Composite material wrapped extended range power system and method of thermal energy utilization thereof

Abstract

The application provides a composite material wrapped extended-range power system and a heat energy utilization method thereof, wherein the composite material wrapped extended-range power system comprises: a high-temperature reaction hydrogen separator; an extender; a heat preservation and heat exchange device, the heat preservation and heat exchange device comprising an exhaust gas catalytic reduction device, a basalt composite material heat preservation layer and a heat conducting oil pipe; a power supply assembly; and an electric heater; wherein a first output end of the electric heater and a heat conducting oil output end of the high-temperature reaction hydrogen separator are respectively connected to input ends of the heat conducting oil pipe, a second output end of the electric heater and an output end of the heat conducting oil pipe are respectively connected to heat conducting oil input ends of the high-temperature reaction hydrogen separator, and the output end of the heat conducting oil pipe is further connected to an input end of the electric heater.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle power system technology, and in particular to a range-extended power system wrapped in composite materials and its thermal energy utilization method. Background Technology

[0002] In the field of new energy power systems, range-extended electric vehicles are an effective way to alleviate range anxiety of pure electric vehicles. Hydrogen internal combustion engines, with their advantages such as zero carbon emission potential and fast refueling speed, are regarded as one of the ideal power sources for range extenders.

[0003] In recent years, basalt composite materials have shown potential in the field of high-temperature insulation due to their excellent long-term high-temperature resistance, extremely low thermal conductivity and good thermal stability. However, there are currently no reports of their deep integration with hydrogen internal combustion engine range extender systems to systematically solve the problems of exhaust insulation, waste heat recovery and intelligent thermal management.

[0004] In existing technologies, range-extending systems using hydrogen internal combustion engines still face a series of key technical bottlenecks in practical applications:

[0005] First, the performance of hydrogen internal combustion engines and their after-treatment systems is limited during cold starts. Exhaust after-treatment devices, such as integrated systems of diesel oxidation catalysts and selective catalytic reduction devices, need to reach high operating temperatures to effectively catalyze the reduction of nitrogen oxides and unburned hydrogen. During the cold start phase, these devices heat up slowly, which not only causes pollutant emissions to exceed the standard momentarily, but also makes the system start-up efficiency low.

[0006] Secondly, the system suffers from significant thermal energy waste. The exhaust temperature of the hydrogen internal combustion engine is as high as 400-600℃, containing a large amount of waste heat, and existing technologies generally lack effective recovery and utilization of this part of the heat energy. At the same time, the high-temperature reaction process used to separate high-purity hydrogen from the liquid hydrogen storage medium requires external heat source input, which results in "high-quality but low-use" energy and a reduction in the overall energy efficiency of the system.

[0007] Furthermore, traditional insulation materials do not perform well in adapting to the wide temperature range and highly fluctuating working environment of hydrogen internal combustion engine exhaust systems. For example, materials such as ceramic fibers may have problems such as insufficient long-term temperature resistance and poor thermal stability, resulting in large fluctuations in the working temperature of the catalyst, which affects the stability and durability of its purification efficiency.

[0008] Finally, the control strategy of the existing system is relatively simple and fails to achieve deep coordination and dynamic optimization among multiple subsystems such as hydrogen production, internal combustion engine combustion, exhaust aftertreatment and heat recovery. In particular, under different operating conditions such as cold start and hot engine start, there is a lack of intelligent heat management and distribution strategies, which makes it difficult for the system to simultaneously achieve multiple goals such as rapid start-up, low emissions and high energy efficiency. Summary of the Invention

[0009] Based on this, the purpose of the present invention is to provide a range-extended power system wrapped in composite materials and a method for utilizing its thermal energy, which can effectively solve the shortcomings of the prior art.

[0010] A range-extended powertrain system encased in composite materials, comprising:

[0011] High-temperature reaction hydrogen separator;

[0012] A range extender connected to the outlet of the high-temperature reactive hydrogen separator, the range extender comprising a hydrogen internal combustion engine connected to the outlet of the high-temperature reactive hydrogen separator and a motor drivenly connected to the hydrogen internal combustion engine.

[0013] A heat exchange device connected to the exhaust end of the hydrogen internal combustion engine, the heat exchange device including an exhaust catalytic reducer connected to the exhaust end of the hydrogen internal combustion engine, a basalt composite material insulation layer wrapped around the outside of the exhaust catalytic reducer, and a heat-conducting oil pipe disposed between the basalt composite material insulation layer and the exhaust catalytic reducer and wound around the outside of the exhaust catalytic reducer.

[0014] A power supply assembly electrically connected to the motor, the power supply assembly including an AC / DC inverter electrically connected to the motor and a battery electrically connected to the AC / DC inverter;

[0015] An electric heater electrically connected to the battery for heating the heat-conducting oil;

[0016] The first output end of the electric heater and the heat transfer oil output end of the high-temperature reactive hydrogen separator are respectively connected to the input end of the heat transfer oil pipe. The second output end of the electric heater and the output end of the heat transfer oil pipe are respectively connected to the heat transfer oil input end of the high-temperature reactive hydrogen separator. The output end of the heat transfer oil pipe is also connected to the input end of the electric heater.

