VEHICLE-INTEGRATED FUEL CELL DRIVE CHAINS · Innovative Vehicle Concepts in a Lasting Traffic System The Institute of Vehicle Concepts Professor Horst E. Friedrich. Dipl.-Ing. Andreas

VEHICLE-INTEGRATED FUEL CELL DRIVE CHAINSSpring Course 2005 „The Quest For Alternative Drive Systems”

of theBonding Initiative at the University of Stuttgart

Institute of Vehicle ConceptsDipl.-Ing. Andreas Brinner

Pfaffenwaldring 38-40, D-70569 Stuttgart

Tel: ++(0)711 685 74 -64/-61/-58 Fax: ++(0)711 685 7465Internet: www.dlr.de/fk

Dipl.-Ing. Andreas Brinner 29.03.05Institute of Vehicle Concepts

Contents of the Presentation

➢ Overview about the DLR-Institute of Vehicle Concepts in Stuttgart➢ Comparison of selected new power trains➢ Components of fuel cell power trains➢ Overview about the HyLite fuel cell power train➢ HyLite fuel cell system package➢ Fuel cell systems for small vehicle applications➢ Modular fuel cell system package➢ Results of fuel cell system operation➢ Summary


Innovative TechniqueSystems: SynergyRoad / Rail Vehicles

Fuel- &Energy Storage

Alternative Drives &Energy Transformation

Lightweight &Hybrid AssemblyMethods

Innovative Vehicle Concepts in a Lasting Traffic System

The Institute of Vehicle ConceptsProfessor Horst E. Friedrich


Research Fields and CompetencesFuel and energy storageProcedural knowledge of admission & test

Batteries, super caps, pressure storage

Lightweight & hybrid structuresConception

Construction, computation, simulation

Materials technology (metal, polymer)

Joining & mounting techniques

Assembly & examination of demonstrators

Innovative technical systemsLCA, Technology analysis

Smart Systems

Alternative drives and energy transformationSystem Design, modeling, simulation

System integration, demonstrator assembly

H2-safety technique, operation permission

Energy transformation techniques

Control software and equipment

available under construction in planning


Fuel Cell System Test Vehicle „HyLite®“

Development platform for component manufacturersNew system components: Industrial partnersFuel cell stacks: NUVERASystem design and integration into the vehicle: DLREnergy management strategy: DLR

TÜV Süd


Air Supply Module

Control Module

Fuel Cell CoreModule

„Minimal“ and rugged fuel cell systemAir-cooled stacksNo humidificationOperation near to atmospheric pressureModularization of the system

H2 Supply Module

Small Fuel Cell Powered Vehicles


Conventional Drive Train of Combustion Engine

Source: „GM Well to Wheel Analysis... – A European Study“, GM Adam Opel AG, 2002

Comparison of Selected Power Trains



Drive Train with Fuel Cell Power Supply

Comparison of Selected Power Trains



Hybrid Drive Train with Fuel CellComparison of Selected Power Trains


Functional Units of a Fuel-Cell Vehicle

Fuel Cell SystemFuel TreatmentAir SupplyWater & Thermal Energy ManagementControl Systems

Fuel Cell SystemFuel TreatmentAir SupplyWater & Thermal Energy ManagementControl Systems

Cooling SystemCooling System

Vehicle Air ConditioningVehicle Air Conditioning

SuspensionUndercarriageSuspension

Undercarriage

Electrical EquipmentElectrical Equipment Drive TrainDrive Train

Body & ChassisBody & Chassis Safety SystemsSafety Systems Control SystemsControl Systems

Components of Fuel Cell Drive Chains


Sub-Systems of a H2-Fuel-Cell Vehicle

Source: „System Integration, Modeling and Validation of aFuel Cell Hybride Electric Vehicle“, Ogburn at Virginia Polytech, 2000



Conventional H2-PEFC System Package of OPEL/GM HydroGen 1

Source: „Technische Daten des „HydroGen 1“, GM Adam Opel AG, 2002



Source: „Opels Brennstoffzellenautos,Wasser marsch für die Zukunft“,GM Adam Opel AG 2003

Advanced HYWIRE Package Prototype Package of General

Motors & Opel

Components of Fuel Cell Power Trains


HyLite® Vehicle with Fuel Cell Hybride SystemOverview about the HyLite® Fuel Cell Power Train


Energy Flows in the Drive Train of a Fuel-Cell VehicleAir and water

EnergyStorage

Short-timeEnergyStorage

ElectricMotor /

Generator

Fuel cell

Air Compressor

Hydrogen Storage

Battery Waste Heat

Energy converterelectr. ↔ mech.

