Two-Stage Fuel Cell Compressor With Integrated Intercooling
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Solution Overview
Problem
Fuel cell systems face significant parasitic power loss due to inefficient air supply compression, with the compressor assembly being the largest secondary consumer, limiting energy efficiency.
Innovation Solution
Incorporating an intercooler to cool the air mass flow between the two compressors, integrated into the compressor assembly, and utilizing a cooling circuit with a coolant pump and power electronics to regulate temperatures and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If air compression is performed using conventional compressors without intercooling, then the compression process is simpler and requires fewer components, but the energy efficiency is reduced due to higher parasitic power loss
Solution Approach 1:
The intercooler is integrated into the compressor assembly by nesting it within the existing structure. The intercooler utilizes the space between the first and second compressors, allowing the cooling function to be embedded within the compression system without requiring separate external cooling equipment. This nested arrangement reduces parasitic power loss while avoiding significant increases in overall system complexity.
Solution Approach 2:
The invention merges the intercooler with the compressor assembly into a single integrated unit. The intercooler is positioned to receive hot air directly from the first compressor and cool it before the air enters the second compressor. This combination allows the cooling function to be performed within the compression system itself, improving energy efficiency without requiring separate standalone cooling equipment.
2Use of energy by moving object
If an intercooler is added to cool the air mass flow between compressors, then the compression efficiency increases approaching isothermal conditions, but the device complexity and installation space requirements increase
Solution Approach 1:
The intercooler is nested within the compressor assembly structure, utilizing the spatial arrangement between the first and second compressors. This integration allows the intercooler to be embedded in the existing system footprint, improving compression efficiency while minimizing the increase in overall device complexity and installation space requirements.
3Loss of energy
If the air temperature is reduced between compressors, then the compression process approaches isothermal conditions improving efficiency, but additional cooling components and systems are required
Solution Approach 1:
The intercooler is merged with the compressor assembly into a single integrated unit. The cooling function is combined with the compression system, allowing temperature reduction between compressors without requiring separate standalone cooling equipment. This integration improves energy efficiency while minimizing the addition of separate cooling system components.
Solution Approach 2:
The intercooler is nested within the compressor assembly, utilizing the existing structural space between compressors. This nested arrangement provides the necessary cooling function while avoiding the need for extensive external cooling system infrastructure, thereby improving energy efficiency with minimal increase in overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The intercooler reduces air temperature, bringing compression closer to isothermal conditions, thereby increasing compressor assembly efficiency and reducing parasitic power loss, enhancing overall energy efficiency of the fuel cell system.
Implementation Method 1
the compressor assembly has an additional intercooler, which is configured to cool the air mass flow from the first compressor before its entry into the second compressor
Implementation Method 2
the compressor assembly has a cooling circuit and a coolant pump which is connected to the cooling circuit in order to convey a coolant in the cooling circuit
Data Source
AI summary
A compressor assembly is for a fuel cell system, in particular for a fuel cell system for commercial vehicles. The compressor assembly has two compressors connected in series and an electric motor for driving the compressors. The compressors are configured to take in an air mass flow, to compress it and to discharge the compressed air mass flow as a reactant supply, and the second compressor is configured to further compress the air mass flow coming from the first compressor. The compressor assembly has an intercooler which is configured to cool the air mass flow from the first compressor before its entry into the second compressor.