[0017] Compared with existing technologies, the beneficial effects of this invention are as follows: By constructing a complete physical architecture for a hydrogen energy range extender system, the high-temperature reactive hydrogen separator, range extender, heat exchange device, and electric heater are integrated into an integrated thermodynamic circulation system through an innovative physical connection method. This system architecture fundamentally changes the traditional range extender system's unidirectional heat flow and decentralized management mode. By connecting the heat transfer oil pipelines of the electric heater, high-temperature reactive hydrogen separator, and heat exchange device end to end, a completely closed heat transfer oil circulation network is formed. This structural innovation provides a physical carrier for multi-level utilization of thermal energy, cross-subsystem transfer, and intelligent allocation. The combined design of the basalt composite material insulation layer and the wound heat transfer oil pipe achieves efficient heat preservation of the exhaust catalytic reduction unit on the one hand, and active heat transfer and temperature control through the flow of heat transfer oil on the other hand. The power supply component can both supply power to the electric heater and receive power from the motor, establishing a bidirectional conversion and collaborative management channel between electrical energy and thermal energy.

[0018] Furthermore, the range extender outputs power via a transmission.

[0019] Furthermore, a liquid hydrogen-rich oil storage tank is provided at the hydrogen oil input end of the high-temperature reaction hydrogen separator, and a liquid hydrogen-lean oil storage tank is provided at the hydrogen oil output end of the high-temperature reaction hydrogen separator. A hydrogen-lean oil and hydrogen re-enrichment device is also connected to the output end of the heat-conducting oil pipe. The output end of the liquid hydrogen-lean oil storage tank is connected to the input end of the liquid hydrogen-rich oil storage tank through the hydrogen-lean oil and hydrogen re-enrichment device. A residual oil storage tank that cannot be further enriched is provided at the residual hydrogen oil output end of the hydrogen-lean oil and hydrogen re-enrichment device.

[0020] Furthermore, the heat balance calculation formula for the heat transfer oil system of the electric heater is as follows:

[0021] ;

[0022] In the formula, The heat supplied to the electric heater, For the heat recovery of the heat exchange device, This refers to the heat consumption of the high-temperature reactive hydrogen separator. The heat consumption of the heat exchange device is [not specified]. To account for heat loss of the heat transfer oil, This refers to the heat consumption of the hydrogen re-enrichment device for the hydrogen-poor oil.

[0023] Furthermore, the formula for calculating the exhaust heat recovery efficiency of the heat exchange device is as follows:

[0024] ;

[0025] ;

[0026] In the formula, The heat recovered from the heat transfer oil by the heat exchange device. The exhaust heat of the heat exchange device, The exhaust mass flow rate of the heat exchange device is [missing information]. The exhaust specific heat capacity of the heat exchange device is given. The change in exhaust temperature of the heat exchange device.

[0027] Furthermore, the formula for calculating the SOC (State of Charge) capacity balance of the battery is as follows:

[0028] ;

[0029] In the formula, The state of charge of the battery at time t. The state of charge of the battery at the initial time t0 is... The capacity of the battery, For the time integral from t0 to t, For charging power, For discharge power, The power of the electric heater.

[0030] Furthermore, the temperature PID control calculation formula for the heat exchange device is as follows:

[0031] ;

[0032] In the formula, For heat transfer oil flow rate, The proportional coefficient for PID control. For PID control, the integral coefficient is... The derivative coefficients of the PID control are... The target temperature of the heat exchange device is [temperature value missing]. The actual temperature of the heat exchange device is given.

[0033] On the other hand, the present invention also provides a method for utilizing the thermal energy of a range-extended power system encased in composite materials as described above, the method comprising:

[0034] S1, Range extender mode determination, determines whether the range extender needs to work through the controller;

[0035] S2. Hydrogen internal combustion engine start-up condition judgment: When the current SOC of the battery is lower than the set threshold. Or the power demand exceeds the battery's maximum output power. If it is determined that the hydrogen internal combustion engine needs to be started, proceed to step S3; otherwise, do not start the hydrogen internal combustion engine and the process ends.

[0036] S3. Temperature judgment of the heat exchange device, if If the system is determined to be in a cold start state, proceed to step S4. If the system is determined to be in a hot-start state, proceed to step S5.

[0037] in, This refers to the actual temperature of the heat exchange device. This refers to the lower limit of the operating temperature of the heat exchange device.

[0038] S4, Cold start operation;

[0039] S5, Operation during warm-up startup.

