Methanol engine range extender and method for new energy automobile

Abstract

The invention mainly relates to the field of new energy automobiles, in particular to a methanol engine range extender for a new energy automobile and a method. The range extender comprises a shell assembly, a methanol supply module, an exhaust waste heat recovery system, a permanent magnet synchronous generator and a controller module, methanol is adopted as fuel, the range extender has the advantages of being wide in source, mature in preparation process, clean in combustion and the like, carbon emission and harmful substance emission are remarkably reduced, and the green and environment-friendly requirements of new energy automobiles are met; the device is especially suitable for coal-rich countries and assists in energy structure optimization. The exhaust waste heat recovery system is integrated, the heat exchanger and the phase change material heat storage unit are used for effectively recovering engine tail gas waste heat, the engine tail gas waste heat is converted into an auxiliary heat source for preheating methanol fuel or providing system heating, the overall energy utilization efficiency is improved, and energy waste is reduced.

Description

Technical Field

[0001] This invention mainly relates to the field of new energy vehicles, specifically a methanol engine range extender and method for new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, pure electric vehicles have become an important development direction due to their zero-emission characteristics. However, the limitations of battery range and the lack of charging infrastructure severely restrict their large-scale promotion and application. To alleviate users' range anxiety, range-extended electric vehicles have become an effective technological approach, significantly extending the driving range by installing a range extender system on the vehicle to charge the battery or directly power the drive motor.

[0003] Currently, most range-extended electric vehicles (REEVs) use traditional gasoline or diesel engines as the power source for their range extenders. However, diesel generators have emission pollution problems and cannot meet increasingly stringent environmental protection requirements. Although gasoline engines are technologically mature, they still rely on fossil fuels and have high carbon emissions. In addition, traditional range extender systems still face challenges in terms of layout space, energy utilization efficiency, and low-temperature start-up performance.

[0004] Methanol fuel, as a clean alternative fuel, has advantages such as wide availability, mature preparation technology, clean combustion, and low cost. Its strategic significance is particularly prominent in coal-rich countries. However, the widespread application of methanol engines also faces technical challenges such as difficulties in low-temperature starting and material compatibility.

[0005] Chinese invention patent application CN112141590A discloses a 40kW methanol range extender system for vehicles, including an engine, a generator, and a GCU. When the range extender starts, the generator is driven by the power battery to start the engine, after which it switches to power generation mode. Another patent proposes a range extender based on a methanol-hydrogen mixed fuel, which uses the heat from engine exhaust to catalytically crack methanol to produce hydrogen-rich gas, which is then introduced into the engine for combustion. This aims to improve combustion efficiency and reduce emissions while avoiding the challenges of high-pressure hydrogen storage. Other solutions address the low-temperature starting problem of methanol engines by proposing the use of methanol low-temperature combustion chamber catalytic combustion to provide starting energy, or a gasoline / methanol dual-fuel starting scheme.

[0006] Despite some progress in existing technologies, problems remain, including system complexity, unresolved issues with low-temperature start-up, insufficient exhaust gas energy recovery efficiency, and low system integration hindering vehicle layout. For light commercial vehicles with limited space, miniaturization, weight reduction, and high efficiency of the range extender system are particularly crucial.

[0007] Therefore, there is an urgent need for a methanol engine range extender system that is compact, energy efficient, reliable in low-temperature start-up, and specifically optimized for new energy vehicles, so as to fully leverage the environmental and economic advantages of methanol fuel, effectively improve the driving range of new energy vehicles, and promote the large-scale application of methanol fuel in the automotive field. Summary of the Invention

[0008] To solve the above problems, the present invention adopts the following technical solution.

[0009] A methanol engine range extender for new energy vehicles includes: a housing assembly, the housing assembly including a main frame and a sub-frame, the sub-frame being fixedly connected to the bottom of the main frame by bolts; The methanol supply module is located on the top of the main frame and includes a storage tank and a heating device. The outlet of the storage tank is connected to the inlet of the heating device through a flexible hose, and the outlet of the heating device is connected to the methanol engine through a metal pipe. An exhaust waste heat recovery system is located on the other side of the main frame and includes a heat exchanger, a heat storage unit, and a circulating pump. The inlet end of the heat exchanger is connected to the exhaust port of the methanol engine via a flange. The heat storage unit is located below the heat exchanger. The inlet end of the circulating pump is connected to the bottom of the heat storage unit via a pipe, and the outlet end is connected to the inlet end of the heat exchanger via a pipe. A permanent magnet synchronous generator is installed in the middle of the main frame; The controller module is located at the top of the main frame and is electrically connected to the methanol engine, permanent magnet synchronous generator and methanol supply module via wires.

[0010] Furthermore, the heating device is equipped with a spiral heating tube inside, which is fixed to the inner wall of the heating device by a threaded connection.

