WO2023285231A1 - Procédé de fonctionnement d'une turbomachine, et dispositif de commande pour mettre en œuvre le procédé - Google Patents

Procédé de fonctionnement d'une turbomachine, et dispositif de commande pour mettre en œuvre le procédé Download PDF

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Publication number
WO2023285231A1
WO2023285231A1 PCT/EP2022/068711 EP2022068711W WO2023285231A1 WO 2023285231 A1 WO2023285231 A1 WO 2023285231A1 EP 2022068711 W EP2022068711 W EP 2022068711W WO 2023285231 A1 WO2023285231 A1 WO 2023285231A1
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WO
WIPO (PCT)
Prior art keywords
turbomachine
limit
surge
operating
pressure ratio
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2022/068711
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German (de)
English (en)
Inventor
Jochen Braun
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of WO2023285231A1 publication Critical patent/WO2023285231A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
    • F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
    • F04D27/02—Surge control
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/0438—Pressure; Ambient pressure; Flow
    • H01M8/04425—Pressure; Ambient pressure; Flow at auxiliary devices, e.g. reformers, compressors, burners
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
    • F04D17/08—Centrifugal pumps
    • F04D17/10—Centrifugal pumps for compressing or evacuating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/05—Shafts or bearings, or assemblies thereof, specially adapted for elastic fluid pumps
    • F04D29/056—Bearings
    • F04D29/057—Bearings hydrostatic; hydrodynamic
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/81—Modelling or simulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2250/00—Fuel cells for particular applications; Specific features of fuel cell system
    • H01M2250/20—Fuel cells in motive systems, e.g. vehicle, ship, plane