[0040] Furthermore, step S4 specifically includes:

[0041] The battery-powered electric heater operates, with electrical energy supplied by the battery via an AC / DC inverter, thus satisfying power constraints. ;

[0042] in, For battery output power, Power required for the electric heater;

[0043] After the heat transfer oil is heated by the electric heater, it heats the high-temperature reaction hydrogen separator through the second output end of the electric heater, and heats the heat exchange device through the first output end of the electric heater.

[0044] When the temperature of the high-temperature reaction hydrogen separator Reaching the hydrogen separation operating temperature ,and achieve At that time, the liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank to the high-temperature reaction separator, and the separated high-purity hydrogen enters the hydrogen internal combustion engine through the outlet of the high-temperature reaction hydrogen separator.

[0045] When the exhaust heat is sufficient to meet the subsequent insulation requirements, the electric heater stops working.

[0046] When the hydrogen internal combustion engine starts, the exhaust gas produced by burning high-purity hydrogen enters the exhaust catalytic reducer for catalytic reduction.

[0047] The exhaust gas, after being catalytically reduced by the exhaust catalytic reducer, is emitted through the outlet of the exhaust catalytic reducer.

[0048] Furthermore, step S5 specifically includes:

[0049] The heat exchange device utilizes waste heat to heat the high-temperature hydrogen separator via heat transfer oil, while maintaining the operating temperature of the heat exchange device itself.

[0050] When the temperature of the high-temperature reaction hydrogen separator Reaching the hydrogen separation operating temperature Liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank to the high-temperature reaction separator, and the separated high-purity hydrogen enters the hydrogen internal combustion engine through the outlet of the high-temperature reaction hydrogen separator.

[0051] The exhaust gas, after being catalytically reduced by the exhaust catalytic reducer, is emitted through the outlet of the exhaust catalytic reducer. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of the frame of the range-extended power system wrapped with composite material in Embodiment 1 of the present invention;

[0053] Figure 2 This is a schematic diagram of the overall structure of the heat exchange device in Embodiment 1 of the present invention;

[0054] Figure 3 This is a schematic flowchart of the thermal energy utilization method of the range-extended power system wrapped with composite material in Embodiment 2 of the present invention.

[0055] Figure 4 This is a schematic diagram of the framework of the thermal energy utilization method of the range-extended power system wrapped with composite material in Embodiment 2 of the present invention;

[0056] Explanation of key component symbols:

[0057]

[0058] The following detailed description, in conjunction with the accompanying drawings, will further illustrate the present invention. Detailed Implementation

[0059] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Several embodiments of the invention are illustrated in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

[0060] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0061] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0062] Example 1

[0063] Please see Figures 1-2 The range-extended power system encased in composite material in Embodiment 1 of the present invention includes:

[0064] High-temperature reaction hydrogen separator 10;

[0065] Specifically, in this embodiment, the operating temperature of the high-temperature reactive hydrogen separator 10 is 250℃±20℃, the operating pressure of the high-temperature reactive hydrogen separator 10 is 0.8MPa (absolute pressure), the separation efficiency of the high-temperature reactive hydrogen separator 10 is ≥96% (high-purity hydrogen), and the processing flow rate of the high-temperature reactive hydrogen separator 10 is ≥110kg / h (hydrogen-rich hydrogen oil).

[0066] A range extender 20 is connected to the outlet end of the high-temperature reaction hydrogen separator 10. The range extender 20 includes a hydrogen internal combustion engine 21 connected to the outlet end of the high-temperature reaction hydrogen separator 10 and a motor 22 that is drivenly connected to the hydrogen internal combustion engine 21.

[0067] Specifically, in this embodiment, the rated power / speed of the hydrogen internal combustion engine 21 is 300kW / 1900rpm, the maximum torque / speed of the hydrogen internal combustion engine 21 is 1900Nm / 1400rpm, the rated / peak power of the motor 22 is 300kW / 350kW, the rated / peak torque of the motor 22 is 1900Nm / 2400Nm, and the voltage platform of the motor 22 is 600V / DC.

[0068] A heat exchange device 30 is connected to the exhaust end of the hydrogen internal combustion engine 21. The heat exchange device 30 includes an exhaust catalytic reducer 31 connected to the exhaust end of the hydrogen internal combustion engine 21, a basalt composite material insulation layer 32 wrapped around the outside of the exhaust catalytic reducer 31, and a heat-conducting oil pipe 33 disposed between the basalt composite material insulation layer 32 and the exhaust catalytic reducer 31 and wound around the outside of the exhaust catalytic reducer 31.

[0069] Specifically, in this embodiment, the exhaust catalytic converter 31 is a DOC+SCR exhaust catalytic converter, and the operating temperature range of the exhaust catalytic converter 31 is 220℃-600℃. The NO emission from the exhaust catalytic converter 31...X The conversion rate is ≥95%, the unburned hydrogen oxidation rate of the exhaust catalytic reducer 31 is ≥98%, the long-term temperature resistance of the basalt composite material insulation layer 32 is ≥600℃, the thickness of the basalt composite material insulation layer 32 is 30mm, and the density of the basalt composite material insulation layer 32 is 280kg / m³-320kg / m³. 3 The heat transfer oil pipe 33 is made of 304 stainless steel, and its specifications are φ25mm*2mm (outer diameter*wall thickness). The heat exchange area of ​​the heat transfer oil pipe 33 is ≥22m². 2 .

