New Technologies for Fuel Cells in Future Powertrain ...Simulation Technology AVL Instrumentation and Test Systems AVL Powertrain Engineering 3 Rethinking Propulsion. AVL – Technical

Wasserstoff und Brennstoffzellen-Projekte, F&E-Institutionen, Firmenstrategien und technologiepolitische

Förderinstrumente in Deutschland und Österreich

13.12.2007 TechGate Vienna

New Technologies for Fuel Cellsin Future Powertrain Applications

Peter PRENNINGER

2

Rethinking Propulsion.

AVL Company Profile

Turnover:

2006: 537 Mio €

Employeesmployees:

2006: 3640

Average R&D spending:

10 % of turnover

AVL AdvancedSimulation Technology

AVLInstrumentationand Test Systems

AVLPowertrain Engineering

3


AVL – Technical Centers

Ann Arbor, Michigan

SwedenNew Delhi Shanghai

Peterborough, UKGermany

Plymouth, MichiganHeadquarters Graz

4


AVL – Examples R&D Activities

First Magnesium DI Diesel Engine

First TurbochargedDI Gasoline Engine

5


ECO TargetTM – ICE Hybrid Concept

9498

102106110114118122126130

0 0.1 0.2 0.3 0.4

CO

2-

g/k

m

NOx - g/km

908682

90 -

120

g/k

m

Downsizing and conventional HSDI Diesel combustion

Hybridization (idle shut-off, regenerative braking, electrical boosting)

Alternative Diesel combustion

Potential of thermal encapsulation

Mid-Class PassengerCar (1350 kg)Mild Hybrid Conceptwith 3-Cylinder DI Diesel EngineAchievement of CO2Emissions < 100 g/km

6


AVL – Selected A3 Projects

SOFC Auxiliary Power Unit PTSUTM

Fuel Cell Vehicle Controller for the HyLite Project

Stack Monitoring TechniqueAVL-THDATM

7



Offer and Implementation! Development partnership of AVL and leading fuel cell

manufacturer Topsoe Fuel Cell (TOFC)

! Prototype development

! Sub-system and single component development

! Integration and economic feasibility studies! HiL test bench for system and component development

Solution! Stand alone and highly integrated concept

PTSUTM(1) developed

! Solid oxide fuel cell technology, fuel: Diesel

! Cabin climatisation, electrification, engine pre-heating and exhaust gas after treatment

! End-consumer pay back period below 2 years

! Modular design of 2 concepts (1 manufacturing line for 2 products)

! Significant reduction of idling noise and emissions

Motivation: Reduction of heavy duty truckidling costs and emissions

SOFC Stack - TOFC AVL Diesel ATR/CPOX Reformer

(1) PTSU

8



1 kW SOFC Stack(TOFC)

Reformer

Cathode HEX

9



37% System Efficiency(compared to 35% designtarget)

55% Peak Efficiency

92% Fuel Utilization

SOFC APU Load Profile Test

0

100

200

300

400

500

600

0 60 120 180 240

time [s]

elec

tric

Po

wer

[W

]

-0.4

-0.2

0

0.2

0.4

0.6

0.8

Eff

icie

ncy

[-]

P_demandP_grossP_netSystem Efficiency

10


HyLite – PEMFC-Battery Hybrid EV

HyLite® - a consortium of 10 automotive supplier industry partners.

The partners built a hydrogen fuelled PEM fuel cell – battery hybrid energy system for an electrical driven vehicle.

TargetsDevelopment of optimised components for fuel cells systems i.e. in particular air and fuel supply subsystems, thermal and energy management systems

Build up of an open testing platform for fuel cell and electrical driven power trains.

