有轨电车超级电容模组液冷散热仿真分析

超级电容模组因其快速充放电和适应大功率需求的能力被视为有轨电车未来动力电源的发展趋势。然而,在运行和充放电过程中,超级电容模组会产生大量热量,并导致温度在短时间内迅速上升。为解决该问题,本工作提出一种采用微型通道液体冷却的热管理方式,其原理是利用液冷板微型通道内的低温流体对超级电容单体进行冷却,通过改变边界条件确保超级电容模组在不同散热工况下的工作温度始终保持在适宜的范围内。为了比较液冷板性能,本工作设计了三种液冷板微型通道的模型,并使用ANSYS仿真软件对其进行了数值模拟,建立了新型液冷板最高温度预测模型,研究了边界条件对新型液冷板性能的影响。结果表明,design-3液冷板模型具有较好的流动和散热性能,当提高冷却液入口质量流量时,可以有效降低超级电容单体的最大温差和最高温度,改善单体间的均温性。但随着冷却液入口质量流量增至0.35 kg/s后,超级电容单体最高温度降幅逐渐减小,对其散热性能改善有限,提高流量会使热管理系统能量损失增加;当提高冷却液入口温度时,超级电容单体间温差不断减小,但冷却液入口温度对单体的均温性影响不大。     

沟槽式散热器水冷服务器基板流动与散热性能的研究

如何在较低功耗下,使服务器基板CPU低于规定温度已成为数据中心冷却问题的关键。研究了沟槽式水冷散热器对服务器基板芯片的散热。首先,通过开展沟槽式散热器冷却一个模拟CPU服务器基板的实验,对散热器水冷却过程的流动特性和传热特性做了研究,并分别获得"压降-流量"和"进口水温-流量"的性能拟合公式。其次,开展采用集成式沟槽散热器冷却含多CPU服务器基板的实验研究,通过实验测试,改变冷却水的流量和入口温度,以期获取芯片温度为70和80℃时所提供的最小能耗。实验结果表明:进口温度为25℃时,芯片温度维持在80℃以下的最佳流量为0.8 L/min;使芯片温度稳定在70℃以下的最佳流量为1.0 L/min。     

直条缝翅片管换热器传热与流动阻力性能研究

为了解翅片间距、翅片厚度、翅片材料和基管材料对直条缝翅片管换热器的传热和流阻性能的影响,以及获得通用的换热与流动阻力计算关联式,对一种直条缝翅片管换热器进行了实验研究。通过风洞试验台共进行了7个试件的试验,试验过程中管内水的进口温度和速度保持60℃和1.5 m/s不变,进风温度保持21℃,入口风速为1.5～4.5 m/s。结果表明：在管外空气侧雷诺数Re_a为2647～8143范围内,随着翅片间距的增大,对流换热系数先增大后减小,存在一个峰值;翅片间距对阻力的影响与管外空气侧雷诺数有关,当Re_a≤5 000时翅片间距越小摩擦系数越大,当Re_a>5 000时,翅片间距越小,摩擦系数越小;翅片厚度的增加会增加对流换热系数和摩擦系数;紫铜(T2)翅片的对流换热系数高于8011铝合金(AL8011)翅片,但摩擦系数较低;T2基管的对流换热系数最高,铁白铜(B10)基管次之,316L不锈钢(316L)基管最低;不同的基管材料对摩擦系数没有影响。     

电子元件散热器翅片自然对流散热性能研究

针对室外电子设备在自然对流条件下的散热问题,设计开发了一种新型散热器翅片结构——翅片开孔式涡流发生器,易于加工且直接与翅片连接,不存在焊接的问题。利用数值模拟的方法探究了涡流发生器的布置方式与攻角对散热器散热的影响。结果表明:翅片开设三角孔,在翅片间空气流动过程中起到了明显的作用,有效降低了三角形涡流发生器造成的流动阻力,增加了空气的扰动;当涡流发生器间距为40 mm、攻角为15°时,散热器翅片高温热源区域的散热效果最好。     