Brakingenergy

DriveEnergy

H2

Air Air

H2

Power adapterelectr. ↔electr.

Boostconverter

Energy Converterchem. → electr.

®

Overview about the HyLite® Fuel Cell Power Train


PEFC-System P&I-Principle of the HyLite VehicleOverview about the HyLite® Fuel Cell Power Train


HyLite Power Train Main Components

Fuel Cell System

M3

IC

Electronic Control Unit

ElectricEngine

DriveController

Battery Set

Bi-directional DC/DC-Converter



EM-ValveGSR


CondensorAKG

IntercoolerAKG

Air CompressorRietschle

Air Intake FilterMahle

Heat ExchangerAKG

Liquid SeparatorMahle

Liquid FilterMahle Bi-directional DC/DC-Converter

FhG

HyLite Partner Components for the Fuel Cell System


Safety Concept of the HyLite® Vehicle

H2-Storage Compartment 1

H2-Storage Compartment 2

AmbientPEFC-

Stack Case

H2-ComponentCompartment

Ambient

H2-Sensor 1

H2-Sensor 3 in the Passenger Compartment

HyLite® Fuel Cell System Package

H2-Sensor 2


System Integration Compartments in the Passenger Area

H2-Storage Vessel 1

H2-Storage Vessel 2

PEFC-Peripheral SystemDI-Water / Coolant

ControlComponents

1

ControlComponents

2

BatterySet 1

ElectricEquipm.

1

BatterySet 2


ElectricEquipm.

2


HyLite® Fuel Cell System PackageOverview about the HyLite® System Package


Battery setHAWKER

Air charge coolerAKG

H2-storage vesselAIR LIQUIDE

Air intake filterMAHLE

Fuel cell stacksNUVERA

Separator vesselDLR

Liquid pumpDLR / SPECK

DI-water filterMAHLE

Front main coolerAKG

Cell voltage meas. unitSMART

Magnetic valveGSR

DC/DC-converterFhG / DLR

Drive controllerMES-DEA

Primary heatexchanger

AKG

SeparatorMAHLE

Air compressorRIETSCHLE-THOMAS

CondenserAKG



H2- Circuit Components and Installation Location

Pressure Reducer

Fuel Cell Stacks

Mass Flow Sensor

Vent Valve

Pressure Indicator

Safety Valve

Pressure Switch

H2 Pressure Storage

Flame Arrestor

Pressure Controller



Development Goal

Simple Polymer-Electrolyte-Membrane Fuel Cell system (PEFC) for the dynamic stand-alone, group and hybrid operation for the use as

power supply of the drive train of small vehicle,as an auxiliary power unit (APU) in vehicles and asan autonomous transportable separate power pack

with identical basic system conceptfor the different areas of applicationIn the power output range between 0.05 and 1 kW of net power output.

Fuel Cell Systems for Small Vehicle Applications


Modularization and StandardizationModularization by a concept with 4 – 6 compact sub-systems:

Hydrogen storage moduleHydrogen supply moduleAir supply modulePEFC-system core moduleCooling moduleControl & energy adaptation module

Standardization by well-defined connections of sub-systems: Piping & tubing for mediaWiring for control signalsWiring for power supply



Block Diagram of the Air-Cooled PEFC System

H2-Storage

Air

WaterSeparator

AirCompressor

Filter

WaterRelease

Vent Valve

Luft

In

H2

In

PressureAdjustement

Valve

H2

Out

EM-ValveBZ-Block

SafetyValve

Out

EM-Valve

Flame Arrestor

Quick coupling

Hydrogen Supply Module

Air Supply Module

Fuel Cell Core Module

Safety Valve

PressureIndicator

PressureSwitch

TemperatureSwitch

Air CoolingModule

Out

Hydrogen StorageModule

PressureSwitch

PressureIndicator

PressureIndicator

PressureSwitch

PressureIndicator

PressureIndicator



Development Continuity of the PEFC-Operated LP Vehicles

1999 2000 2001 2002 2003

0,2 kWReplacer21

0,4 kWJeep

0,5 kWA-class

0,15 kWTravel Bus

0,2 kWUrban Bus

1,0 / 0,5 kWScooter

2004 2005

1,5 / 0,5 kWATV



Application Areas & Operating Modes


POWER SUPPLY UNIT manned cars / commercial vehicles / FOR DRIVE CHAINS boats

unmanned autonomous transport vehicles

AUXILIARY POWER UNIT energy supply for motorcars & com. vehicles(APU) for driver’s cabs in vans

for motor homes & caravansfor ships

POWER GENERATING UNIT automotive application or attached on a trailer

MODES OF OPERATION manually / automatic / load followerstand-alone- / group- / hybrid operationstatically / quasi-statically / dynamically


