Structure-electromagnetism collaborative optimization device of ultrahigh-speed permanent magnet motor driven centrifugal hydrogen circulating pump

Abstract

The invention relates to the technical field of collaborative design of ultra-high-speed motors and fluid machinery, in particular to a structure-electromagnetic collaborative optimization device of a centrifugal hydrogen circulating pump driven by an ultra-high-speed permanent magnet motor, which comprises an ultra-high-speed permanent magnet motor module consisting of a stator iron core, a permanent magnet rotor, a high-frequency inverter and a non-contact bearing, the permanent magnet rotor is rigidly connected with the centrifugal impeller, and the rotating speed of the rotor ranges from 80000 r / min to 200000 r / min; the centrifugal hydrogen pump module comprises a pump body, a three-dimensional flow channel impeller, a hydrogen sealing assembly and an inlet and outlet pressure sensor, an impeller blade profile is designed based on pneumatic-electromagnetic coupling simulation optimization, collaborative optimization of structure-electromagnetic parameters is achieved, an independently designed matching blind area is eliminated through an integrated controller, and under the working condition of 150000 r / min, the matching blind area of the three-dimensional flow channel impeller is controlled to be matched with the matching blind area of the three-dimensional flow channel impeller. The comprehensive efficiency of the system is improved by 8%-12%, and the vibration noise is reduced by 15-20 dB; when the hydrogen flow suddenly changes (0.5 kg / h to 3 kg / h), the cooperative adjustment time of the rotating speed of the motor and the opening degree of the guide vane of the impeller is smaller than or equal to 0.3 s, and surge and overload are effectively avoided.

Description

Technical Field

[0001] This application relates to the field of collaborative design technology of ultra-high speed motors and fluid machinery, specifically to a structure-electromagnetic collaborative optimization device for an ultra-high speed permanent magnet motor-driven centrifugal hydrogen circulation pump. Background Technology

[0002] Driven by the global energy transition and the "dual-carbon" goal, hydrogen energy, as a clean and efficient secondary energy source, has seen its key technologies across the industry chain become a focal point of competition among nations. The hydrogen circulation pump, a core component in fuel cell systems and hydrogen storage and transportation equipment, is responsible for pressurizing, circulating, and regulating the flow of hydrogen; its performance directly impacts system efficiency and safety. Ultra-high-speed permanent magnet motors, due to their high power density and wide speed range, have become an ideal choice for driving centrifugal hydrogen circulation pumps, significantly reducing equipment size and improving response speed.

[0003] In existing designs of centrifugal hydrogen circulation pumps driven by ultra-high-speed permanent magnet motors, structural design (such as impeller aerodynamic parameters, pump body flow channel morphology, and rotor support structure) and electromagnetic design (such as motor magnetic circuit topology, winding parameters, and loss suppression) typically adopt a step-by-step independent optimization model: first, the pump body structural parameters are determined based on fluid dynamics simulation; then, the electromagnetic scheme is designed based on motor theory; and finally, simple assembly is performed. For example, patent CN114584257A proposes a hydrogen circulation pump driven by an ultra-high-speed permanent magnet motor, but its core lies in the optimization of the motor cooling structure, without addressing the coordinated control of structural and electromagnetic parameters.

[0004] The existing technology has the following shortcomings:

[0005] The disconnect between structural and electromagnetic design leads to poor system matching: the rotor vibration caused by the aerodynamic load of the impeller is coupled with the electromagnetic force of the motor, which easily generates resonance noise, especially at ultra-high speed conditions above 100,000 r / min.

[0006] Independent optimization makes it difficult to balance multiple performance objectives: excessive pursuit of motor electromagnetic efficiency may lead to insufficient rotor stiffness, while strengthening the structural strength may increase magnetic circuit losses, thus restricting the overall efficiency improvement.

[0007] Insufficient dynamic adaptability: When hydrogen flow fluctuates, the dynamic matching between motor speed and pump operating conditions lags, which can easily lead to surge or electromagnetic overload, affecting the stability of the fuel cell system. Summary of the Invention

[0008] This application provides a structure-electromagnetic synergistic optimization device for a centrifugal hydrogen circulation pump driven by an ultra-high-speed permanent magnet motor. By integrating a real-time control mechanism for structural and electromagnetic parameters, it solves the problems of poor system matching, multi-objective performance imbalance, and insufficient dynamic adaptability in the prior art, and realizes efficient and stable operation of the hydrogen circulation pump under ultra-high-speed conditions.

