Embed Size (px)
Citation preview
1
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: [email protected]
2
Content
• Company Overview
• Motivation
• Fuel Cell Range Extender Concept
• Model Parameters
• Dynamo Test Results
• Summary
3
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.
4
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
5
Development Partnership
• Specialist for Battery Powered Electric Vehicles
• Located in Newcastle, UK
• Over 1.000 Employees
• World Wide over 1.000 Customers
6
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)
7
Motivation
Drivers for change
• Oil Price/ Energy Security
• Air Quality/ Emissions
• Legislation and Taxation
• Cost of maintenance
• Sound pollution
• Positive Carbon Credits
• Economics
8
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
9
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
10
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
11
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
12
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 %
13
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 %
14
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 %
15
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 %
16
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
17
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
18
ApplicationExamples
19
Acknowledgments
Financial support of this work by German Federal Ministry of Transport, Building and Urban Development (reference 03BS107) is gratefully acknowledged.
20
Thank you very much for your kind attention!
... more than just fuel cells... more than just fuel cells
21
Back up: Transient Simulation Results
22
Back up: Transient Simulation Results
23
Back up: NEDC
NEDC, cut off at 80 km/h:
24
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]
