Compressor

Abstract

The invention relates to a compressor (20) for generating a compressed air flow for a fuel cell (10), having a compressor element (21), in particular a compressor wheel, wherein the compressor element (21) is coupled in a to a drive shaft (23) for co-rotation, the drive shaft (23) being driven by a motor (22), in particular an electric motor, wherein at least one hydrodynamic or hydrostatic bearing (24, 25) is used to mount the shaft (23) in a rotatable manner, wherein the plain bearing (24, 25) is connected to a lubricant supply means (30), which is used to supply a lubricant for hydrodynamic or hydrostatic pressure generation to the plain bearing (24, 25), wherein the lubricant is water or a fluid mixture, predominantly comprising water, wherein the plain bearing (24, 25) has a lubricant inlet and a lubricant outlet, wherein the lubricant can be routed to the plain bearing (24, 25) via the lubricant inlet and the lubricant can be discharged from the plain bearing (24, 25) via the lubricant outlet, and wherein a discharge area of the circulation system (30) is disposed in the area of the lubricant outlet. An operationally safe design can be implemented for such a compressor if provision is made for the cross-section area of the outlet of the liquid outlet of the plain bearing (24, 25) to be completely covered by the lubricant held in the discharge area.

Claims

1-16. (canceled)

17. A compressor for generating a compressed air flow for a fuel cell, comprising: a drive shaft; a compressor wheel mounted on the drive shaft for co-rotation with the drive shaft; an electric motor configured to drive the drive shaft; at least one plain bearing rotatably supporting the drive shaft, the plain bearing including a lubricant inlet for receiving a lubricant for hydrodynamic or hydrostatic pressure generation and a lubricant outlet for discharging the lubricant; a lubricant supply connected to the plain bearing to supply the lubricant to the lubricant inlet of the plain bearing, the lubricant being water or a fluid mixture predominantly comprising water; and a discharge area arranged to hold the lubricant discharged from the lubricant outlet of the plain bearing such that an entire cross-section area of the lubricant outlet is completely covered by the lubricant held in the discharge area.

18. The compressor of claim 17, wherein: the lubricant supply is completely filled with the lubricant and the lubricant supply is vented.

19. The compressor of claim 17, wherein: the lubricant supply comprises a closed circulation system.

20. The compressor of claim 17, wherein: the lubricant supply is configured such that a lubricant pressure at the lubricant outlet of the plain bearing is greater than an ambient pressure surrounding the compressor.

21. The compressor of claim 17, wherein: the lubricant supply is configured such that a lubricant pressure at the lubricant outlet of the plain bearing is at least 0.5 bar.

22. The compressor of claim 21, wherein: the lubricant supply is configured such that the lubricant pressure at the lubricant outlet of the plain bearing is at most 5 bar.

23. The compressor of claim 17, further comprising: a lubricant discharge line located at a geodetic height above the plain bearing such that any gas transported in the lubricant is at least partially separated from the lubricant.

24. The compressor of claim 17, wherein: the lubricant supply includes a lubricant supply line configured to supply the lubricant to the plain bearing from beneath the plain bearing relative to a direction of gravity.

25. The compressor of claim 17, wherein: the lubricant supply includes a lubricant discharge line configured to discharge the lubricant from the plain bearing above the plain bearing relative to a direction of gravity.

26. The compressor of claim 17, wherein: the lubricant supply includes a lubricant pump configured to supply the lubricant to the plain bearing, the lubricant pump being disposed at a geodetic height beneath the plain bearing relative to a direction of gravity.

27. The compressor of claim 17, further comprising: a heat exchanger fluidically connected to the plain bearing and configured to extract heat from the lubricant.

28. The compressor of claim 17, further comprising: a compressor housing, the compressor wheel, the drive shaft and the electric motor being disposed in the compressor housing; and wherein the lubricant supply is a closed circulation system located within or on the compressor housing, the closed circulation system including a lubricant pump.

29. The compressor of claim 28, further comprising: a power electronics connected to the electric motor, the power electronics being attached to or secured in the compressor housing; a heat exchanger in heat-exchanging contact with a heat-generating area of the power electronics; and wherein the lubricant supply is configured such that the lubricant is routed as coolant to the plain bearing downstream of the heat exchanger.