[0009] To achieve the above objectives, this application provides the following technical solution: a structure-electromagnetic synergistic optimization device for an ultra-high-speed permanent magnet motor driven centrifugal hydrogen circulation pump, comprising...

[0010] Ultra-high speed permanent magnet motor module: It consists of a stator core, a permanent magnet rotor, a high-frequency inverter and a contactless bearing. The permanent magnet rotor is rigidly connected to a centrifugal impeller, and the rotor speed range is 80,000-200,000 r / min.

[0011] Centrifugal hydrogen pump module: including pump body, three-dimensional flow channel impeller, hydrogen sealing assembly and inlet and outlet pressure sensors, the impeller blade profile is based on aerodynamic-electromagnetic coupling simulation optimization design;

[0012] Structure-electromagnetic co-optimization controller: It has a built-in multi-physics coupling algorithm module, which is electrically connected to the current sensor and temperature sensor of the ultra-high speed permanent magnet motor module and the pressure sensor and vibration sensor of the centrifugal hydrogen pump module, respectively. It can adjust the motor excitation current and the impeller inlet guide vane opening in real time.

[0013] Cooling module: It adopts a dual-channel liquid cooling structure to control the temperature of the motor stator and the pump body flow channel respectively. The coolant is a 50% ethylene glycol aqueous solution.

[0014] The structure-electromagnetic co-optimized controller forms a closed-loop control with the high-frequency inverter. It dynamically corrects the permanent magnet pole curvature and winding turns ratio by acquiring rotor vibration acceleration signals (10-2000Hz frequency band) and motor back electromotive force waveforms. The hydrogen sealing assembly adopts a composite structure of metal bellows mechanical seal and magnetohydrodynamic seal to ensure a hydrogen leakage rate ≤1×10⁻⁶. -6 Pa·m 3 / s.

[0015] Preferably, the permanent magnet rotor adopts an integrated structure of neodymium iron boron 38SH magnet and titanium alloy sheath. The magnet is distributed in a V-shape along the circumference, with a pole arc coefficient of 0.72-0.78. The sheath wall thickness is optimized by calculation of electromagnetic repulsion and centrifugal force coupling, and is 0.8-1.2 mm.

[0016] Preferably, the blade inlet angle of the three-dimensional flow channel impeller is 18°-22°, the outlet angle is 30°-35°, the hub ratio is 0.35-0.4, the number of blades is 7-9, and the blade profile is fitted with NURBS curves to reduce the excitation of rotor electromagnetic vibration by aerodynamic load.

[0017] Preferably, the multiphysics coupling algorithm module of the structure-electromagnetic co-optimization controller includes:

[0018] Electromagnetic-structural coupling unit: Establishes a mapping relationship between the permanent magnet demagnetization curve and rotor deformation. When the rotor radial deformation exceeds 0.05mm, the stator winding current frequency is automatically adjusted.

[0019] Flow field-electromagnetic coupling unit: Based on the change in hydrogen flow rate (0.1-5kg / h), the motor output torque is corrected in real time to ensure that the pump head and motor power match ≥90%.

[0020] Preferably, the non-contact bearing is a hybrid magnetic levitation bearing, including a radial electromagnetic bearing and a thrust magnetic bearing. The bearing stiffness coefficient can be adjusted by a coordinating controller, and the rotor shaft offset is controlled within 0.02 mm at a speed of 100,000 r / min.

[0021] Preferably, the high-frequency inverter uses SiCMOSFET devices with a switching frequency of 20-50kHz and a total harmonic distortion (THD) of ≤3% for the output voltage waveform, so as to reduce the high-frequency iron loss of the motor.

[0022] Preferably, the inlet and outlet pressure sensors have a measurement accuracy of ±0.2 kPa and a sampling frequency of 1 kHz, which can capture hydrogen pressure pulsation signals and feed them back to the co-controller to achieve anti-surge control of the pump body.

[0023] Preferably, the motor stator cooling channel of the cooling module is spiral-shaped, and the pump body flow channel cooling jacket is annular. The flow distribution ratio of the two can be adjusted by a coordinating controller to make the motor stator temperature ≤120℃ and the pump body wall temperature ≤80℃.

[0024] Preferably, the titanium alloy sheath is plated with a nickel-phosphorus alloy layer with a thickness of 5-10 μm, which improves the resistance to hydrogen embrittlement and reduces the shielding effect on the magnetic circuit.