相变换热器烟气侧流动及传热特性的数值模拟

对壁温均匀的相变换热器换热管外烟气的流动状态与翅片管的换热过程进行数值模拟,分析烟气入口速度、翅片间距及翅片管横向间距、纵向间距对流动传热特性的影响。结果表明:随着烟气入口速度的增加,换热量和烟气流动阻力均增加;一定范围内增大翅片间距,能够强化传热性能,降低烟气流动阻力;翅片管横向间距的增大能强化传热,而纵向间距的增大会减弱传热性能,二者均能够降低烟气的流动阻力。     

超临界CO_2在水平螺旋槽管内冷却换热的数值研究

建立了螺旋槽管的三维实体模型,使用ANSYS Fluent软件模拟了在不同的冷却压力、质量流量以及进口温度下超临界CO_2在水平螺旋槽管内的流动与传热特性。结果表明:流体的整体换热系数随冷却压力的增大而降低,随进口温度变化不显著;随着质量流量的增加,浮力效应所产生的影响降低,局部换热系数的峰值增大。在考虑了流体性质的基础上,建立了槽管冷却过程中超临界CO_2对流换热系数关联式,并与文献实验值进行了对比,验证了关联式的准确性。     

基于仿生翅脉流道冷板的锂离子电池组液冷散热北大核心CSCD

基于方形锂离子电池生热特点,设计了一款新型仿生翅脉流道冷板。在数值传热学理论基础上,建立了仿生翅脉流道冷板的电池组液冷冷却散热模型,对仿生翅脉流道冷板和进出口位置不同的两种并行流道冷板的锂离子电池组冷却散热分别进行了数值模拟计算,并分析了电池组相邻冷板冷却液流向和流道槽深等参数对仿生翅脉流道冷板散热的影响。结果表明:与并行流道冷板相比,仿生翅脉流道冷板冷却不仅能够进一步降低电池组最高温度和温差,提升温度分布均匀性,还可以减小流道压力损失,降低能量消耗。电池组相邻冷板冷却液交错流比同向流电池组的表面最高温度降低了0.62 K,温差减小了1.13 K,平均温度变化相差不大,温度场分布均匀性得到进一步提升;冷却液质量流量不变,随着流道槽深的增大,电池组的最高温度、平均温度和温差均出现先增大后减小的现象,但随着流道槽深的增加,电池组的重量和所占空间也会增加,当流道槽深为2 mm时冷板冷却效果最优。研究结果可为探索散热性能更好、能耗更低的电池组热管理系统提供参考。     

翅片式热管散热器自然对流换热特性分析与多目标结构优化

采用数值计算方法对一种应用于半导体制冷片热端散热的翅片式热管散热器进行模拟,探究自然对流条件下不同翅片参数对散热器换热特性的影响。结合多目标遗传算法(NSGA-Ⅱ),以影响散热器散热的两个主要参数——翅片表面传热系数和肋面效率为优化目标,对散热器整体做出综合优化,并对优化结果进行K均值聚类分析,提出了翅片端优化原则。结果表明,肋面效率对散热器性能的影响有限,提高表面传热系数可显著降低散热器总热阻;与未优化方案相比,所选优化方案可使基板热端面温度下降3.5K,散热器热阻降低18.22%。     

平行流式电机周向水套结构参数对散热性能影响研究

针对电力机车上某功率密度为1.27 kW/kg的平行流式电机周向水套结构的散热问题进行了研究。首先利用热阻网络法建立了平行流多通道截面的热阻数学模型;然后借助FLUENT软件对水套的电机散热过程进行了数值模拟,并对结构参数进行了优化;最后通过实验验证了计算的正确性。结果表明:当通道孔数n增大时,总热阻普遍减小;当通道单孔宽度x增大时,总热阻先增大后减小,当n=6个、x=1.670 mm时,水套具有最佳的散热性能;水套各测温点的数值模拟温度与实验测量温度之间的相对误差均低于5.00%。     

两型间冷器芯体热动力特性试验研究

为了提高间冷器芯体结构的热动力性能,根据芯体翅片不同排布方式,设计了两型间冷器芯体结构:翅片轴向排布式芯体结构(A型)和翅片周向排布式芯体结构(B型),其通流部分均按照空气层和水层交替叠加的方式排布,通过模拟不同工况下的间冷器运行状态,测量两型间冷器芯体结构的进/出口温度、进/出口压力和冷却水流量,对两型间冷器芯体结构的换热性能及流阻特性进行对比分析。结果表明:翅片轴向排布式间冷器芯体的换热特性及水侧阻力特性优于翅片周向排布式芯体,但翅片周向排布式间冷器芯体的空气侧阻力特性优于翅片轴向排布式芯体。     

