Simulation and dynamo test results of a fuel cell range ... · PDF fileSimulation and dynamo...

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Simulation and dynamo test results of a fuel cell range extender system

in a battery powered vehicleHHFC Budapest; Hungary

29. September 2011

... more than just fuel cells... more than just fuel cells

Bernhard Wolshofer Proton Motor Fuel Cell GmbHBenzstraße 7, D-82178 Puchheim

Tel: +49 (0)89 - 127 62 65 67Fax: +49 (0)89 - 127 62 65 99Email: n.chmielewski@proton-motor.de

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Content

• Company Overview

• Motivation

• Fuel Cell Range Extender Concept

• Model Parameters

• Dynamo Test Results

• Summary

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Company Overview

Proton Motor Fuel Cell GmbHwas founded 1998 as spin-off of Magnet Motor where the development of fuel cells started back in 1994

Holding, founded in 2006 andlisted at London Stock Exchange since Oct. 2006100% owner of Proton Motor

Proton Fuel Cell GmbH offers Fuel Cell Hybrid Solutions for stationary and naval applications and „back to base“ commercial vehicles like busses and light duty vehicles.

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The development of fuel cell systems at Proton Motor is always considering the complete drive or power supply application. In most cases the result of detailed engineering and planning will be an innovative electric hybrid system.

Proton develops and manufactures its own hydrogen powered PEM fuel cell stacks and fuel cell systems and acts as system integrator for customized power and drive solutions.

References

Projects in 2009/10

ZEMShipTriple Hybrid Bus

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Development Partnership

• Specialist for Battery Powered Electric Vehicles

• Located in Newcastle, UK

• Over 1.000 Employees

• World Wide over 1.000 Customers

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Fuel Cell Range Extender Concept

Battery AC Drive Motor

Controller/Inverter

DC to AC

Battery Charger(Rectifies AC to

DC)

AC Electricity Supply

AC Voltage

DC Voltage

Driver Demand

Fuel Cell System (REX)

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Motivation

Drivers for change

• Oil Price/ Energy Security

• Air Quality/ Emissions

• Legislation and Taxation

• Cost of maintenance

• Sound pollution

• Positive Carbon Credits

• Economics

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Expectations

Advantages of a Battery & Fuel Cell Solution

• Extended Range of Operation

• Hydrogen Refueling in 5 Minutes

• Support of AC for Driver Cabin

• No Emissions, low noise

• Battery Management can be optimized

• Longer Lifetime of the Battery Packs

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Model Parameters

Ele

ctric

al C

onve

rsio

n (E

C)

Battery (Batt)

Vehicle (V)Electric

Traction /Generation (TG)

PEMFCSystem (FC)

ElectricalConsumer (ECo)

Mec

hnic

al T

rans

mis

sion

(M

T)

Legend:

Electrical

Mechanical

† Ehsani M. et al., Modern Electric, Hybrid Electric, and Fuel Cell Vehicles, CRC Press, 2010 * In accordance with typical values, e.g. Guzzella, L. et al., Vehicle Propulsion Systems – Introduction to Modeling and Optimization, Springer, 2007 ‡ VDI-Wärmeatlas, Springer, 2006 § Edison Technical Specification, Smith Electric Vehicles, 2010 ¶ Estimated

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Simulation Results

Consistency of algebraic and transient simulation is satisfactorily: Rel. Error in distance estimation: 2-3%.

With average REX power of approx. 6.4 kW doubling o f range possible. (increase up to 180km)Necessary hydrogen mass approx. 2.5 kg

Range doubling with REx: ca. 180 km

Estimated avg. Rex-Power: 6.4 kW

Estimated H2 demand: 2.5 kg

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Dynamo Test Results

Dynamo Test at the DLR Stuttgart

• In total 956 km, thereof approx. 700 km with FC

• REX power 5,5 kW

• Cycles tested:NEDC and Artemis urban cycle

• Load 2,5 t and 4,6 t

• Recuperation on / off

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Dynamo Test Results (NEDC, Curb Weight)