11


ASMASMDC DC

ACAC

ASMASMASMASMDC DC

ACAC

DC DC

ACAC

battery packbattery packNiMHNiMH, 8kW, 8kW

PEFC systemPEFC system15kW net15kW net

energy management energy management unitunit

DC DC

DCDC

DC DC

DCDC

gas. H2 tankgas. H2 tank

VMUVMUR D N PR D N P

VMUVMUR D N PR D N PR D N PR D N P

driving conditions

state of charge

propulsion power

regenerative power area

city

extra-urban

highway

actual SOC

SOC target principle principle

driving conditions

state of charge

propulsion power

regenerative power area

city

extra-urban

highway

actual SOC

SOC target principle principle

Detection of VehicleDriving State and Driver Demand

Energy Management considering SOC and FC State

Testing of Operation Strategy with VehicleSimulation Model


12


PEMFC Model fromCDL-FCS TU Graz

Implementation in AVL-MCUTM

Basis for RT-HIL Model in EU Project HySys

HIL Demonstrator at AVL Exhibition


FC-HEV Powertrain System

Hydrogen PathHydrogen Path

PowertrainControl

Electric Control BOP Control

drive torquebrake torque

electric powerdemand drive

electric powerdemand FC

Anode Pressure Control

reference pressure hydrogenreference mass flow hydrogen

HMD Driver

HMD

Pressure Sensor Driver

sensor reading

Pressure Sensor

anodepressure

actuator output

referenceHMD signalfuel cell power limit

DriverVehicle

E-Drive

vehicle speed

wheel speedwheel torque

motor speedmotor torqueefficiencies

Further Elements

Further Elements

Target System: dSPACE Microautobox

Brake pedal Acceleration pedal

13


Stack Monitoring Technique AVL-THDATM

0 5 10 15 20 30 35 40

0.2

0.3

0.7

0.9

0.0

stack current, A

cell voltage, V

nodistortion

harmonicdistortion

critical cell typ. V/I curve

i thda

(t)

tim

e

time

AVL THDA – TOTAL HARMONIC DISTORTION ANALYSIS

area of linear transfer function

operating point

0 5 10 15 20 30 35 40

0.2

0.3

0.7

0.9

0.0

stack current, A

cell voltage, V

nodistortion

harmonicdistortion

critical cell typ. V/I curve

i thda

(t)

tim

e

time

AVL THDA – TOTAL HARMONIC DISTORTION ANALYSIS

area of linear transfer function

operating point

If defects or critical conditions occur in one or few cells, local non-linearities in the transfer function distort a superimposed signal and form harmonics

Extra spectral components (i.e. harmonics) are detectable in theentire stack sum voltage

Reduced measurement effort: stack voltage & stack current only

Low cost approach (2 channel instrumentation)

*patented, registered trademark

Effects resulting from voltage drifts are analyzed instead of voltage drift measurement

““THDATHDA™™”” –– Total Harmonic Distortion Analysis* Total Harmonic Distortion Analysis*

14



battery pack

fuel cell system

M

DC

AC

DCDC

DC

DC

FC control

iAC

inverters, converters, ect.& signal modulation

w/ THDA

≈

iFC

+12V

b.

a.

a. Modulation of specific current signal pattern by converterb. Embedded signal distortion analysis by existing FC controller (SW function)

" cost reduction to minimum

15



„THDA level“is indicatingon-line criticalvoltage drifts(somewhere) in the stack

5kW PEMFC System: Varying Air Supply Conditions Load = 2.5kW, AVL List GmbH 2007

0.0

0.5

1.0

1.5

2.0

200 220 240 260 280 300 320 340 360 380 400

time scale [s]

cell

volt

age

[V]

air

lam

bd

a [-

]

0

15

30

45

60

TH

DA

leve

l

air lambda

THDA

CVM (~100 channels)

5kW PEMFC System: Dead End Operation with Delayed Anode-Purge load = 2.4kW; AVL List GmbH 2007

-2.0

-1.0

0.0

1.0

2.0

25 50 75 100 125 150 175 200 225 250 275 300 325

time scale [s]

cell

volt

age

[V]

0

12

24

36

48

TH

DA

leve

l

H2 purge

THDA

CVM (~100 channels)

H2 purgeH2 purge

16



Changes in impedances are differently influenced by several

critical conditions " correlates to harmonic distortion effects# Basis for separation of cathode/anode effects with THDA

0.000

0.005

0.010

0.015

0.020

0.025

0.030

1 10 100 1000 10000

frequency [Hz]

imp

edan

ce [

�]

Dead End t=230s

Low hydrogen partial pressure p=0.25

Low air stoichiometry �=1.4

Normal operation

f THDA2 f THDA3f THDA1 f Membrane

CDL PEMFC V2:25cm² standard MEA&GDL

EIS: electrical impedance spectroscopy

17


AVL – Selected A3 Projects


Fuel Cell Vehicle Controller for the HyLite Project

Stack Monitoring TechniqueAVL-THDATM

18


Kontakt

Dr. Peter Prenninger

AVL List GmbH

Anschrift: Hans List Platz 18020 Graz

Tel: +43-316 787 1484Fax: +43-316 787 570web: www.avl.comEmail: [email protected]

Documents

New Technologies for Fuel Cells in Future Powertrain ...Simulation Technology AVL Instrumentation and Test Systems AVL Powertrain Engineering 3 Rethinking Propulsion. AVL – Technical