[0070] A power supply assembly 40 electrically connected to the motor 22, the power supply assembly 40 including an AC / DC inverter 41 electrically connected to the motor 22 and a battery 42 electrically connected to the AC / DC inverter 41;

[0071] Specifically, in this embodiment, the battery 42 is a ternary lithium-ion battery with a rated voltage of 600V / DC and a capacity of ≥150kw / h.

[0072] An electric heater 50 is electrically connected to the battery 42 for heating the heat-conducting oil;

[0073] Specifically, in this embodiment, the rated power of the electric heater 50 is 350kW-400kW, the input voltage of the electric heater 50 is 600V / DC, the working pressure of the electric heater 50 is ≤1.0Mpa (adapted to the heat transfer oil circulation pressure), the heat transfer oil is a synthetic terphenyl heat transfer oil, and the long-term working temperature of the heat transfer oil is 220℃-420℃.

[0074] The first output terminal of the electric heater 50 and the heat transfer oil output terminal of the high-temperature reactive hydrogen separator 10 are respectively connected to the input terminal of the heat transfer oil pipe 33. The second output terminal of the electric heater 50 and the output terminal of the heat transfer oil pipe 33 are respectively connected to the heat transfer oil input terminal of the high-temperature reactive hydrogen separator 10. The output terminal of the heat transfer oil pipe 33 is also connected to the input terminal of the electric heater 50.

[0075] It should be noted that, specifically in this embodiment, the exhaust waste heat of the heat exchange device 30 is 400℃-600℃, and the working temperature of the heat transfer oil is 200℃-320℃ (circulation stage).

[0076] Understandably, by constructing a complete physical architecture for the hydrogen energy range extender system, the high-temperature reaction hydrogen separator, range extender, heat exchange device, and electric heater are integrated into a unified thermodynamic cycle system through an innovative physical connection method. This system architecture fundamentally changes the traditional range extender system's unidirectional heat flow and decentralized management mode. By connecting the heat transfer oil pipelines of the electric heater, high-temperature reaction hydrogen separator, and heat exchange device end to end, a completely closed heat transfer oil circulation network is formed. This structural innovation provides a physical carrier for multi-level utilization of thermal energy, cross-subsystem transfer, and intelligent allocation. The combined design of the basalt composite material insulation layer and the wound heat transfer oil pipe achieves efficient insulation of the exhaust catalytic reduction unit on the one hand, and active heat transfer and temperature control through the flow of heat transfer oil on the other hand. The power supply component can both supply power to the electric heater and receive power from the motor, establishing a bidirectional conversion and collaborative management channel between electrical energy and thermal energy.

[0077] Furthermore, the range extender 20 outputs power through the transmission 23.

[0078] Understandably, the introduction of the transmission 23 decouples the operating speed of the hydrogen internal combustion engine 21 from the actual driving conditions of the vehicle. The hydrogen internal combustion engine 21 can always operate at its most efficient or optimal power output point, significantly improving the energy conversion efficiency of the fuel. Through the gear adjustment of the transmission 23, the power generation of the motor 22 or the direct drive torque can be precisely controlled according to different vehicle speeds and load requirements, realizing refined management of power output.

[0079] Furthermore, a liquid hydrogen-rich oil storage tank 60 is provided at the hydrogen oil input end of the high-temperature reaction hydrogen separator 10, and a liquid hydrogen-lean oil storage tank 70 is provided at the hydrogen oil output end of the high-temperature reaction hydrogen separator 10. A hydrogen-lean oil and hydrogen re-enrichment device 80 is also connected to the output end of the heat-conducting oil pipe 33. The output end of the liquid hydrogen-lean oil storage tank 70 is connected to the input end of the liquid hydrogen-rich oil storage tank 60 through the hydrogen-lean oil and hydrogen re-enrichment device 80. A residual oil storage tank 90 that cannot be further enriched is provided at the residual hydrogen oil output end of the hydrogen-lean oil and hydrogen re-enrichment device 80.