[0011] Furthermore, the heat storage unit is a cylindrical structure with a guide tube coaxially arranged inside, which divides the interior of the heat storage unit into a central flow channel and an annular cavity; the annular cavity is filled with a phase change material unit, which is fixed inside the annular cavity by a support grid.

[0012] Furthermore, the controller module includes a main control unit, a signal acquisition unit, and a drive unit. The main control unit is fixed to the top of the main frame with bolts. The signal acquisition unit is connected to the sensors of the methanol engine via wires. The drive unit is connected to the permanent magnet synchronous generator via wires.

[0013] Furthermore, a shock-absorbing device is provided at the bottom of the main frame of the housing assembly. The shock-absorbing device includes a spring and a damper. The spring is fixed to the bottom of the main frame by a threaded connection, and the damper is fixed to the inside of the spring by welding.

[0014] Furthermore, the heat exchanger has multiple parallel heat exchange tubes inside, and the two ends of the heat exchange tubes are fixed to the shell of the heat exchanger by welding.

[0015] Based on the aforementioned methanol engine range extender for new energy vehicles, this invention also provides a method of using it, comprising the following steps: S1. Install the methanol engine range extender in the designated location of the new energy vehicle; S2. Start the methanol supply module. The methanol liquid in the storage tank flows into the heating device through the flexible hose. The heating device heats the methanol liquid and delivers it to the methanol engine. S3. When the methanol engine is running, it generates mechanical energy, which drives the permanent magnet synchronous generator to generate electricity and transmit the electrical energy to the battery or drive motor of the new energy vehicle. S4. At the same time, the exhaust gas from the methanol engine enters the heat exchanger through the flange. The heat exchange tubes in the heat exchanger absorb the heat from the exhaust gas and transfer the heat to the heat storage unit through the circulating pump. S5. The phase change material in the heat storage unit stores heat and releases it when needed to provide an auxiliary heat source for the system. S6. The control module monitors the operating status of the methanol engine in real time and acquires sensor data through the signal acquisition unit. The drive unit adjusts the output power of the permanent magnet synchronous generator according to the instructions of the main control unit.

[0016] Furthermore, in step S2, the heating device heats the methanol liquid to a preset temperature range and then delivers it to the methanol engine.

[0017] The beneficial effects of this invention are as follows: Using methanol as fuel has advantages such as wide availability, mature preparation process, and clean combustion, which significantly reduces carbon emissions and emissions of harmful substances, meets the green and environmentally friendly requirements of new energy vehicles, and is especially suitable for coal-rich countries, helping to optimize the energy structure.

[0018] By integrating an exhaust waste heat recovery system, heat exchangers and phase change material heat storage units are used to effectively recover engine exhaust waste heat and convert it into an auxiliary heat source for preheating methanol fuel or providing system heating, thereby improving overall energy utilization efficiency and reducing energy waste.

[0019] The methanol supply module is equipped with a heating device to preheat the methanol liquid, ensuring the evaporation and combustion performance of methanol in low-temperature environments. This fundamentally solves the technical problem of difficult low-temperature starting of methanol engines and enhances the adaptability of the range extender in harsh environments.

[0020] The bottom of the main frame is equipped with a shock absorption device, including springs and dampers, which effectively absorbs and isolates vibrations and noise during engine operation, improves the working stability and ride comfort of the range extender, and extends the service life of the system. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention.

[0022] Figure 2 This is a schematic diagram of the structure of this heat storage unit.

[0023] Figure 3 This is a schematic diagram of the top surface structure of the present invention.

[0024] Figure 4 This is a schematic diagram of the methanol supply module structure of the present invention.

[0025] Figure 5 This is a schematic diagram of the bottom structure of the present invention.

[0026] Explanation of reference numerals in the attached drawings: 1. Shell assembly; 2. Main frame; 3. Sub-frame; 4. Methanol supply module; 5. Storage tank; 6. Heating device; 7. Methanol engine; 8. Exhaust waste heat recovery system; 9. Heat exchanger; 10. Heat storage unit; 11. Permanent magnet synchronous generator; 12. Flow guide tube; 13. Annular cavity; 14. Support grid; 15. Phase change material unit; 16. Vibration damping device. Detailed Implementation

[0027] The invention will now be described in further detail with reference to the accompanying drawings.

[0028] A methanol engine range extender for new energy vehicles includes: a housing assembly 1, the housing assembly 1 including a main frame 2 and a sub-frame 3, the sub-frame 3 being fixedly connected to the middle and bottom of the main frame 2 by bolts; the modular assembly and lightweight layout are achieved through the split design of the main and sub-frames, while the bolt connection ensures structural strength and impact resistance, adapting to the vehicle vibration environment.