[0025] Preferably, the multiphysics coupling algorithm module further includes a life prediction unit, which displays the remaining life of the device in real time based on the electromagnetic loss and structural fatigue damage accumulation model, and issues an early warning when the predicted life is less than 5000 hours.

[0026] Compared with the prior art, the beneficial effects of this application are:

[0027] This invention achieves coordinated optimization of structural and electromagnetic parameters: by eliminating the matching blind zone of independently designed systems through an integrated controller, the overall system efficiency is improved by 8%-12% and vibration and noise are reduced by 15-20dB at 150,000r / min.

[0028] Fast dynamic response: When the hydrogen flow rate changes abruptly (0.5→3kg / h), the coordinated adjustment time of the motor speed and the impeller guide vane opening is ≤0.3s, effectively avoiding surge and overload;

[0029] Significantly improved reliability: The composite sealing structure and multi-physics monitoring mechanism ensure zero hydrogen leakage. After 1000 hours of continuous operation, the motor's magnetic performance attenuation rate is ≤2%, and the rotor deformation is stable within 0.03mm. Attached Figure Description

[0030] Figure 1 This is a flowchart of the application process. Detailed Implementation

[0031] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0032] In the description of this application, if directional descriptions are involved, such as "up," "down," "front," "back," "left," "right," etc., indicating directional or positional relationships, they are based on the appendix. Figure 1 The orientations or positional relationships shown are for the convenience of describing this application and simplifying the description only, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. When a feature is referred to as "set", "fixed", or "connected" to another feature, it can be directly set, fixed, or connected to the other feature, or it can be indirectly set, fixed, or connected to the other feature.

[0033] Please see Figure 1 This application provides the following technical solution: a structure-electromagnetic synergistic optimization device for an ultra-high-speed permanent magnet motor driven centrifugal hydrogen circulation pump, comprising...

[0034] Ultra-high speed permanent magnet motor module: It consists of a stator core, a permanent magnet rotor, a high-frequency inverter and a contactless bearing. The permanent magnet rotor is rigidly connected to a centrifugal impeller, and the rotor speed range is 80,000-200,000 r / min.

[0035] Centrifugal hydrogen pump module: including pump body, three-dimensional flow channel impeller, hydrogen sealing assembly and inlet and outlet pressure sensors, the impeller blade profile is based on aerodynamic-electromagnetic coupling simulation optimization design;

[0036] Structure-electromagnetic co-optimization controller: It has a built-in multi-physics coupling algorithm module, which is electrically connected to the current sensor and temperature sensor of the ultra-high speed permanent magnet motor module and the pressure sensor and vibration sensor of the centrifugal hydrogen pump module, respectively. It can adjust the motor excitation current and the impeller inlet guide vane opening in real time.

[0037] Cooling module: It adopts a dual-channel liquid cooling structure to control the temperature of the motor stator and the pump body flow channel respectively. The coolant is a 50% ethylene glycol aqueous solution.

[0038] The structure-electromagnetic co-optimized controller forms a closed-loop control with the high-frequency inverter. It dynamically corrects the permanent magnet pole curvature and winding turns ratio by acquiring rotor vibration acceleration signals (10-2000Hz frequency band) and motor back electromotive force waveforms. The hydrogen sealing assembly adopts a composite structure of metal bellows mechanical seal and magnetohydrodynamic seal to ensure a hydrogen leakage rate ≤1×10⁻⁶. -6 Pa·m 3 / s.

[0039] Furthermore, the permanent magnet rotor adopts an integrated structure of neodymium iron boron 38SH magnet and titanium alloy sheath. The magnet is distributed in a V-shape along the circumference, with a pole arc coefficient of 0.72-0.78. The sheath wall thickness is optimized by calculation of electromagnetic repulsion and centrifugal force coupling, and is set to 0.8-1.2 mm.

[0040] Furthermore, the blades of the three-dimensional flow channel impeller have an inlet angle of 18°-22°, an outlet angle of 30°-35°, a hub ratio of 0.35-0.4, and 7-9 blades. The blade profile is fitted with NURBS curves to reduce the excitation of rotor electromagnetic vibration by aerodynamic load.

[0041] Furthermore, the multiphysics coupling algorithm module of the structure-electromagnetic cooperative optimization controller includes:

[0042] Electromagnetic-structural coupling unit: Establishes a mapping relationship between the permanent magnet demagnetization curve and rotor deformation. When the rotor radial deformation exceeds 0.05mm, the stator winding current frequency is automatically adjusted.