[0080] It should be noted that, specifically in this embodiment, the single-tank volume of the liquid hydrogen-rich oil storage tank 60, the liquid hydrogen-lean oil storage tank 70, and the residual oil storage tank 90 is 600L; the design pressure of the liquid hydrogen-rich oil storage tank 60, the liquid hydrogen-lean oil storage tank 70, and the residual oil storage tank 90 is 0.1MPa (gauge pressure, atmospheric pressure storage); the material of the liquid hydrogen-rich oil storage tank 60, the liquid hydrogen-lean oil storage tank 70, and the residual oil storage tank 90 is 316L stainless steel; and the liquid hydrogen-rich oil storage tank 60 and the liquid hydrogen-lean oil storage tank 70... The residual oil storage tank 90 is equipped with a level gauge with an accuracy of ±2%, a temperature sensor of -40℃ to 100℃, and a safety valve with a starting pressure of 0.15Mpa. The external dimensions of the liquid hydrogen-rich oil storage tank 60, the liquid hydrogen-lean oil storage tank 70, and the residual oil storage tank 90 are φ800mm*1200mm (outer diameter*wall thickness). The hydrogen re-enrichment device 80 for hydrogen-lean oil can efficiently recover about 4% of the hydrogen remaining in the hydrogen-lean oil while fully reusing the exhaust waste heat and heat transfer oil circulation architecture of the existing system without adding any additional energy sources.

[0081] Understandably, by setting up the liquid hydrogen-rich oil storage tank 60, the liquid hydrogen-lean oil storage tank 70, the hydrogen-lean oil hydrogen re-enrichment device 80, and the residual oil storage tank 90, a complete material cycle of "hydrogen-rich oil → separation → hydrogen-lean oil → re-enrichment → hydrogen-rich oil" is constructed. This allows for the deep extraction of approximately 4% hydrogen remaining in the discarded hydrogen-lean oil in traditional systems, increasing the overall hydrogen utilization rate of the system from 96% to over 98%. Furthermore, the hydrogen-lean oil hydrogen re-enrichment device 80 innovatively reuses the waste heat of the existing heat transfer oil circulation system as its reaction heat source, eliminating the need for an additional independent heating device. This achieves a highly integrated design of "one heat source, two-stage utilization." At the same time, by integrating the hydrogen-lean oil hydrogen re-enrichment device 80 into the original heat transfer oil circuit, the system complexity caused by additional pipelines and heat sources is avoided, maintaining a compact overall structure. This not only improves energy utilization but also reduces energy consumption and emissions in upstream links such as hydrogen-rich oil extraction and transportation, bringing environmental benefits throughout the entire life cycle.

[0082] Furthermore, the heat balance calculation formula for the heat transfer oil system of the electric heater 50 is as follows:

[0083] ;

[0084] In the formula, The heat supplied to the electric heater 50 The heat is recovered by the heat exchange device 30. This refers to the heat consumption of the high-temperature reactive hydrogen separator 10. The heat consumption of the heat exchange device 30 is [the heat consumption of the heat exchange device 30]. To account for heat loss of the heat transfer oil, This refers to the heat consumption of the hydrogen re-enrichment device 80 for the hydrogen-poor oil.

[0085] Understandably, this formula incorporates the heat consumption of the hydrogen-poor oil and hydrogen re-enrichment device 80 into the overall system heat balance, establishing a complete thermodynamic equation covering all heat sources, heat sinks, and heat losses, and realizing a full-element quantitative description of the system's energy flow. At the same time, the controller can calculate the heat supply and demand relationship of each link in real time based on this model, dynamically adjust parameters such as the distribution of heat transfer oil flow and the power of the electric heater 50, and ensure that the total energy consumption of the system is minimized while meeting the temperature requirements of each component.

[0086] Furthermore, the formula for calculating the exhaust heat recovery efficiency of the heat exchange device 30 is as follows:

[0087] ;

[0088] ;

[0089] In the formula, The heat transferred from the heat exchanger 30 is the heat recovered from the heat transfer oil. The exhaust heat of the heat exchange device 30 is the heat from the heat exchange. The exhaust mass flow rate of the heat exchange device 30 is [missing information]. The exhaust specific heat capacity of the heat exchange device 30 is given. The change in exhaust temperature of the heat exchange device 30.

[0090] Understandably, through real-time calculation It can monitor the performance degradation of the heat exchange device 30 (such as a decrease in heat exchange efficiency due to carbon buildup) and trigger cleaning maintenance or control strategy adjustments accordingly.

[0091] And can As a key performance indicator, it can be fed back to the control system to dynamically optimize parameters such as heat transfer oil flow, hydrogen internal combustion engine 21, and exhaust temperature, so as to maximize the recovery efficiency online.

[0092] Furthermore, the SOC capacity balance calculation formula for the battery 42 is as follows:

[0093] ;

[0094] In the formula, The state of charge of the battery 42 at time t. The state of charge of the battery 42 at the initial time t0 is... The capacity of the battery 42, For the time integral from t0 to t, For charging power, For discharge power, The power of the electric heater.

[0095] Understandably, in high-power heating scenarios such as cold starts, this model can predict the battery SOC change trend and prevent over-discharge of the battery. At the same time, by optimizing the charging strategy (such as appropriately increasing the recharge power during heating), the charging and discharging stress of the battery can be balanced, extending the battery cycle life. Furthermore, under different vehicle operating modes (pure electric, range extended, regenerative braking, etc.), this model can solve the optimal power distribution scheme that meets the thermal demand conditions in real time, ensuring the vehicle's power and economy.