带扰流片的矩形通道的实验研究

以高温透平叶片冷却为应用背景，对带有顺排、错排扰流片的矩形通道进行了实验研究。实验结果表明：在相同的雷诺数下，错排扰流片比顺排扰流片具有更好的强化换热效果，即便保持相同的流动阻力，错排扰流片的冷却效果仍强于顺排扰流片。     

有扰流片的矩形通道内空气流动和传热过程的数值模拟

以高温透叶片尾部区内部冷却为应用背景，对带顺排、错排扰流片肋的通道内空气流动和传热过程进行了数值模拟。计算结果表明，在相同雷诺数下，错排扰流片的阻力系数比针肋和顺排绕流片的阻力因子均增大约2%，而冷却能力分别增大约50%和9%。     

Development of an OAPCP-micropump liquid cooling system in a laptop

An innovative one-side actuating piezoelectric micropump (OAPCP-micropump), which is combined with a 45 mm × 28 mm × 4 mm cold plate chamber, has been developed to drive liquid in a cooling system for a laptop. The results show that the shape and the numbers of the fins inside the cold plate chamber have strong effects on the pressure drops and flow profiles. The fluid in the pump chamber may impinge on the fins and increase the heat dissipation rate due to the oscillation by the actuator. The measured maximum flow rate of the OAPCP-micropump is 4.1 ml/s, and its maximum pump head reaches 9807 Pa. The new cooling system with an OAPCP-micropump design shows a stable performance on total thermal resistance due to the high flow rate.     

High heat flux thermal management through liquid metal driven with electromagnetic induction pump

In this paper, a novel liquid metal-based minichannel heat dissipation method was developed for cooling electric devices with high heat flux. A high-performance electromagnetic induction pump driven by rotating permanent magnets is designed to achieve a pressure head of 160 kPa and a flow rate of 3.24 L/min, which could enable the liquid metal to remove the waste heat quickly. The liquid metal-based minichannel thermal management system was established and tested experimentally to investigate the pumping capacity and cooling performance. The results show that the liquid metal cooling system can dissipate heat flux up to 242 W/cm² with keeping the temperature rise of the heat source below 50°C. It could remarkably enhance the cooling performance by increasing the rotating speed of permanent magnets. Moreover, thermal contact resistance has a critical importance for the heat dissipation capacity. The liquid metal thermal grease is introduced to efficiently reduce the thermal contact resistance (a decrease of about 7.77 × 10⁻³ °C/W). This paper provides a powerful cooling strategy for thermal management of electric devices with large heat power and high heat flux.     

Novel investigation strategy for mini-channel liquid-cooled battery thermal management system

Many researchers have focused on liquid-cooled devices with simple structure and high efficiency, which promoted the gradual development of the mini-channel liquid-cooled plate battery thermal management system (BTMS), due to the advancement of liquid cooling technology. This paper has proposed an electrochemical-thermal coupling model to numerically predict the thermal behavior of the battery pack in different parameters of mini-channel cold plates and optimize the parameter combinations. The effects of cooling plate width, mini-channel interval, and inlet mass flow rate on the heat dissipation performance of the system were analyzed at a constant C-rate to provide a reliable experimental basis for the optimization model. Results indicate that increasing the cold plate width and the inlet mass flow rate reduce the temperature and temperature gradients. In addition, the minimum temperature difference is obtained at the mini-channel interval of 6 mm. The optimum cooling plate width (90 mm), mini-channel interval (4 mm), and inlet mass flow rate (80 g/s) are determined using the orthogonal test, analysis of variance, and comprehensive analysis of multi-index results. The addition of an auxiliary cooling system based on the optimized combination further reduces the maximum temperature and temperature difference of the battery pack by 4.9% and 9.2%, respectively. The developed strategy and methods can further improve the performance of the BTMS and provide a reference for the development of a compact battery pack at high discharge rates for engineering applications.     