30. The compressor of claim 17, wherein: the plain bearing includes a rotor and a stator, the rotor being rotated relative to the stator, the rotor including a rotor bearing surface facing a counter surface of the stator for hydrodynamic pressure generation in an area of a converging gap, wherein the rotor bearing surface and/or the counter surface in a section along and through an axis of rotation in sectional view form a continuous bearing contour formed from at least two contour sections to generate hydrodynamic load-bearing capacities in both radial and axial directions.

31. The compressor of claim 30, wherein: the rotor bearing surface and the counter surface form a multi-surface plain bearing.

32. A compressor for generating a compressed air flow for a fuel cell, comprising: a drive shaft; a compressor wheel mounted on the drive shaft for co-rotation with the drive shaft; an electric motor configured to drive the drive shaft; at least one plain bearing rotatably supporting the drive shaft; and a closed circulation system configured to supply a lubricant to the plain bearing, the lubricant being water or a fluid mixture predominantly comprising water, the closed circulation system including: a pump; lubricant supply line arranged to supply the lubricant from the pump to the plain bearing from beneath the plain bearing; a collector arranged to collect lubricant discharged from a lubricant outlet of the plain bearing, the collector being arranged such that the lubricant outlet is completely covered by the lubricant.

33. The compressor of claim 32, further comprising: a compressor housing, the compressor wheel, the drive shaft and the electric motor being disposed in the compressor housing; and wherein the closed circulation system is located within or on the compressor housing.

34. The compressor of claim 32, wherein: the closed circulation system is completely filled with the lubricant.

35. The compressor of claim 32, wherein: the pump is configured to pressurize the closed circulation system such that a pressure of the lubricant at the lubricant outlet of the plain bearing is at least 0.5 bar and at most 5 bar.

36. The compressor of claim 32, wherein: the arrangement of the collector such that the lubricant outlet is completely covered by the lubricant reduces formation of foam in the lubricant.

Description

[0027] The invention is explained in greater detail below based on exemplary embodiments shown in the drawings. In the Figures:

[0028] FIGS. 1 and 2 each show a block diagram of a fuel cell system having a compressor,

[0029] FIGS. 3 to 7, respectively, show block diagrams of a compressor for use in a fuel cell system according to FIG. 1.

[0030] FIG. 1 shows a schematic view of a fuel cell 10 having a reaction chamber 13. A membrane 14 is disposed in the reaction chamber 13, separating an anode chamber from a cathode chamber. An anode 15 is mounted in the anode compartment and a cathode 16 is mounted in the cathode compartment. A supply line 12 can be used to supply hydrogen to the anode compartment from a hydrogen tank 11.

[0031] A compressor 20 can be used to supply compressed air to the cathode chamber. A discharge line 17 is routed out of the reaction chamber 13. This discharge line 17 can be used to discharge the exhaust gas generated during the chemical reactions in the fuel cell 10 in the form of water vapor.

[0032] A water separator 18 may be integrated into the discharge line 17. The water separator 18 has a water drain 18.1. It can be used to discharge any separated water. Furthermore, the water separator 18 has a gas line 18.2. It can be used to discharge the gas phase separated in the water separator 18.

[0033] The anode 15 and the cathode 16 are connected to a voltage transformer 40. A cable 42 can be used to connect the battery 43 via the voltage converter 40. Accordingly, the fuel cell 10 can charge the battery 43 during operation. Further, a cable 44 can also be used to connect an inverter 50 to the voltage converter 40. In the inverter 50, the direct current generated by the fuel cell 10, or the direct current supplied from the battery 43, is converted to alternating current. A power cable 51 is used to feed this alternating current to an electric motor 60. For instance, the electric motor 60 may be the prime mover of a motor vehicle.

[0034] The compressor 20 has a compressor housing 27. A bearing housing (not shown) is disposed in the compressor housing 27. The bearing housing comprises two spaced-apart plain bearings 24, 25. These are preferably designed as hydrodynamic bearings 24, 25. The plain bearings 24, 25 are used to mount a drive shaft 23 in a rotatable manner in the bearing housing. A motor 22, namely an electric motor, is connected to the drive shaft 23.