[0096] Furthermore, the temperature PID control calculation formula for the heat exchange device 30 is as follows:

[0097] ;

[0098] In the formula, For heat transfer oil flow rate, The proportional coefficient for PID control. For PID control, the integral coefficient is... The derivative coefficients of the PID control are... The target temperature for the heat exchange device 30 is... The actual temperature of the heat exchange device 30 is given.

[0099] Understandably, by using a PID algorithm to perform rapid and precise closed-loop control of the temperature of the exhaust catalytic converter 31, it is possible to ensure that it always operates within a high-efficiency catalytic window above 220℃, thereby stabilizing the nitrogen oxide conversion rate and unburned hydrogen oxidation rate at over 95% and 98%, respectively. This effectively addresses complex and changing driving conditions and eliminates the risk of exceeding emission standards. At the same time, precise temperature control prevents the catalytic converter from sintering and deactivating due to local overheating (>600℃), and also prevents the accumulation and poisoning of intermediate products such as sulfides due to excessively low temperatures, significantly extending the service life of the expensive catalytic converter. Compared with traditional on / off or fuzzy control, PID control can suppress interference caused by exhaust flow and temperature fluctuations more quickly, making the system thermal state more stable and the response faster. Furthermore, through precise control, only the minimum heat transfer oil flow required to maintain the target temperature needs to be provided, avoiding pump power loss and heat waste caused by excessive hot oil circulation.

[0100] Example 2

[0101] Please see Figures 3-4 The present invention also provides a method for utilizing the thermal energy of a range-extended power system encased in composite materials as described above, the method comprising:

[0102] S1, Range extender 20 mode determination: The controller determines whether the range extender 20 needs to work.

[0103] S2, Hydrogen internal combustion engine 21 start-up condition judgment: When the current SOC of battery 42 is lower than the set threshold. Or the power demand exceeds the battery's maximum output power. If it is determined that the hydrogen internal combustion engine 21 needs to be started, proceed to step S3; otherwise, do not start the hydrogen internal combustion engine 21 and the process ends.

[0104] S3, Temperature judgment of heat exchange device 30, if If the system is determined to be in a cold start state, proceed to step S4. If the system is determined to be in a hot-start state, proceed to step S5.

[0105] in, The actual temperature of the heat exchange device 30. This is the lower limit of the operating temperature of the heat exchange device 30.

[0106] S4, Cold start operation;

[0107] Furthermore, step S4 specifically includes:

[0108] Battery 42 drives electric heater 50. The electrical energy is provided by battery 42 through AC / DC inverter 41, which meets the power constraint. ;

[0109] in, For battery 42 output power, The required power for the electric heater is 50.

[0110] After the heat transfer oil is heated by the electric heater 50, it heats the high-temperature reaction hydrogen separator 10 through the second output end of the electric heater 50, and heats the heat exchange device 30 through the first output end of the electric heater 50.

[0111] When the temperature of the high-temperature reaction hydrogen separator 10 Reaching the hydrogen separation operating temperature ,and achieve At that time, the liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank 60 to the high-temperature reaction separator 10, and the separated high-purity hydrogen enters the hydrogen internal combustion engine 21 through the outlet of the high-temperature reaction hydrogen separator 10.

[0112] When the exhaust heat is sufficient to meet the subsequent insulation requirements, the electric heater 50 stops working.

[0113] The hydrogen internal combustion engine 21 starts, and the exhaust gas produced by burning high-purity hydrogen enters the exhaust catalytic reducer 31 for catalytic reduction.

[0114] The exhaust gas after being catalytically reduced by the exhaust catalytic reducer 31 is discharged through the outlet of the exhaust catalytic reducer 31.

[0115] S5, Operation during hot start-up;

[0116] Furthermore, step S5 specifically includes:

[0117] The heat exchange device 30 utilizes waste heat to heat the high-temperature reaction hydrogen separator 10 through heat transfer oil, while maintaining the operating temperature of the heat exchange device 30 itself.

[0118] When the temperature of the high-temperature reaction hydrogen separator 10 Reaching the hydrogen separation operating temperature Liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank 60 to the high-temperature reaction separator 10, and the separated high-purity hydrogen enters the hydrogen internal combustion engine 21 through the outlet of the high-temperature reaction hydrogen separator 10.

[0119] The exhaust gas after being catalytically reduced by the exhaust catalytic reducer 31 is discharged through the outlet of the exhaust catalytic reducer 31.