Thermal analysis and management of proton exchange membrane fuel cell stacks for automotive vehicle

The thermal management of a proton exchange membrane fuel cell (PEMFC) is crucial for fuel cell vehicles. This paper presents a new simulation model for the water-cooled PEMFC stacks for automotive vehicles and cooling systems. The cooling system model considers both the cooling of the stack and cooling of the compressed air through the intercooler. Theoretical analysis was carried out to calculate the heat dissipation requirements for the cooling system. The case study results show that more than 99.0% of heat dissipation requirement is for thermal management of the PEMFC stack; more than 98.5% of cooling water will be distributed to the stack cooling loop. It is also demonstrated that controlling cooling water flow rate and stack inlet cooling water temperature could effectively satisfy thermal management constraints. These thermal management constraints are differences in stack inlet and outlet cooling water temperature, stack temperature, fan power consumption, and pump power consumption.     

The heat transfer characteristics of liquid cooling heat sink with micro pin fins

This paper numerically and experimentally investigated the liquid cooling efficiency of heat sinks containing micro pin fins. Aluminum prototypes of heat sink with micro pin fin were fabricated to explore the flow and thermal performance. The main geometry parameters included the diameter of micro pin fin and porosity of fin array. The effects of the geometrical parameters and pressure drop on the heat transfer performance of the heat sink were studied. In the experiments, the heat flux from base of heat sink was set as 300 kW/m². The pressure drop between the inlet and the outlet of heat sink was set < 3000 Pa. Numerical simulations with similar flow and thermal conditions were conducted to estimate the flow patterns, the effective thermal resistance. It was found that the effective thermal resistance would reach an optimum value for various pressure drops. It was also noted that the effective thermal resistance was not sensitive to porosity for sparsely packed pin fins.     

Experimental research on thermal characteristics of PCM thermal energy storage units

To explore thermal management integration in electric vehicles (EVs), a phase change materials (PCMs) thermal energy storage unit using flat tubes and corrugated fins is designed. The investigation focuses on the thermal characteristics of the PCM unit, such as the temperature variation, heat capacity, and heat transfer time, etc. Meanwhile, the heat storage and release process will be influenced by different inlet temperature, liquid flow rate, melting point of the PCM, and the combination order of the units. Under the same inlet temperature and flow rate condition, the PCM unit with higher melting point enters the latent heat storage stage slowly and enters the phase change melting release stage quickly. Furthermore, the heat storage and release rates increase with increasing liquid flow rates, but the effects are diminishing in the middle and later periods. The multiple PCM units with different melting temperatures are cascaded to help recycle low-grade heat energy with different temperature classes and exhibit well heat storage and release rates.     

径向错列翅片管内凝结对流换热数值模拟分析

采用数值模拟方法,对径向错列翅片管内含不凝结气体水蒸气的凝结对流换热及阻力特性进行了综合分析。将编写的自定义函数(UDF)导入ANSYS FLUENT软件,对新型强化管传热性能和阻力性能进行了数值模拟,并根据管长方向壁面上蒸汽质量分数的变化情况,讨论分析了凝结过程中翅片管传热性能的变化规律。分析结果表明:与光管相比,内翅片管的强化传热效果随翅数增多、翅片换热接触面积增大而更加显著;另一方面,翅片管的流动阻力相应增大,对管路换热产生不良影响。在所研究翅型范围内16翅y=2x~2型翅片管综合强化换热效果更优;此外随着换热过程的持续,蒸汽凝结逐渐放缓;入口速度增大导致水蒸气凝结不充分,对换热效果的提升有一定制约。     

Numerical investigation on integrated thermal management for lithiumion battery pack with phase change material and liquid cooling

为满足3 C放电倍率下电池组散热要求,提出了PCM\液冷复合式散热方案,利用有限元分析了液体流速、流道排列方式、铝制框架鳍宽和环境温度对电池组温度的影响。结果表明,增加流速可优化电池组散热性能,但当流速大于0.08 m/s时,流速的增加对散热系统无明显优化;各流速下Type I散热方式效果均为最优且电池组满足散热要求;鳍宽为2 mm时可将电池组最高温度进一步降低1.6℃;当环境温度从38℃增至42℃时,复合式散热系统体现了良好的热稳定性能。