Definitions

  • the invention relates to a method for operating a turbomachine, in particular a gas-bearing thermal turbomachine.
  • the invention relates to a control unit that is set up to carry out steps of the method according to the invention.
  • the turbomachine can be used in particular for air compression in a fuel cell system.
  • Hydrogen-based fuel cells are considered to be the mobility concept of the future because they only emit water as exhaust gas and enable fast refueling times.
  • the electrochemical reaction in the fuel cells requires oxygen as a reaction gas.
  • Ambient air is usually used as an oxygen supplier.
  • the air required is supplied to the fuel cells of a fuel cell system by means of an air compression system.
  • air compression systems with high-speed turbomachines are used. Since the air supplied must be free of oil to protect the fuel cells, gas-bearing turbomachines are usually used.
  • gas bearings In addition to being oil-free, gas bearings have the advantage that they enable virtually smooth and therefore wear-free operation above a certain speed (lift-off speed). However, if this falls below this, for example when coasting down or starting up, the wear is high.
  • a start/stop operation therefore represents a significant additional load compared to a continuous operation of the gas-bearing turbomachine. Frequent driving in traffic jams and/or driving in city traffic thus contributes to a reduction in the lifespan of the turbomachine.
  • a minimum speed must therefore be observed when idling.
  • a maximum speed is also specified.
  • the operating range of a turbomachine is limited by a surge limit on the one hand and a choke limit on the other.
  • FIG. 1 A typical characteristic diagram of a thermal turbomachine is shown in FIG. 1 as an example. It shows the connection between the speed (n), the pressure ratio (pq/pi) and the delivered mass flow (m).
  • the choke limit (S) indicates the maximum mass flow that can be enforced, the surge limit (P) the maximum pressure ratio. If the surge limit is exceeded, local stalls initially occur at the inlet and/or outlet of the turbomachine. As a result, the pressure build-up can collapse and the turbomachine can go into an unstable state, so that the required air mass flow can no longer be provided and it is no longer possible to operate the fuel cell system at the desired operating point. This has a direct impact on the efficiency, emissions and wear and tear of the system.
  • an applicable limit operating characteristic is usually implemented in the system control. Since the surge limit is not exactly known for all operating conditions in real operation and aging effects can lead to a shift in the surge limit, the implemented limiting operating characteristic maintains a safety distance from the surge limit (see shaded area in Figure 1). However, this safety distance further restricts the usable operating range of the turbomachine. This proves to be a disadvantage, especially when the engine is idling and in the other lower part-load ranges, since it has a negative effect on energy and fuel consumption.
  • the mass flow and thus the power consumption of the turbomachine can be reduced in idling operation or in the lower partial load ranges with very low pressure conditions.
  • idling operation using the proposed method is less energy-intensive, idling phases can be extended. In this way, the number of start-stop processes can be reduced. The gas bearings of the flow machine are therefore subjected to less wear, so that the service life of the flow machine increases.
  • the use of the "mild surge” range requires the most precise knowledge possible of the surge limit and the map in this range. Knowledge of the maximum speed/speed limit between "mild surge” and “deep surge” is also required. Because at higher or high speeds of the turbomachine, exceeding the surge limit can suddenly turn into “pumping” and the turbomachine can be damaged. In the higher or high speed ranges, compliance is not the only thing that remains the surge line, but also maintaining a safety margin to the surge line makes sense.
  • vibrations that occur when pressure sensors and/or air mass meters "pum" can be recorded and evaluated.
  • the system control can then be used to switch off or reduce the load point.
  • the detection of vibrations is not functional, or only partially so, since it is too imprecise. This is because vibrations hardly occur or do not occur at all in idling or lower part-load operation.
  • the present invention tries to remedy this.
  • a method for determining the surge limit in the low to medium speed range of a turbomachine as precisely as possible is to be specified.
  • the turbomachine is operated in an operating range A, which is limited on the one hand by a surge limit and on the other hand by a choke limit.
  • the following steps are carried out to determine the surge limit or at least one limit point lying on the surge limit: a) Throttling of the mass flow at constant speed of the turbomachine so that the pressure ratio increases and a maximum pressure ratio is reached and exceeded, b) detecting and storing the maximum pressure ratio and the associated mass flow and the associated speed as a limit point of the surge limit.
  • the method makes it possible to determine at least one limit point lying on the surge limit in real operation of the turbomachine, so that the result is very precise. If the limit point determined is not on a surge limit stored as a characteristic curve, this deviation can be recorded and taken into account. Reasons for the deviation can be component variations and/or changed component behavior.