[0120] Understandably, introducing real-time judgment of the actual temperature of the heat exchange device 30 as the sole basis for selecting the start-up mode is a simple and reliable decision-making logic based on physical state, avoiding the uncertainty of traditional methods that rely on time or complex operating conditions for estimation. Through a differentiated strategy, resources are concentrated for rapid heating during cold starts, and existing waste heat is fully utilized during hot starts, resulting in a reduction of average system start-up energy consumption by approximately 40% and a reduction in start-up time by approximately 50%. The power supply logic and power constraints of the battery 42 to the electric heater 50 during cold starts are clearly defined, ensuring rapid heating while preventing the battery 42 from triggering protection or being damaged due to excessive instantaneous power demand. After the heat transfer oil is heated, one path heats the high-temperature hydrogen separator 10, and the other path heats the heat exchange device 30. This parallel heating strategy, rather than a series heating strategy, allows both key components to heat up simultaneously, maximizing the utilization of heat from the initial heating stage and minimizing the impact of cold starts. Preparation time is reduced by approximately 30%; strict temperature interlock conditions are set, allowing hydrogen-rich oil feeding and hydrogen internal combustion engine 21 to start only when the high-temperature reactive hydrogen separator 10 and the exhaust catalytic reducer 31 simultaneously reach their minimum operating temperatures. This fundamentally eliminates problems such as impure hydrogen separation, low catalytic efficiency, and excessive emissions caused by insufficient component temperatures; the hot start process completely eliminates the electric heater 50, relying solely on the residual heat stored in the heat exchange device 30 or the exhaust heat being generated, which is used to heat the high-temperature reactive hydrogen separator 10 through heat transfer oil circulation. This means that restarting after a short stop (such as waiting at a red light or a short rest) consumes almost no energy from the battery 42, achieving a truly "zero-energy" hot start; it avoids the impact of frequent high-power discharge on the battery 42, making it particularly suitable for frequent start-stop of the range extender in congested urban traffic conditions, and significantly beneficial for maintaining the battery's health.

[0121] In summary, the composite material-encased range-extended power system and its thermal energy utilization method in the above embodiments of the present invention, by constructing a complete physical architecture for the hydrogen energy range-extending system, integrates the high-temperature reactive hydrogen separator, range extender, heat exchange device, and electric heater into an integrated thermodynamic cycle system through an innovative physical connection method. This system architecture fundamentally changes the traditional unidirectional heat flow and decentralized management mode of range-extending systems. By connecting the heat transfer oil pipelines of the electric heater, high-temperature reactive hydrogen separator, and heat exchange device end to end, a completely closed heat transfer oil circulation network is formed. This structural innovation provides a physical carrier for multi-level utilization of thermal energy, cross-subsystem transfer, and intelligent allocation. The combined design of the basalt composite material insulation layer and the wound heat transfer oil pipeline achieves efficient heat preservation of the exhaust catalytic reduction unit on the one hand, and active heat transfer and temperature control through the flow of heat transfer oil on the other hand. The power supply component can both supply power to the electric heater and receive power from the motor, establishing a bidirectional conversion and collaborative management channel between electrical energy and thermal energy.

[0122] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0123] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A composite wrapped extended range powertrain, characterized by, include: High-temperature reaction hydrogen separator; A range extender connected to the outlet of the high-temperature reactive hydrogen separator, the range extender comprising a hydrogen internal combustion engine connected to the outlet of the high-temperature reactive hydrogen separator and a motor drivenly connected to the hydrogen internal combustion engine. A heat exchange device connected to the exhaust end of a hydrogen internal combustion engine, the heat exchange device including an exhaust catalytic reducer connected to the exhaust end of the hydrogen internal combustion engine, a basalt composite material insulation layer wrapped around the outside of the exhaust catalytic reducer, and a heat-conducting oil pipe disposed between the basalt composite material insulation layer and the exhaust catalytic reducer and wound around the outside of the exhaust catalytic reducer. A power supply assembly electrically connected to the motor, the power supply assembly including an AC / DC inverter electrically connected to the motor and a battery electrically connected to the AC / DC inverter; An electric heater electrically connected to the battery for heating the heat-conducting oil; The first output end of the electric heater and the heat transfer oil output end of the high-temperature reactive hydrogen separator are respectively connected to the input end of the heat transfer oil pipe. The second output end of the electric heater and the output end of the heat transfer oil pipe are respectively connected to the heat transfer oil input end of the high-temperature reactive hydrogen separator. The output end of the heat transfer oil pipe is also connected to the input end of the electric heater.

2. The composite wrapped extended-range powertrain of claim 1, wherein, The range extender outputs power through a transmission.

3. The composite wrapped extended-range powertrain of claim 1, wherein, A liquid hydrogen-rich oil storage tank is provided at the hydrogen oil input end of the high-temperature reaction hydrogen separator, and a liquid hydrogen-lean oil storage tank is provided at the hydrogen oil output end of the high-temperature reaction hydrogen separator. A hydrogen-lean oil and hydrogen re-enrichment device is also connected to the output end of the heat-conducting oil pipe. The output end of the liquid hydrogen-lean oil storage tank is connected to the input end of the liquid hydrogen-rich oil storage tank through the hydrogen-lean oil and hydrogen re-enrichment device. A residual oil storage tank that cannot be further enriched is provided at the residual hydrogen oil output end of the hydrogen-lean oil and hydrogen re-enrichment device.