Battery Vehicle w/o REX Battery Vehicle with REX

Increase in range from 113 km to 208 km with 5,5 kW REX power���� Enhancement in range of 84 %

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Dynamo Test Results (NEDC, Curb Weight)

0 3600 7200 10800 14400-80

-70

-60

-50

-40

-30

-20

-10

0

10

20P

ower

[kW

]

Time [s]

Vbat * IBat [kW] BMU: Battery power [kW] Power at dyno [kW]

SE092010 - Dyno Test (Regen off, REx off)

0

10

20

30

40

50

60

70

80

90

100

Veh

icle

Spe

ed [k

m/h

]

0

10

20

30

40

50

60

70

80

90

100

BM

U: S

OC

[%]

Dynamo Test (w/o Rex)

Decrease in SOC per each cycle: approx. 7 %

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Dynamo Test Results (NEDC, Curb Weight)

0 3600 7200 10800 14400 18000 21600 25200-200

-180

-160

-140

-120

-100

-80

-60

-40

-20

0

20P

ower

[kW

]

Time [s]

Vbat * IBat [kW] BMU: Battery power [kW] Power at dyno [kW]

SE092810 - Dyno Test (Regen on, REx off)

0

10

20

30

40

50

60

70

80

90

100

Veh

icle

Spe

ed [k

m/h

]

0

10

20

30

40

50

60

70

80

90

100

BM

U: S

OC

Dynamo Test (with Rex)

Decrease in SOC per each cycle: approx. 4 %

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Dynamo Test Results (Artemis Urban Cycle)

0 100 200 300 400 500 600 700 800 900 1000 1100-100-90-80-70-60-50-40-30-20-10

0102030405060708090

100P

ower

[kW

]

Time [s]

Vbat * IBat [kW] BMU: Battery power [kW] Power at dyno [kW]

SE0927810 - Dyno Test (Regen on, REx off)

0

10

20

30

40

50

60

70

80

90

100

Veh

icle

spe

ed [k

m/h

]

0

10

20

30

40

50

60

70

80

90

100

BM

U: S

OC

Delta SOC over one cycle: ca. -4%

Dynamo Test (w/o Rex)

Decrease in SOC per each cycle: approx. 4 %

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Dynamo Test Results (Artemis Urban Cycle)

200 300 400 500 600 700 800 900 1000 1100 1200 1300-100-90-80-70-60-50-40-30-20-10

0102030405060708090

100P

ower

[kW

]

Time [s]

Vbat * IBat [kW] BMU: Battery power [kW] Power at dyno [kW]

SE092710 - Dyno Test (Regen on, REx on)

Delta SOC over one cycle: ca. -1%

0

10

20

30

40

50

60

70

80

90

100

Veh

icle

Spe

ed [k

m/h

]

0

10

20

30

40

50

60

70

80

90

100

BM

U: S

OC

Dynamo Test (with Rex)

Decrease in SOC per each cycle: approx. 1 %���� Increase in range by a factor of 4 possible

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Summary of the Results

• 700 km dynamo test drive without any failure of the FC-system

• In dynamo tests with REXpower of 5.5 kW an increase in range of 84 % achieved (NEDC)

• For doubling in range REX power of approx. 6.4 kW required

• With Artemis Urban Cycle increase in range by a factor of 4 possible

• Model underestimates range and hydrogen demand. Model optimization necessary

• Next step: increase REX power > 7 kW

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ApplicationExamples

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Acknowledgments

Financial support of this work by German Federal Ministry of Transport, Building and Urban Development (reference 03BS107) is gratefully acknowledged.

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Thank you very much for your kind attention!

... more than just fuel cells... more than just fuel cells

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Back up: Transient Simulation Results

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Back up: Transient Simulation Results

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Back up: NEDC

NEDC, cut off at 80 km/h:

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Back up: Artemis Urban Cycle

0 200 400 600 800 10000

10

20

30

40

50

60V

eloc

ity [k

m/h

]

Time [s]

Artemis urban cycle

0

1

2

3

4

5Duration: ca. 1000s, Distance: ca. 4.5kmAvg. Velocity: ca. 17.5 km/h

Dis

tanc

e [k

m]