Advanced powertrain systems serve as the foundational and core technology for new energy vehicles and intelligent vehicles. In recent years, our institute has conducted research on cutting-edge powertrain technologies, including internal combustion engines, hybrid systems, pure electric drives, hydrogen and fuel cells, power batteries, and intelligent energy systems, achieving a series of significant outcomes.
(1) We have made breakthroughs in "high torque-density in-wheel motor technology." The research clarified the coupling mechanisms of key design parameters for high torque-density in-wheel motors, invented a design methodology for high pole-pair outer-rotor configurations to achieve high torque density, and developed multi-fidelity surrogate models for such motors. This has led to advancements in the design and manufacturing of high torque-density motors, with direct-drive in-wheel motors achieving a torque density of >40 Nm/kg, reaching internationally advanced levels. Related findings have been published in journals such as eTransportation, Energy, and Proc IMechE Part D. The work has been recognized with global awards for pioneering and innovative new energy vehicle technologies and has been applied in passenger vehicle in-wheel motors as well as several heavy-duty in-wheel motor systems.
(2) The "high-safety semi-solid-state power battery" was developed. The reaction mechanism of thermal runaway induced by off-site crosstalk of energetic materials was revealed, and a method for controlling the reaction sequence of thermal runaway was invented. An EC-Free type safe electrolyte formulation was modulated. Combined with in-situ polymerization technology, a high-safety semi-solid-state battery was successfully developed. The non-ignition tolerance temperature in a hot box test for a 360 Wh/kg-class semi-solid-state battery was increased to 200°C, reaching internationally advanced levels. Results have been published in top-tier energy journals such as Joule, Advanced Materials, Advanced Energy Materials, and Energy Storage Materials.
(3) Addressing fundamental materials and water/thermal management for high-efficiency, long-life fuel cells, the research elucidated the high oxygen transport mechanism in mesoporous carbon supports and achieved a breakthrough in controlling the catalyst-ionomer microstructure. It clarified the drainage mechanism at the lands of large-format bipolar plates and invented an ordered water removal technology for large-area stacks, overcoming design challenges for large-area, ultra-long stacks. The mechanisms of water/thermal imbalance and performance degradation under extreme conditions were revealed. A scalable fuel cell kinetic model accounting for in-plane state variations was established. A stack state reconstruction and identification method based on multi-sensor information fusion of pneumatic/electrochemical impedance was invented, achieving a breakthrough in water/thermal management technology across all operating conditions. The membrane electrode assembly (MEA) achieves an area ≥325 cm² with performance >0.8 V @ 0.8 A/cm², and stack lifetime exceeds 20,000 hours. The world's first liquid hydrogen fuel cell heavy-duty truck (range >1000 km) and long stacks for power generation scenarios were developed, representing a domestically leading technical level. The outcomes have been applied in vehicle and stationary power generation scenarios, generating economic benefits exceeding 8 billion RMB.
(4) To address the prominent issues of high impedance/low current density in conventional alkaline water electrolysis (AWE) and high cost/short lifespan in proton exchange membrane (PEM) water electrolysis, focusing on triple-phase boundaries and emphasizing innovations in separators and electrodes, next-generation AWE ion-solvating membranes and PEM electrolysis non-uniformly loaded, ordered integrated electrodes were developed with the aid of AI. These achieved high performance of 1.25 A/cm² @ 1.8 V and 3 A/cm² @ 1.8 V, respectively, reducing AWE impedance by 50% and PEM electrolysis iridium loading by 75%. Thousand-hour-level durability validation was completed, with related results reaching internationally advanced levels. The outcomes have been applied in startup companies, such as those from research groups including YuanTai NengCai, which has developed the world's first most advanced fifth-generation ion-solvating membrane product with a 60 cm width and MW-scale electrolysis system prototypes.
(5) A chemical reaction kinetic model for ammonia-hydrogen combustion was developed, improving the prediction accuracy of the combustion process in ammonia-hydrogen internal combustion engines. A stable combustion and low-pollutant emission control method for ammonia-hydrogen engines using hydrogen jet ignition was invented, achieving an ammonia-to-hydrogen ratio of 97%. A multi-cylinder engineering prototype of a heavy-duty ammonia engine was co-developed, achieving a thermal efficiency of 48%, placing it at an internationally leading level. The results have been demonstrated on heavy-duty trucks and mining trucks, supporting China's transition of heavy-duty transportation powertrain equipment towards zero-carbon energy sources.