Small Electric Vehicle with Air-Cooled PEFC-System

The car has a range of max. 60 km with 75 kg as a load and a max. speed of 10 km/h. The nominal power of the PEFC system is 0.4 kW at a short-time peak output of 0.8 kW.

One hydrogen load allows an operating time period of maximum 8 hours.

This fuel cell system concept shall be used in small manned and un-manned vehicles and as an auxiliary power unit.



Control Module

Air Supply Module

Packaging following Vehicle and Operation RequirementsH2 Supply Module

H2 Storage Module

PEFC System Core Module

Power Conversion Module



Small Vehicle with modularised 0,5 kW H2-PEFC System

H2 Supply Module

H2-Storage Module Electric Motor PEFC SystemCore Module

Control Module

Air Supply Module

This fuel cell system concept with its 5 sub-system modules is to be used in small manned and un-manned vehicles and self-propelled energy supply units which offer only small distributed installation volumes.



Electric Scooter with compact PEFC-SystemBasic scooter assembly with 0,3 kW motor

and 24 V/0,17 kWh battery setFuel cell scooter with 0,4 kW PEFC-system

and 6 kWh hydrogen storage



Electric Scooter with compact 0,4 KW PEFC-SystemSteuerungsmodulSteuerungsmodul Cooling Module

Air Supply Module

Control Module




Independently Operating Transportation Vehicle ATV with1,5 kWp / 0,5 kWN PEFC Hybrid Power Supply

Vehicle Weight 100 kg, Load max. 400 kg

ATV-Development Partner of DLR:

Motors/Gears FTS-Design PEFC-Stack PEFC-StackDrive Control FTS-Assembly Production Development



ATV with 1,5 kWp / 0,5 kWN – PEFC-Hybrid Power Supply

Freely MovingRear Wheels

Front Wheel-Integrated Motor Units

Sensor-basedDrive Control

PEFC-Battery-Hybrid System

Manual Controls forVehicle & Power Supply



PEFC- Module System of the 3rd Generation


H2 Supply & Storage ModuleControl Module

Air Supply Module

Modular Fuel Cell System Package


Test Assembly of a Modularised PEFC-SystemPEFCSystem Core ModuleH2- Supply Module

Control Module

Air Supply Module



Packaging Continuity of the Air Supply Module

→45% Reduction in Volume

Cooler

Filter

Separator

Compressor

p-Supervision

ModuleInter-connector



Air Supply Module of a 0,5 kW System

PressureOutlet

PressureSupervision

AirIntercooler

Electric / SignalInterface

Air Filters

Air Compressor



PEFC System Core Module of a 1,5 kWp / 0,5 kWN System

PressureAdjustment

Outlet Fan

PEFC-Stack withAir Path Control

Gas Intakes

Gas Outlets

Intake Fan



H2 Supply Module of a 0,5 kW System

Core System Connector

Pressure Adjustment

Electric / SignalInterface

Safety Equipment

Storage Connectors



Operation Strategy „Load Following of mair & p“

0.4

0.6

0.8

1.0

0

5

10

15

20

0 10 20 30 40 50 60 70 80 90 1000

40

80

120

mean cell voltage minimum cell voltage

volta

ge /

V power

pow

er /

kW

set current actual current

I / A

time / s

Results of Fuel Cell System Operation (>20 kW)


Operation Strategy „Constant Maximum Supply of Fuel & Air“

0

40

80

120

0.4

0.6

0.8

1.0

0

4

8

12

16

20

24

Time / s


Cur

rent

/ A

mean cell voltage maximum cell voltage

Volta

ge /

V

Power

Pow

er /

kW



Operation Strategy „Load Following of mair & p“

1.2

1.6

2.0

2.4

0.010

0.015

0.020

0.025

0.030

0 10 20 30 40 50 60 70 80 90 1000

4080

120

0

1

2

3

4

5

p / b

ar phydrogene

pair

mair

mai

r / (k

g/s)

time / s


curre

nt /

A

λoxygene

λox

ygen

e



0 10 20 30 40 50 60 70 80 90 1001.21.62.02.4

0.0100.0150.0200.0250.030

04080

120

012345

0.4

0.6

0.8

1.0

04812162024

t / s

p / b

ar

phydrogene

pair

mai

r / (k

g/s)