[0043] Flow field-electromagnetic coupling unit: Based on the change in hydrogen flow rate (0.1-5kg / h), the motor output torque is corrected in real time to ensure that the pump head and motor power match ≥90%.

[0044] Furthermore, the contactless bearing is a hybrid magnetic levitation bearing, including a radial electromagnetic bearing and a thrust magnetic bearing. The bearing stiffness coefficient can be adjusted by a coordinating controller, and the rotor shaft offset is controlled within 0.02 mm at a speed of 100,000 r / min.

[0045] Furthermore, the high-frequency inverter uses SiCMOSFET devices with a switching frequency of 20-50kHz and a total harmonic distortion (THD) of ≤3% for the output voltage waveform, in order to reduce the high-frequency iron loss of the motor.

[0046] Furthermore, the inlet and outlet pressure sensors have a measurement accuracy of ±0.2 kPa and a sampling frequency of 1 kHz, which can capture hydrogen pressure pulsation signals and feed them back to the co-controller to achieve anti-surge control of the pump body.

[0047] Furthermore, the motor stator cooling channel of the cooling module is spiral-shaped, and the pump body flow channel cooling jacket is annular. The flow distribution ratio between the two can be adjusted by a coordinating controller to ensure that the motor stator temperature is ≤120℃ and the pump body wall temperature is ≤80℃.

[0048] Furthermore, the titanium alloy sheath is plated with a nickel-phosphorus alloy layer with a thickness of 5-10 μm, which improves the resistance to hydrogen embrittlement and reduces the shielding effect on the magnetic circuit.

[0049] Furthermore, the multiphysics coupling algorithm module also includes a life prediction unit, which displays the remaining lifespan of the device in real time based on the electromagnetic loss and structural fatigue damage accumulation model, and issues an early warning when the predicted lifespan is less than 5000 hours.

[0050] After the device starts up, the structure-electromagnetic co-optimization controller 12 first collects initial parameters (such as ambient temperature and initial hydrogen pressure), and generates an initial optimization scheme through its built-in algorithm: setting the motor speed to 80,000 r / min and the impeller inlet guide vane opening to 30%. During operation:

[0051] When the outlet pressure sensor 11 detects pressure fluctuations (such as ±5kPa), the co-controller 12 calculates the optimal matching point through the flow field-electromagnetic coupling unit, adjusts the output frequency of the high-frequency inverter 4 (corresponding to the change in motor speed), and simultaneously adjusts the guide vane opening to keep the pump body operating point in the high-efficiency zone.

[0052] If the vibration sensor 13 detects that the rotor vibration acceleration exceeds 10g, the electromagnetic-structure coupling unit immediately analyzes the vibration source (electromagnetic force fluctuation or aerodynamic load impact) and reduces the vibration by correcting the permanent magnet excitation current (±5%) or fine-tuning the impeller blade angle (by driving the guide vane with a servo motor).

[0053] The cooling module 16 dynamically allocates flow rate based on the data from the temperature sensor 15: when the motor stator temperature is >100℃, the flow rate of the motor cooling channel 17 is increased to 60% of the total flow rate; when the pump body wall temperature is >60℃, the flow rate ratio of the pump body flow channel cooling jacket 18 is increased.

[0054] It is worth noting that in this embodiment, the SiC MOSFET of the high-frequency inverter 4 is Infineon IMZA65R040M1H, with a switching loss ≤50mJ; the multiphysics coupling algorithm of the structure-electromagnetic co-optimization controller 12 has been verified by MATLAB / Simulink simulation, and the calculation error under typical operating conditions is ≤3%; the leakage rate of the hydrogen sealing assembly 9 has been tested by a third party and is 5×10⁻⁶ under a working pressure of 1.5MPa. -7 Pa·m 3 The speed is / s, which complies with the safety requirements of GB / T34542.2-2018. In the control logic, the timing control of sensor data acquisition, algorithm calculation and actuator adjustment is implemented using a real-time operating system (RTOS) in the existing technology to ensure timely response.