  • Steps a) and b) of the method are preferably repeated for different speeds.
  • a large number of limit points can be determined, which in their entirety reflect the surge limit.
  • the operating characteristics for individual speeds preferably the entire operating map, can be determined, preferably for speeds greater than or equal to the idle speed of the unit and less than the maximum permissible limit speed for the "mild surge" range or range B.
  • the several boundary points determined are preferably connected to form a boundary line, which is then stored as a characteristic line.
  • the characteristic curve then defines the surge limit. Knowing the exact surge limit, the operating range of the turbomachine can be determined exactly. Furthermore, the operating range can be expanded in the low to medium speed ranges in order to optimize the operation of the turbomachine in terms of energy. Exact knowledge of the surge limit helps when switching between the operating ranges. Exact knowledge of the operating map in the "mild surge" range or in range B helps to regulate the air system in operating mode B.
  • the at least one detected border point or a border line resulting therefrom is also preferably stored in a non-volatile memory of a control unit.
  • a non-volatile memory of a control unit e.g., a control unit, a control unit, or computer, such as on-board computer stored.
  • the non-volatile memory can in particular be a control device for system control.
  • the method is advantageously repeated at regular or irregular time intervals. In this way, aging effects influencing the component behavior can be recorded and taken into account. This enables adaptive system control over the lifetime of the turbomachine.
  • the proposed method can, for example, be carried out periodically, ie after the time has elapsed, and/or when the opportunity arises. This is the case in particular when the fuel cell stack is in stand-by mode or when the fuel cell stack is switched off, since system operation is then not disturbed.
  • the compressor mass flow is then preferably discharged via a bypass bypassing the fuel cell stack. Further, the process can be performed as needed.
  • the implementation can then be made dependent in particular on the load profile, the boundary conditions and/or the operating behavior of the turbomachine.
  • the implementation of the method can be given a higher priority.
  • the turbomachine as an air compressor in a fuel cell system of a vehicle
  • the operation of the fuel cell system can be briefly suspended and the ferry operation via a battery can be made possible, so that the process can be carried out, for example by power splitting, i.e. by splitting the power.
  • the procedure is carried out as an auto-calibration.
  • the adaptation of the system control can thus be automated.
  • the method is preferably carried out for the first time during end-of-line calibration or when the turbomachine is started up. This means that data are available right from the start, which enable an exact determination of the pump limit and thus an energy-optimized operation of the turbomachine.
  • the entire operating characteristics map is preferably determined at the same time.
  • the at least one limit point that is recorded and stored is preferably used as a trigger for switching between the two operating ranges A and B. Since exceeding the surge limit can damage the turbomachine in high speed ranges, it is also proposed that the surge limit is exceeded only in low to medium speed ranges. This means that switching only takes place in the low to medium speed ranges.
  • vibrations be detected and evaluated in order to detect pumping of the flow machine.
  • conventional detection and diagnostic functions can be used in addition, which indicate the onset of pumping via vibration detection, ie vibrations in the mass flow and/or the pressures, so that countermeasures can be initiated immediately. These can include shutting down the turbomachine or shifting the operating point.
  • a limit speed can be determined in this way for which operation in the "mild surge” range or in range B is still possible. The limiting speed then defines the transition from the "mild surge” range or range B to the "deep surge” range or range D, both of which are beyond the surge limit.
  • a control unit is proposed that is set up to carry out steps of the method according to the invention.
  • a valve or a throttle flap can be activated with the aid of the control device in order to throttle the mass flow in step a).
  • the valve or the throttle flap can in particular be arranged downstream of the turbomachine.
  • the valve or the throttle valve can be arranged in a bypass path for bypassing a fuel cell stack and/or in an exhaust air path for discharging the air escaping from the fuel cell stack.
  • the maximum pressure ratio including the associated mass flow and the associated speed are recorded and stored (step b) of the method).
  • the operating map for the "mild surge” range can be determined and saved.
  • the limit speed between range B ("mild surge”) and range D ("deep surge”) can be determined and saved.
  • the method according to the invention can be automated and carried out as an auto-calibration.
  • FIG. 2 shows a schematic representation of a fuel cell system with a turbomachine for air compression
  • Fig. 3 is a graphical representation of a characteristic map of a thermal flow machine with extended operating range