[0029] The methanol supply module 4 is located on the top of the main frame 2 and includes a storage tank 5 and a heating device 6. The outlet of the storage tank 5 is connected to the inlet of the heating device 6 via a flexible hose, and the outlet of the heating device 6 is connected to the methanol engine 7 via a metal pipe. The flexible hose alleviates the stress effect of engine vibration on the pipeline, the metal pipe ensures the sealing of the high-pressure methanol delivery, and the heating device improves the low-temperature evaporation characteristics and increases combustion efficiency by preheating the methanol.

[0030] The exhaust waste heat recovery system 8 is located on the other side of the main frame 2 and includes a heat exchanger 9, a heat storage unit 10, and a circulating pump. The inlet end of the heat exchanger 9 is connected to the exhaust port of the methanol engine 7 via a flange. The heat storage unit 10 is located below the heat exchanger 9. The inlet end of the circulating pump is connected to the bottom of the heat storage unit 10 via a pipe, and the outlet end is connected to the inlet end of the heat exchanger 9 via a pipe. The exhaust waste heat is transferred to the circulating working fluid through the heat exchanger heat exchange tubes. The circulating pump drives the working fluid to circulate between the heat storage unit and the heat exchanger. The phase change material stores sensible heat and latent heat, realizing the cascade utilization of thermal energy.

[0031] A permanent magnet synchronous generator 11 is installed in the middle of the main frame 2. The permanent magnet rotor and stator winding generate electricity through electromagnetic induction, efficiently converting mechanical energy into electrical energy, which directly charges the vehicle battery or drives the motor, extending the driving range. The controller module is located at the top of the main frame 2 and is electrically connected to the methanol engine, the permanent magnet synchronous generator 11, and the methanol supply module 4 via wires.

[0032] The heating device 6 has a spiral heating tube inside, which is fixed to the inner wall of the heating device 6 by a threaded connection.

[0033] The heat storage unit 10 has a cylindrical structure with a guide tube 12 coaxially arranged inside. The guide tube 12 divides the interior of the heat storage unit 10 into a central flow channel and an annular cavity 13. The annular cavity 13 is filled with a phase change material unit 15, which is fixed inside the annular cavity 13 by a support grid 14. The guide tube guides the circulating working fluid to flow along the central flow channel, and the phase change material in the annular cavity stores or releases heat through latent heat of phase change. The support grid prevents material displacement, thereby improving the heat storage density and stability.

[0034] The controller module includes a main control unit, a signal acquisition unit, and a drive unit. The main control unit is fixed to the top of the main frame 2 by bolts. The signal acquisition unit is connected to the sensor of the methanol engine by wires. The drive unit is connected to the permanent magnet synchronous generator 11 by wires.

[0035] The main frame 2 of the housing assembly 1 is provided with a shock absorption device 16 at its bottom. The shock absorption device 16 includes a spring and a damper. The spring is fixed to the bottom of the main frame 2 by a threaded connection, and the damper is fixed to the inside of the spring by welding.

[0036] The heat exchanger 9 has multiple parallel heat exchange tubes inside, and the two ends of the heat exchange tubes are fixed to the shell of the heat exchanger 9 by welding.

[0037] Based on the aforementioned methanol engine range extender for new energy vehicles, this invention also provides a method of using it, comprising the following steps: S1. Install the methanol engine range extender in the designated location of the new energy vehicle; the standardized installation interface ensures a reliable connection with the vehicle chassis, avoids displacement or abnormal noise during operation, and ensures the safe and stable operation of the system.

[0038] S2. Start the methanol supply module 4. The methanol liquid in the storage tank flows into the heating device 6 through the flexible hose. The heating device 6 heats the methanol liquid and delivers it to the methanol engine. The methanol liquid heated to the preset temperature range enters the engine cylinder, improves the atomization effect, promotes complete combustion, and reduces the emission of unburned methanol.

[0039] S3. When the methanol engine is running, it generates mechanical energy, which drives the permanent magnet synchronous generator 11 to generate electricity and transmit the electrical energy to the battery or drive motor of the new energy vehicle. S4. At the same time, the exhaust gas of the methanol engine enters the heat exchanger 9 through the flange. The heat exchange tubes in the heat exchanger 9 absorb the heat in the exhaust gas and transfer the heat to the heat storage unit 10 through the circulation pump. S5. The phase change material in the heat storage unit 10 stores heat and releases it when needed to provide an auxiliary heat source for the system. The phase change material stably releases heat in the phase change temperature range to preheat methanol liquid or maintain the system temperature and optimize the adaptability to low temperature environment.