Stro

m /

A

λox

ygen

e

mean cell voltage minimum cell voltage

Spa

nnun

g / V

P /

kW

Operation Strategy „Constant Maximum Supply of Fuel & Air“



Single Cell Voltage Behavior during „Load Following“

500600700800900

1000

500600700800900

1000

0 10 20 30 40 50 60 70 80 90 100 110 120500600700800900

1000

500600700800900

1000vo

latg

e / m

V

t = 26 s, I = 140 A

t = 15,5 s, I = 75 A

vol

tage

/ m

Vt = 9 s, I = 1 A

vol

tage

/ m

V

t = 86 s, I = 140 A

vol

tage

/ m

V

number of cell



Stationärer 24 V – Systembetrieb mit 15 A Laststrom

Results of Fuel Cell System Operation (< 1 kW)


Dynamic Operating Behavior of an Air-cooled Fuel Cell System

0

6

12

18

0 200 400 600 800 1000 1200

Zeit t [s]

Span

nung

U [V

] / S

trom

I [A

]

0

2

4

6

Ges

chw

indi

gkei

t v [k

m/h

]

Gesamtstrom IBZ

Gesamtspannung UBZ

Geschwindigkeit vBus

0

10

20

30

40

0 200 400 600 800 1000 1200

Zeit t [s]

Lei

stun

g P

[W]

-0,6

-0,4

-0,2

0,0

0,2

Bes

chle

unig

ung

a [m

/s2 ]

Motorleistung Pmech

LeistungGegenmoment Pgeg

Beschleunigung aBus

Test operation of a 200 We PEFC-System in a Labcar with the New

European Drive Cycle NEDC



Load change at –5°C(System thermally insulated)

0

10

20

30

40

50

60

0 15 30 45 60Zeit [min]

Tem

pera

tur [

°C]

0

2

4

6

8

10

12

Last

stro

m [A

]

T_Stack obenT_Luft einT_Luft ausT_MHSI_Last

Operation Test Results of Small Fuel Cell Systems

Selected Boundary Conditions

15,00

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00 80,00

Versuchsdauer (min)

Tem

pera

tur (

°C)

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

16,00

Stro

m I

(A)

Stack

H2-Speicher

Abluft Speicher

Abluft Stack

Messung

Simulation

Cold start up atambient temperature 20°C



CASINGPlastic/ metalworking

FUEL STORAGE / FUEL SUPPLY ADJUSTMENTPlastic/ metalworking/ foundry/ process engineering/ equipment construction

PEFC-SYSTEMProcess engineering/ plant construction/ subsystem manufacturing/ engineer service

COOLING SYSTEMConstruction unit manufacturing/ plastic/ metalworking/ engineer service

POWER ADAPTATION / OPERATION CONTROLElectro-technology/ electronics/ construction unit/ component manufacturing/ wiring

SAFETY EQUIPMENTConstruction unit manufacturing/ plastic/ metalworking

SYSTEM ASSEMBLY / TESTING / SYSTEM INTEGRATIONEquipment construction/ organization/ storekeeping/ flow control/ final equipment

Industrial Branches with Creation of Value Portions

Summary


All performance requirements can be fulfilled in direct or hybrid operation modeA common system design can be used for all areas of applicationSimple operation, safety, reliability and long life time can be achievedAll necessary variations of packaging can be realizedA start of production is possible because all system components existFC-systems can start as niche products in to the mass marketMass production of systems can be achievedCosts goals for system production can be achieved because methods of production and components can be be compared with well-known systemsCritical path is still the production of FC stacks

First PEFC Drives are near to the Market

Summary


THANK YOU VERY MUCH FOR YOUR KIND ATTENTION!

You may find us under:

Institute of Vehicle ConceptsDipl.-Ing. Andreas Brinner

Pfaffenwaldring 38-40, D-70569 Stuttgart

Tel: ++(0)711 685 74 -64/-61/-58 Fax: ++(0)711 685 7465Internet: www.dlr.de/fk

Documents

VEHICLE-INTEGRATED FUEL CELL DRIVE CHAINS · Innovative Vehicle Concepts in a Lasting Traffic System The Institute of Vehicle Concepts Professor Horst E. Friedrich. Dipl.-Ing. Andreas