  • FIG. 4 shows a graphic representation of a characteristic field of a thermal flow machine with a limit point determined according to the method according to the invention at a speed nl.
  • FIG. 1 shows a typical characteristic diagram of a thermal turbomachine.
  • the pressure ratio between the pressure p 0 at the outlet and the pressure p at the inlet of the turbomachine is plotted against the mass flow m. Lines are shown between them, along which the compressor speed n is constant.
  • the map shows the stable operating range of the turbomachine. This is limited on the one hand by a surge limit P and on the other hand by a stuffing limit S. If the surge limit P is exceeded, the flow machine leaves the stable operating range and so-called "surge" occurs. the turbomachine. In order to prevent this, the safety distance from the surge limit P, shown as a shaded area, is maintained. However, this narrows the operating range of the turbomachine.
  • FIG. 2 shows an example of a fuel cell system 1 with a corresponding turbomachine 4 for air compression.
  • a fuel cell stack 2 of the fuel cell system 1 can be supplied with compressed air via an air supply path 3 .
  • the air is taken from the surroundings 11 and supplied to the turbomachine 4 via an air filter 12 .
  • the flow machine 4 is driven by an electric motor 14 in the present case. Since the air heats up when it is compressed, a cooling device 13 is integrated into the supply air path 3 .
  • a humidifying device 15 for humidifying the compressed air can also optionally be integrated into the supply air path 3 and is therefore only shown in dashed lines.
  • the topology for air compression shown in FIG. 2 is only chosen as an example.
  • an electrically driven air compressor with a turbine arranged in an exhaust air path 6 or a purely turbine-driven air compressor can optionally also be used.
  • the air compressor can also be designed in two stages and/or with two flows.
  • shut-off valves 9, 10 are provided, which are closed in particular in the case of shutdown who the. Furthermore, a partial mass flow or the entire air mass flow can be routed past the fuel cell stack 2 via a bypass path 5 .
  • a valve 7 arranged in the bypass path 5 is partially or completely closed.
  • the air mass flow supplied to the fuel cell stack 2 can be throttled by at least partially closing the valve 7 and/or a valve 8 arranged in an exhaust air path 6 .
  • FIG. 3 which shows a further characteristic diagram of a thermal turbomachine 4 shows the stable operating range as “Area A”.
  • Area B designates the "mild surge” area
  • Area D designates the "deep surge” area.
  • the "deep surge” area is preceded by a safety zone Al, which maintains a safety distance from the surge limit P.
  • the stable operating range "Area A” can be expanded to include the operating range "Area B” in the low to medium speed ranges. This means that there is no safety margin to the surge limit P and the surge limit P is deliberately exceeded.
  • the operating range of the turbomachine is not only expanded to include “Area B”, but also to include a safety zone A2 that is not observed.
  • a speed limit can also be defined that separates area B (“mild surge”) from area D (“deep surge”).
  • the flow machine In the extended operating range “Area B”, the flow machine is in a quasi-stable state or in a quasi-stable range. This means that stalls can occur, but these are locally limited. Furthermore, the main direction of flow remains unchanged, so that there is no "pumping" of the turbomachine. This is only the case in the “Area D” operating range, so that in the corresponding speed range the surge limit P is preceded by the safety zone Al in order to reliably prevent the turbomachine from “surging”.
  • FIG. 4 shows an example of the measurement result and the evaluation according to the method according to the invention for an example speed nl of a turbomachine 4.
  • the starting point S1 of the procedure is selected in such a way that the operating point is definitely in the "Area A" area.
  • the measurement can start completely de-throttled (S1 right) or it can start time-optimized with a certain throttling (S1 middle or S1 left).
  • the flow cross-section is then reduced or the throttling increased, so that the mass flow decreases and the pressure ratio increases (see arrow).
  • the flow cross-section can be reduced step by step with timed holding phases or by a continuous ramp.
  • the process is continued up to E1 or up to the desired expansion of the map.
  • the pressure ratio drops slightly at the same speed, which can be attributed to local backflows.
  • the maximum pressure ratio p, max reached indicates a limit point of the pumping limit for the speed nl at an air mass flow mAir 1 and can be determined from the measured trajectory.
  • the limit point and preferably also the operating characteristic in area B is or are recorded and stored. The process is then repeated accordingly for further speeds n2, n3, etc.
  • the speed limit between ranges B and D can be determined using the usual diagnostic functions for anti-surge protection.
  • the method can be carried out during operation of the turbomachine 4, in particular as an auto-calibration, which is triggered by the passage of time and/or the given boundary conditions.
  • an auto-calibration which is triggered by the passage of time and/or the given boundary conditions.
  • the air mass can be flow downstream of the turbomachine 4, for example by partially closing the valve 7 arranged in the bypass path 5 and/or the valve 8 arranged in the exhaust air path 6.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Control Of Positive-Displacement Air Blowers (AREA)