[0035] The motor 22 drives the drive shaft 23. Furthermore, a compressor element 21 is connected to the drive shaft 23 for co-rotation. The compressor element 21 is a compressor wheel, preferably a radial fan. This radial fan takes in ambient air along its axis of rotation. In the compressor wheel, the intake air is compressed and blown off radially. A pressure line 21.2 is used to supply the compressed air to the cathode 16 of the fuel cell 10. An air supply 21.2 is used to supply the ambient air.

[0036] The motor 22 is powered by a power source. In this exemplary embodiment, the battery 43 is used as the power source. The electric motor 22 is connected to power electronics 26 that control the operation of the electric motor 22. The power electronics 26 are preferably located at or in the compressor housing 27. A power line 26.1 leads from the power electronics 26 to the voltage converter 14 (cable 41).

[0037] FIG. 2 shows an embodiment of the compressor that is largely identical to the embodiment of the compressor shown in FIG. 1. To avoid repetition, reference can be made to the explanations above. Only the differences are explained in more detail below.

[0038] As shown in FIG. 2, the gas line 18.2 is routed into the compressor housing 27, where it is routed to a turbine 28. In the turbine 28, the pressurized reaction gas coming from the fuel cell 10 can be expanded. The expanded gas is discharged via a gas duct 18.5 and led out of the compressor housing 27.

[0039] The turbine 28 is connected to the drive shaft 23 and is connected thereto for co-rotation. In this way, the mechanical drive power generated in the turbine 28 can be transmitted to the drive shaft 23. This unburdens the electric motor 22, thus reducing its power consumption.

[0040] A bypass line 18.3 can be assigned to the turbine 28. The bypass line 18.3 connects the gas line 18.2 to the gas duct 18.5, bypassing the turbine 28. A valve 18.4 is integrated in the bypass line 18.3. The valve 18.4 can be opened or closed depending on the existing pressure conditions. In this way, the turbine 28 is either bypassed or all or part of the reaction gas flows therethrough.

[0041] FIGS. 3 to 7 show variants of a compressor 20. In these illustrations, the turbine 28 (and the gas line 18.2, the gas duct 18.5, and the bypass 18.3) are indicated using dashed lines. These dashed representations are intended to symbolize that two alternative designs of the compressor 20 are feasible, namely one having a turbine 28 and one without a turbine 28.

[0042] The embodiments according to FIGS. 3 to 7 refer in principle to the embodiments of the compressor 20 according to FIGS. 1 and 2. To avoid repetition, reference is made to the explanations above. Only the changes shown in these drawings are explained.

[0043] FIG. 3 shows a lubricant supply 30 that is assigned to the two plain bearings 24, 25. The lubricant supply 30 can be used to supply the required lubricant to the two plain bearings 24, 25.

[0044] In the context of the invention, water or a water mixture is used as the lubricant, wherein additives, for instance antifreeze, can be added to a water, and the use of other additives is also conceivable.

[0045] The lubricant supply 30 has a lubricant supply line 31 routed into the compressor housing 27. The lubricant supply line 31 is connected to a lubricant pump 33 in the compressor housing 27. The lubricant pump 33 pumps the lubricant into a pump line 34. Branch lines 35, 36 extend from the pump line 34, each of which branch lines is routed to a plain bearing 24, 25.

[0046] As can be seen in FIG. 3, the lubricant pump 33 is disposed at geodetic height beneath the two plain bearings 24, 25 when the compressor 20 is installed as intended.

[0047] During operation of the compressor 20, the drive shaft 23 rotates and the compressor element 21 therewith. The lubricant is routed to the plain bearings 24, 25 in the area of their lubricant inlet. As a result of the rotation of the drive shaft 23, the lubricant is pumped through a converging gap of the hydrodynamic bearings 24, 25. The lubricant exits the hydrodynamic bearings 24, 25 in the area of their lubricant outlet. This lubricant outlet opens into a collection area, in which lubricant is held. The lubricant covers the entire cross-section area of the lubricant outlet in the collection area. This reduces or suppresses foam from forming in the lubricant. In addition, the collection area may be pressurized relative to the environment. This further adds to the suppression of foam formation.

[0048] Downstream of the collecting areas of the two plain bearings 24, 25, the lubricant flows into a collector 29. A lubricant discharge line 32 is connected to the collector 29. The lubricant discharge line 32 is routed out of the compressor housing 27.

