Extended Range Fuel Cell Utility Vehicle: Design, Build, and Demonstration

Clay HearnApril 27, 2011

Introduction

• Program Goals• Team Members• Model Based Design• Vehicle Build

Powertrain Series HybridPrime Mover 8.5 kW Fuel CellEnergy Buffer 64V , 125F UltracapacitorFuel Storage 3.7 kg 350 bar compressed H2

Traction Motor 12.9 kW

Range 300 mileCargo Capacity 300 lbs & 12 cu ft

Program Goals

• Program sponsored through Defense Logistics Agency (DLA) and Crane to provide extended range hydrogen fuel cell vehicles for use at Warner Robbins AFB in Georgia– Hydrogen refueling infrastructure on base– Currently using hydrogen fuel cell fork

lifts– Numerous all-electric utility vehicles and

NEVs

• Maximize on-board hydrogen storage without sacrificing vehicle performance

• Build and deliver units in 8 months to Warner Robbins AFB for 12 month evaluation

Project Team Members

Center for Transportation and the EnvironmentProject management

Gas Technology InstituteHydrogen storage development

Vehicle Modeling (PSAT)Vehicle Design

Final IntegrationVehicle Support and Analysis

Fuel cell system and integration support Base vehicle supplier and support

Energy Storage Options

Lead-Acid Nickel Metal Hydride Lithium Ion and Variants Ultracap

Battery Trojan T145 Deka 8G31 SAFT NHE 5-200NiMH

COBASYSSeries 1000

NiMH

ValenceU24-12XP

LiFeMgPO4

PHET DOSBAS

C-LiFePO4

ValenceU1-12XP

LiFeMgPO4

AltairnanoLithium Titanate

MaxwellBMOD0165

ApplicationStock Electric & Plug-In Fuel

CellStock Electric Plug-In Fuel

CellFuel Cell

dominant hybrid

Plug-In Fuel Cell

Fuel Cell dominant

hybrid

Fuel Cell dominant

hybrid State of the art electric

Fuel Cell dominant

hybrid

Specific Energy Storage

39 Wh/kg 36 Wh/kg 64 Wh/kg 45 Wh/kg 90 Wh/kg 63 Wh/kg 79 Wh/kg 71 Wh/kg 2 Wh/kg

Volumetric Energy Storage

91 Wh/L 88 Wh/L 132 Wh/L 86 Wh/L 141 Wh/L 77 Wh/L 110 Wh/L 134 Wh/L 3 Wh/L

Specific Power 75 W/kg 100 W/kg 150 W/kg 1000 W/kg

(10 s pulse) 350 W/kg 830 W/kg 310W/kg 1250 W/kg(10 s pulse) 7900 W/kg

Vehicle Configurations

• Li-Ion batteries double range of vehicle over stock lead-acid batteries

• Range of hydrogen vehicle driven by onboard stored hydrogen– ~ 10X higher specific energy storage with

350 bar hydrogen fuel cell over advanced Li-ion batteries

– Analysis to right assumes 2 kg on-board hydrogen storage

• Plug-in options increase range by 25% – 50% over fuel cell alone, but also increase vehicle mass up to 250 kg

• Fuel cell dominant hybrids increase range 25% – 27% over fuel cell alone

Stock Electric

Lithium Titinate Batteries

Fuel Cell Alone

Plug-In Fuel Cell

Fuel Cell Dominant w/batteries

Fuel Cell Dominant w/ultracaps

0 50 100 150 200 250

ParCar SUV-LN GEM eL

Range [mi]

Hydrogen Storage Options

• Gravimetric capacity– Affects overall vehicle mass – Limits additional cargo bed

capacity– Reduces vehicle economy

• Volumetric capacity– Limits storage volume– Poses integration issues

Evaluating Hydrogen Storage

Increasing on-board H2

Increasing on-board H2

Vehicle Integration• 8-month build schedule to retrofit two vehicles

• Supervisory control and data recording– NI CompactRIO– Labview software– CAN communication between fuel cell and boost

converter

• “Rolling Benchtop” testing

Final Integration and Testing• Completed October 2010• Vehicle Range Testing

– 309 mile range demonstrated– 87.8 mi/kg average– 5 days to complete!

• Vehicles include 120V 1.5 kW inverter for on-site power

• 12 month demonstration at DDWG began November 2010

Questions?