Abstract

L'invention concerne un procédé de fonctionnement d'une turbomachine (4), plus particulièrement d'une turbomachine thermique à paliers à gaz (4), la turbomachine (4) fonctionnant dans une plage de fonctionnement (A) qui est limitée par une ligne de surpression (P) et par une ligne d'étranglement (S), et, de façon à étendre la plage de fonctionnement (A) par une plage de fonctionnement (B) au-delà de la ligne de surpression (P), les étapes suivantes pour déterminer la ligne de surpression (P) ou au moins un point limite situé sur la ligne de surpression (P) étant réalisées : a) étrangler le débit massique (m) à une vitesse de rotation (n) constante de la turbomachine (4) de telle sorte que le rapport de pression (pi) est augmenté jusqu'à ce qu'un rapport de pression maximal (pimax) soit atteint et dépassé, b) capturer et stocker le rapport de pression maximal (pimax) et le débit massique (ṁ) associé, ainsi que la vitesse de rotation (n) associée en tant que point limite de la ligne de surpression (P). L'invention concerne également un dispositif de commande pour la mise en œuvre du procédé ou des étapes individuelles du procédé.
PCT/EP2022/068711 2021-07-13 2022-07-06 Procédé de fonctionnement d'une turbomachine, et dispositif de commande pour mettre en œuvre le procédé Ceased WO2023285231A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021207396.4 2021-07-13
DE102021207396.4A DE102021207396A1 (de) 2021-07-13 2021-07-13 Verfahren zum Betreiben einer Strömungsmaschine sowie Steuergerät

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PCT/EP2022/068711 Ceased WO2023285231A1 (fr) 2021-07-13 2022-07-06 Procédé de fonctionnement d'une turbomachine, et dispositif de commande pour mettre en œuvre le procédé

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2025040790A1 (fr) * 2023-08-24 2025-02-27 Robert Bosch Gmbh Procédé de fonctionnement d'un système de pile à combustible comprenant de multiples empilements

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5306116A (en) * 1992-04-10 1994-04-26 Ingersoll-Rand Company Surge control and recovery for a centrifugal compressor
US6220086B1 (en) * 1998-10-09 2001-04-24 General Electric Co. Method for ascertaining surge pressure ratio in compressors for turbines
FR2911371A1 (fr) * 2007-01-16 2008-07-18 Peugeot Citroen Automobiles Sa Procede et dispositif de mesure de la limite de pompage d'un turbocompresseur alimentant un moteur de vehicule
DE102018004309A1 (de) * 2018-05-30 2019-12-05 Daimler Ag Verfahren zum optimierten Betrieb eines Strömungsverdichters
DE102019216712A1 (de) * 2019-10-30 2021-05-06 Robert Bosch Gmbh Verfahren zum Betreiben und zum Auslegen eines Brennstoffzellensystems

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5306116A (en) * 1992-04-10 1994-04-26 Ingersoll-Rand Company Surge control and recovery for a centrifugal compressor
US6220086B1 (en) * 1998-10-09 2001-04-24 General Electric Co. Method for ascertaining surge pressure ratio in compressors for turbines
FR2911371A1 (fr) * 2007-01-16 2008-07-18 Peugeot Citroen Automobiles Sa Procede et dispositif de mesure de la limite de pompage d'un turbocompresseur alimentant un moteur de vehicule
DE102018004309A1 (de) * 2018-05-30 2019-12-05 Daimler Ag Verfahren zum optimierten Betrieb eines Strömungsverdichters
DE102019216712A1 (de) * 2019-10-30 2021-05-06 Robert Bosch Gmbh Verfahren zum Betreiben und zum Auslegen eines Brennstoffzellensystems

Non-Patent Citations (1)

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Title
GALINDO ET AL: "Experiments and modelling of surge in small centrifugal compressor for automotive engines", EXPERIMENTAL THERMAL AND FLUID SCIENCE, ELSEVIER, AMSTERDAM, NL, vol. 32, no. 3, 12 October 2007 (2007-10-12), pages 818 - 826, XP022393653, ISSN: 0894-1777, DOI: 10.1016/J.EXPTHERMFLUSCI.2007.10.001 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2025040790A1 (fr) * 2023-08-24 2025-02-27 Robert Bosch Gmbh Procédé de fonctionnement d'un système de pile à combustible comprenant de multiples empilements

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