The plastic liner and spiral winding layer were modeled using ABAQUS software. A certain spiral winding angle θ was set, and k groups of models were designed. The number of spiral winding layers in each group was k·l. The outer surface of the plastic liner was bound to the inner surface of the spirally wound layer, periodic boundary conditions were added, and fixed constraints were applied to the ends of the model to prevent rigid displacement. A certain internal pressure value p was applied for calculation. The maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber of each model group were calculated and output. The variation of the maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber were analyzed respectively as the number of spirally wound layers increased. S3. Study on the influence of spiral winding angle on the load-bearing capacity of high-pressure hydrogen storage cylinders; The plastic liner and spiral winding layer were modeled using ABAQUS software. m spiral winding layers were set, and t groups of models with varying spiral winding angles were set. The spiral winding angle of each group of models was t·α. The outer surface of the plastic liner was bound to the inner surface of the spirally wound layer, periodic boundary conditions were added, and fixed constraints were applied to the ends of the model to prevent rigid displacement. A certain internal pressure value p was applied for calculation. The maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber were calculated and output for each group of models. The variation patterns of the maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber were analyzed as the spiral winding angle increased. S4. Study on the influence of the winding sequence of the hoop winding layer and the spiral winding layer on the load-bearing capacity of the high-pressure hydrogen storage cylinder; ABAQUS software was used to model the high-pressure hydrogen storage cylinder and set the spiral winding angle θ; There are three winding modes: x layers of spiral winding + y layers of hoop winding, y layers of hoop winding + x layers of spiral winding, and layer + hoop winding layer y layer + spiral winding layer layer; The outer surface of the plastic liner is bound to the inner surface of the winding layer, periodic boundary conditions are added, and fixed constraints are applied to the ends of the model to prevent rigid displacement. A certain internal pressure value p is applied for calculation. The maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber are calculated and output for each group of models. The magnitude and location of the maximum stress in the fiber direction and the maximum stress in the direction perpendicular to the fiber are analyzed respectively. S5. Preliminary design of composite material layup; According to the design pressure of the high-pressure hydrogen storage cylinder, the number of hoop winding layers, the number of spiral winding layers and the spiral winding angle of the composite material are preliminarily designed; S6. Optimal design of composite material layup; The spiral winding angle is further designed to change layer by layer to ensure that the thickness of the composite material layer near the pole holes at both ends of the high-pressure hydrogen storage cylinder is continuous; S7, lightweight design of composite material layup; Based on the winding parameter influence results of steps S1, S2, S3 and S4, the optimal winding layer distribution range, the optimal spiral winding angle and the appropriate winding sequence are obtained, and the number of circumferential winding layers, the number of spiral winding layers, the spiral winding angle and the winding sequence of the circumferential winding layers and the spiral winding layers are further optimized.

2. The optimization design method for fiber winding layer of plastic liner high pressure hydrogen storage cylinder according to claim 1 is characterized in that: In step S1, a 1 / 4 model is used for modeling.

3. The optimization design method for fiber winding layer of plastic liner high pressure hydrogen storage cylinder according to claim 2 is characterized in that: In steps S2, S3 and S4, a 1 / 36 model is used for modeling.

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