[0055] Although the embodiments of the present application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A structure-electromagnetic synergistic optimization device for an ultra-high-speed permanent magnet motor driven centrifugal hydrogen circulation pump, characterized in that: include Ultra-high speed permanent magnet motor module: It consists of a stator core, a permanent magnet rotor, a high-frequency inverter and a contactless bearing. The permanent magnet rotor is rigidly connected to a centrifugal impeller, and the rotor speed range is 80,000-200,000 r / min. Centrifugal hydrogen pump module: including pump body, three-dimensional flow channel impeller, hydrogen sealing assembly and inlet and outlet pressure sensors, the impeller blade profile is based on aerodynamic-electromagnetic coupling simulation optimization design; Structure-electromagnetic co-optimization controller: It has a built-in multi-physics coupling algorithm module, which is electrically connected to the current sensor and temperature sensor of the ultra-high speed permanent magnet motor module and the pressure sensor and vibration sensor of the centrifugal hydrogen pump module, respectively. It can adjust the motor excitation current and the impeller inlet guide vane opening in real time. Cooling module: It adopts a dual-channel liquid cooling structure to control the temperature of the motor stator and the pump body flow channel respectively. The coolant is a 50% ethylene glycol aqueous solution. The structure-electromagnetic co-optimized controller forms a closed-loop control with the high-frequency inverter. It dynamically corrects the permanent magnet pole curvature and winding turns ratio by acquiring rotor vibration acceleration signals (10-2000Hz frequency band) and motor back electromotive force waveforms. The hydrogen sealing assembly adopts a composite structure of metal bellows mechanical seal and magnetohydrodynamic seal to ensure a hydrogen leakage rate ≤1×10⁻⁶. -6 Pa·m 3 / s.

2. The apparatus according to claim 1, characterized in that: The permanent magnet rotor adopts an integrated structure of neodymium iron boron 38SH magnet and titanium alloy sheath. The magnet is distributed in a V-shape along the circumference, with a pole arc coefficient of 0.72-0.

78. The sheath wall thickness is optimized by calculation of electromagnetic repulsion and centrifugal force coupling, and the value is 0.8-1.2mm.

3. The apparatus according to claim 1, characterized in that: The blades of the three-dimensional flow channel impeller have an inlet angle of 18°-22°, an outlet angle of 30°-35°, a hub ratio of 0.35-0.4, and 7-9 blades. The blade profile is fitted with NURBS curves to reduce the excitation of rotor electromagnetic vibration by aerodynamic load.

4. The apparatus according to claim 1, characterized in that: The multiphysics coupling algorithm module of the structure-electromagnetic cooperative optimization controller includes: Electromagnetic-structural coupling unit: Establishes a mapping relationship between the permanent magnet demagnetization curve and rotor deformation. When the rotor radial deformation exceeds 0.05mm, the stator winding current frequency is automatically adjusted. Flow field-electromagnetic coupling unit: Based on the change in hydrogen flow rate (0.1-5kg / h), the motor output torque is corrected in real time to ensure that the pump head and motor power match ≥90%.

5. The apparatus according to claim 1, characterized in that: The contactless bearing is a hybrid magnetic levitation bearing, including a radial electromagnetic bearing and a thrust magnetic bearing. The bearing stiffness coefficient can be adjusted by a coordinating controller, and the rotor shaft offset is controlled within 0.02 mm at a speed of 100,000 r / min.

6. The apparatus according to claim 1, characterized in that: The high-frequency inverter uses SiCMOSFET devices with a switching frequency of 20-50kHz and a total harmonic distortion (THD) of ≤3% for the output voltage waveform, in order to reduce the high-frequency iron loss of the motor.

7. The apparatus according to claim 1, characterized in that: The inlet and outlet pressure sensors have a measurement accuracy of ±0.2 kPa and a sampling frequency of 1 kHz. They can capture hydrogen pressure pulsation signals and feed them back to the co-controller to achieve anti-surge control of the pump body.

8. The apparatus according to claim 1, characterized in that: The cooling module has a spiral cooling channel for the motor stator and an annular cooling jacket for the pump body flow channel. The flow distribution ratio between the two can be adjusted by a coordinating controller to ensure that the motor stator temperature is ≤120℃ and the pump body wall temperature is ≤80℃.

9. The apparatus according to claim 2, characterized in that: The titanium alloy sheath is plated with a nickel-phosphorus alloy layer with a thickness of 5-10 μm, which improves the resistance to hydrogen embrittlement and reduces the shielding effect on the magnetic circuit.

10. The apparatus according to claim 4, characterized in that: The multiphysics coupling algorithm module also includes a life prediction unit, which displays the remaining service life of the device in real time based on the electromagnetic loss and structural fatigue damage accumulation model, and issues an early warning when the predicted life is less than 5000 hours.

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