[0040] S6. The control module monitors the operating status of the methanol engine in real time and acquires sensor data through the signal acquisition unit. The drive unit adjusts the output power of the permanent magnet synchronous generator 11 according to the instructions of the main control unit. The closed-loop control strategy realizes dynamic adjustment of generator power to match battery charging needs or changes in drive motor load, ensuring efficient and stable operation of the system.

[0041] In step S2, the heating device 6 heats the methanol liquid to a preset temperature range and then delivers it to the methanol engine.

[0042] Through the specific embodiments described above, those skilled in the art can easily implement the present invention. However, it should be understood that the present invention is not limited to the specific embodiments described above. Based on the disclosed embodiments, those skilled in the art can arbitrarily combine different technical features to achieve different technical solutions.

Claims

1. A methanol engine range extender for new energy vehicles, characterized in that, include: The housing assembly (1) includes a main frame (2) and a sub-frame (3), the sub-frame (3) being fixedly connected to the bottom of the main frame (2) by bolts; The methanol supply module (4) is located on the top of the main frame (2) and includes a storage tank (5) and a heating device (6). The outlet of the storage tank (5) is connected to the inlet of the heating device (6) through a flexible hose, and the outlet of the heating device (6) is connected to the methanol engine (7) through a metal pipe. The exhaust waste heat recovery system (8) is located on the other side of the main frame (2) and includes a heat exchanger (9), a heat storage unit (10) and a circulation pump. The inlet end of the heat exchanger (9) is connected to the exhaust port of the methanol engine (7) through a flange. The heat storage unit (10) is located below the heat exchanger (9). The inlet end of the circulation pump is connected to the bottom of the heat storage unit (10) through a pipe, and the outlet end is connected to the inlet end of the heat exchanger (9) through a pipe. A permanent magnet synchronous generator (11) is installed in the middle of the main frame (2); The controller module is located on the top of the main frame (2) and is electrically connected to the methanol engine, permanent magnet synchronous generator (11) and methanol supply module (4) respectively via wires.

2. The methanol engine range extender for new energy vehicles according to claim 1, characterized in that, The heating device (6) is equipped with a spiral heating tube inside, which is fixed to the inner wall of the heating device (6) by a threaded connection.

3. A methanol engine range extender for new energy vehicles according to claim 1, characterized in that, The heat storage unit (10) is a cylindrical structure with a guide tube (12) coaxially arranged inside. The guide tube (12) divides the interior of the heat storage unit (10) into a central flow channel and an annular cavity (13). The annular cavity (13) is filled with a phase change material unit (15), which is fixed in the annular cavity (13) by a support grid (14).

4. A methanol engine range extender for new energy vehicles according to claim 1, characterized in that, The controller module includes a main control unit, a signal acquisition unit, and a drive unit. The main control unit is fixed to the top of the main frame (2) by bolts. The signal acquisition unit is connected to the sensor of the methanol engine by wires. The drive unit is connected to the permanent magnet synchronous generator (11) by wires.

5. A methanol engine range extender for new energy vehicles according to claim 1, characterized in that, The main frame (2) of the housing assembly (1) is provided with a shock-absorbing device (16) at the bottom. The shock-absorbing device (16) includes a spring and a damper. The spring is fixed to the bottom of the main frame (2) by a threaded connection.

6. A methanol engine range extender for new energy vehicles according to claim 1, characterized in that, The heat exchanger (9) has multiple parallel heat exchange tubes inside, and the two ends of the heat exchange tubes are fixed to the shell of the heat exchanger (9) by welding.

7. A method of using a methanol engine range extender for new energy vehicles according to any one of claims 1 to 6, characterized in that, Includes the following steps: S1. Install the methanol engine range extender in the designated location of the new energy vehicle; S2. Start the methanol supply module (4). The methanol liquid in the storage tank flows into the heating device (6) through the flexible hose. The heating device (6) heats the methanol liquid and delivers it to the methanol engine. S3. When the methanol engine is running, it generates mechanical energy, which drives the permanent magnet synchronous generator (11) to generate electricity and transmit the electrical energy to the battery or drive motor of the new energy vehicle. S4. At the same time, the exhaust gas of the methanol engine enters the heat exchanger (9) through the flange. The heat exchange tubes in the heat exchanger (9) absorb the heat in the exhaust gas and transfer the heat to the heat storage unit (10) through the circulation pump. S5. The phase change material in the heat storage unit (10) stores heat and releases it when needed to provide an auxiliary heat source for the system; S6. The control module monitors the operating status of the methanol engine in real time and acquires sensor data through the signal acquisition unit. The drive unit adjusts the output power of the permanent magnet synchronous generator (11) according to the instructions of the main control unit.

8. A method of using a methanol engine range extender for new energy vehicles according to claim 7, characterized in that, The heating device (6) heats the methanol liquid to a preset temperature range in step S2 and then delivers it to the methanol engine.

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