[0049] As can be seen from FIG. 3, in the intended installation state of the compressor, the lubricant discharge line 32 is preferably disposed at geodetic height, above the two plain bearings 24,25. In other words, the lubricant is discharged in the direction of gravity above the plain bearings 24, 25. This results in an additional beneficial effect on degassing the lubricant. In the event that residual gaseous substances are still present in the lubricant, these can be at least partially separated here.

[0050] FIG. 4 shows a further development of the invention according to FIG. 3. As this embodiment shows, a heat exchanger 70 is assigned to the power electronics 26 that actuate the motor 22. This heat exchanger 70 may be mounted directly on the power electronics 26, wherein, for instance, rib-shaped heat exchanger fins are provided in the heat exchanger and connected to heat-generating surfaces of the power electronics 26. The heat exchanger fins are then surrounded by the flowing lubricant, i.e., a heat exchange into the lubricant can occur there.

[0051] It is also conceivable that, for instance, there is a cooling plate in the heat exchanger 70, which cooling plate is connected to the power electronics, for instance by means of a paste having high thermal conductivity. The lubricant can be routed to the heat exchanger through the cooling plate.

[0052] The heat exchanger 70 may be integrated into the lubricant supply 30. For instance, as FIG. 4 shows, the pump line 34 can be connected to the heat exchanger and extend therethrough to transfer the dissipated heat from the power electronics 26 into the lubricant.

[0053] Downstream of the heat exchanger 70, the pump line 34 is again connected to the two hydrodynamic bearings 24, 25, as in FIG. 3.

[0054] FIG. 5 shows a further development of the design according to FIG. 4. Here, as in FIG. 4, a heat exchanger 70 is assigned to the power electronics 26. However, the heat exchanger is now integrated into the lubricant discharge line 32 and connected to the collector 29 via a line section 32.1.

[0055] As in FIG. 4, the heat exchanger 70 and the power electronics 26 are preferably also disposed in the compressor housing 27 in FIG. 5. However, it is also conceivable that one or both of these units are located outside the compressor housing 27.

[0056] In FIG. 4, the heat of the power electronics 26 heats the lubricant before entering the plain bearings 24, 25.

[0057] In FIG. 5, the lubricant coming from the plain bearings 24, 25 is routed to the heat exchanger 70. The advantage of the heat exchanger 70 being located downstream of the plain bearings 24, 25 is that the plain bearings 24, 25 can be lubricated using a liquid of similar temperature under all operating conditions.

[0058] FIG. 6 shows an embodiment of the compressor 20 similar to FIG. 4. As this embodiment shows, a closed circulation system is preferably provided for the lubricant supply 30. This circulation system 30 is completely filled with the lubricant and vented.

[0059] Accordingly, a line 38.1 can be connected downstream of the lubricant discharge line. It can be routed to a heat exchanger 39, for instance. However, the heat exchanger 39 may be integrated at any other point in the circulation system.

[0060] A line 39.1 returns from the heat exchanger 39 to the lubricant pump 33. The heat exchanger 39 is used to transfer heat from the lubricant to the environment. In this way, the temperature level of the lubricant can be lowered.

[0061] Preferably, as FIG. 6 shows, the complete circulation system is located inside the compressor housing 27. In this way, a closed system is formed that does not require any connection to the environment, making for easy installation and operation.

[0062] FIG. 6 further shows that an expansion tank 38 of conventional design is integrated into the circulation system. The expansion tank 38 can be used to compensate for any temperature-related thermal expansion of the lubricant.

[0063] If a closed lubricant circuit is provided, as shown in FIG. 6, which closed lubricant circuit is disposed in or on the compressor housing 27, only the pressure line 21.2 has to be coupled to the fuel cell 10 for connection to the fuel cell 10. The air supply 21.2 then only has to be additionally routed across the area boundary of compressor 20 (dashed illustration of compressor housing 27).

[0064] If the compressor variant using a turbine 28 is implemented, the gas line 18.2 and the gas duct 18.5 also have to be routed across the area boundary.

[0065] However, as FIG. 7 shows, the circulation system 30 does not have to be completely contained within the compressor housing 27 or present at the compressor housing 27. It is also conceivable that only a part of the circulation system 30 is routed in or at the compressor housing 27.

[0066] In particular, it is conceivable that the circulation system 30 is connected to an external heat exchanger 39. This heat exchanger 39 can also be part of a cooling system of a motor vehicle, for instance.