4. The composite wrapped extended-range powertrain of claim 3, wherein, The heat balance calculation formula for the heat transfer oil system of the electric heater is as follows: ； In the formula, The heat supplied to the electric heater, For the heat recovery of the heat exchange device, This refers to the heat consumption of the high-temperature reactive hydrogen separator. The heat consumption of the heat exchange device is [not specified]. To account for heat loss of the heat transfer oil, This refers to the heat consumption of the hydrogen re-enrichment device for the hydrogen-poor oil.

5. The composite wrapped extended-range powertrain of claim 1, wherein, The formula for calculating the exhaust heat recovery efficiency of the heat exchange device is as follows: ； ； In the formula, The heat recovered from the heat transfer oil by the heat exchange device. The exhaust heat of the heat exchange device, The exhaust mass flow rate of the heat exchange device is [missing information]. The exhaust specific heat capacity of the heat exchange device is given. The change in exhaust temperature of the heat exchange device.

6. The composite wrapped extended-range powertrain of claim 1, wherein, The formula for calculating the SOC capacity balance of the battery is as follows: ； In the formula, The state of charge of the battery at time t. The state of charge of the battery at the initial time t0 is... The capacity of the battery, For the time integral from t0 to t, For charging power, For discharge power, This refers to the power of the electric heater.

7. The composite wrapped extended-range powertrain of claim 1, wherein, The temperature PID control calculation formula for the heat exchanger is as follows: ; In the formula, For heat transfer oil flow rate, The proportional coefficient for PID control. For PID control, the integral coefficient is... The derivative coefficients of the PID control are... The target temperature of the heat exchange device is [temperature value missing]. The actual temperature of the heat exchange device is denoted as .

8. A method of utilizing thermal energy of an extended-range power system wrapped in a composite material according to any one of claims 1-7, characterized in that, The heat energy utilization method includes: S1, Range extender mode determination, determines whether the range extender needs to work through the controller; S2. Hydrogen internal combustion engine start-up condition judgment: When the current SOC of the battery is lower than the set threshold. Or the power demand exceeds the battery's maximum output power. If it is determined that the hydrogen internal combustion engine needs to be started, proceed to step S3; otherwise, do not start the hydrogen internal combustion engine and the process ends. S3. Temperature judgment of the heat exchange device, if If the system is determined to be in a cold start state, proceed to step S4. If the system is determined to be in a hot-start state, proceed to step S5. wherein, is the actual temperature of the heat exchanger device, is the lower limit of the operating temperature of the heat exchanger device; S4, Cold start operation; S5, Operation during warm-up startup.

9. The method of claim 8, wherein the composite-wrapped extended-range power system is a composite-wrapped extended-range electric vehicle power system. Step S4 specifically includes: The battery drives the electric heater to work, and electric energy is provided by the battery through an AC-DC inverter to meet the power constraint ; wherein, Pbat is the battery output power, Preq is the electrically powered heater demand power; After the heat transfer oil is heated by the electric heater, it heats the high-temperature reaction hydrogen separator through the second output end of the electric heater, and heats the heat exchange device through the first output end of the electric heater. When the temperature of the high-temperature reaction hydrogen separator Reaching the hydrogen separation operating temperature ,and achieve At that time, the liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank to the high-temperature reaction separator, and the separated high-purity hydrogen enters the hydrogen internal combustion engine through the outlet of the high-temperature reaction hydrogen separator. When the exhaust heat is sufficient to meet the subsequent insulation requirements, the electric heater stops working. When the hydrogen internal combustion engine starts, the exhaust gas produced by burning high-purity hydrogen enters the exhaust catalytic reducer for catalytic reduction. The exhaust gas, after being catalytically reduced by the exhaust catalytic reducer, is emitted through the outlet of the exhaust catalytic reducer.

10. The method of claim 8, wherein the composite-wrapped extended-range power system is a composite-wrapped extended-range electric vehicle power system. Step S5 specifically includes: The heat exchange device utilizes waste heat to heat the high-temperature hydrogen separator via heat transfer oil, while maintaining the operating temperature of the heat exchange device itself. When the temperature of the high-temperature reaction hydrogen separator Reaching the hydrogen separation operating temperature Liquid hydrogen-rich oil is transported from the liquid hydrogen-rich oil storage tank to the high-temperature reaction separator, and the separated high-purity hydrogen enters the hydrogen internal combustion engine through the outlet of the high-temperature reaction hydrogen separator. The exhaust gas, after being catalytically reduced by the exhaust catalytic reducer, is emitted through the outlet of the exhaust catalytic reducer.

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