Remodeling of a commercial plug-in battery electric vehicle to a hybrid configuration with a PEM fuel cell

In the present research, a commercial battery-powered pure electric vehicle was suitably modified to convert it into a hybrid one integrating a PEMFC stack. The hydrogen supply system to the stack included a passive recirculation system based on a Ventury-type ejector. Besides, in order to achieve an optimum operation of the PEMFC stack, a discrete state machine model was considered in its control system. The inclusion of a rehabilitation operating mode prevented the stack from possible failures, increasing its lifetime. It was verified that for the rated operating point when supplying power to the vehicle (2.5 kW) the hydrogen consumption decreased, and the actual efficiency (47.9%) PEMFC was increased close to 1%. Field tests performed demonstrate that the range of the hybrid electric vehicle was increased by 78% when compared to the one of the original battery electric car. Also, under the tested experimental conditions in hybrid mode, 34% of the total energy demanded by the electric machine of the vehicle was supplied by the PEMFC stack.     

Investigation of battery end-of-life conditions for plug-in hybrid electric vehicles

Plug-in hybrid electric vehicles (PHEVs) capable of drawing tractive energy from the electric grid represent an energy efficient alternative to conventional vehicles. After several thousand charge depleting cycles, PHEV traction batteries can be subject to energy and power degradation which has the potential to affect vehicle performance and efficiency. This study seeks to understand the effect of battery degradation and the need for battery replacement in PHEVs through the experimental measurement of lithium ion battery lifetime under PHEV-type driving and charging conditions. The dynamic characteristics of the battery performance over its lifetime are then input into a vehicle performance and fuel consumption simulation to understand these effects as a function of battery degradation state, and as a function of vehicle control strategy. The results of this study show that active management of PHEV battery degradation by the vehicle control system can improve PHEV performance and fuel consumption relative to a more passive baseline. Simulation of the performance of the PHEV throughout its battery lifetime shows that battery replacement will be neither economically incentivized nor necessary to maintain performance in PHEVs. These results have important implications for techno-economic evaluations of PHEVs which have treated battery replacement and its costs with inconsistency.     

Long-term optimization based on PSO of a grid-connected renewable energy/battery/hydrogen hybrid system

This paper presents and evaluates three energy management systems (EMSs) based on Particle Swarm Optimization (PSO) for long-term operation optimization of a grid-connected hybrid system. It is composed of wind turbine (WT) and photovoltaic (PV) panels as primary energy sources, and hydrogen system (fuel cell –FC–, electrolyzer and hydrogen storage tank) and battery as energy storage system (ESS). The EMSs are responsible for making the hybrid system produce the demanded power, deciding on the energy dispatch among the ESS devices. The first PSO-based EMS tries to minimize the ESS utilization costs, the second one to maximize the ESS efficiency, and the third one to optimize the lifetime of the ESS devices. Long-term simulations of 25 years (expected lifetime of the hybrid system) are shown in order to demonstrate the right performance of the three EMSs and their differences. The simulations show that: 1) each EMS outperforms the others in the designed target; and 2) the third EMS is considered the best EMS, because it needs the least ESS devices, and presents the lowest total acquisition cost of hybrid system, whereas the rest of parameters are similar to the best values obtained by the other EMSs.     

Variable structure battery-based fuel cell hybrid power system and its incremental fuzzy logic energy management strategy

A hybrid power system consists of a fuel cell and an energy storage device like a battery and/or a supercapacitor possessing high energy and power density that beneficially drives electric vehicle motor. The structures of the fuel cell-based power system are complicated and costly, and in energy management strategies (EMSs), the fuel cell's characteristics are usually neglected. In this study, a variable structure battery (VSB) scheme is proposed to enhance the hybrid power system, and an incremental fuzzy logic method is developed by considering the efficiency and power change rate of fuel cell to balance the power system load. The principle of VSB is firstly introduced and validated by discharge and charge experiments. Subsequently, parameters matching of the fuel cell hybrid power system according to the proposed VSB are designed and modeled. To protect the fuel cell as well as ensure the efficiency, a fuzzy logic EMS is formulated via setting the fuel cell operating in a high efficiency and generating an incremental power output within the affordable power slope. The comparison between a traditional deterministic rules-based EMS and the designed fuzzy logic was implemented by numerical simulation in three different operation conditions: NEDC, UDDS, and user-defined driving cycle. The results indicated that the incremental fuzzy logic EMS smoothed the fuel cell power and kept the high efficiency. The proposed VSB and incremental fuzzy logic EMS may have a potential application in fuel cell vehicles.     

Optimal energy management system for stand-alone wind turbine/photovoltaic/hydrogen/battery hybrid system with supervisory control based on fuzzy logic

This paper presents a novel hourly energy management system (EMS) for a stand-alone hybrid renewable energy system (HRES). The HRES is composed of a wind turbine (WT) and photovoltaic (PV) solar panels as primary energy sources, and two energy storage systems (ESS), which are a hydrogen subsystem and a battery. The WT and PV panels are made to work at maximum power point, whereas the battery and the hydrogen subsystem, which is composed of fuel cell (FC), electrolyzer and hydrogen storage tank, act as support and storage system. The EMS uses a fuzzy logic control to satisfy the energy demanded by the load and maintain the state-of-charge (SOC) of the battery and the hydrogen tank level between certain target margins, while trying to optimize the utilization cost and lifetime of the ESS. Commercial available components and an expected life of the HRES of 25 years were considered in this study. Simulation results show that the proposed control meets the objectives established for the EMS of the HRES, and achieves a total cost saving of 13% over other simpler EMS based on control states presented in this paper.     

Two new control strategies: For hydrogen fuel saving and extend the life cycle in the hydrogen fuel cell vehicles

With the acceleration of the development process of hydrogen fuel cell electric vehicles (HFCEV), it has become very important to maximize the energy stored in the vehicle and to use the vehicle with high efficiency. This paper puts forward how to cooperate with a proton exchange membrane fuel cell (PEMFC) as the primary energy source, a lithium-ion battery (LiB) and a supercapacitor (SCAP) as the energy storage technology. Furthermore, this paper examines the effect of two new control strategies developed for HFCEV in different road models on the vehicle fuel economy and life cycle of the system components. Both control strategies applied to the system can be easily applied to the different HFCEVs with minor changes due to the simplicity of their structure and parameters. The simulation results of the study have indicated that the impact of control strategies created in different road conditions on the power of energy sources, the life cycle of system components, system efficiency and fuel economy parameters of HFCEV.     

Fuel cell health prognosis using Unscented Kalman Filter: Postal fuel cell electric vehicles case study

The Proton Exchange Membrane Fuel Cell (PEMFC) health monitoring and management are of critical importance for the performance and cost efficiency of Fuel Cell Electric Vehicle (FCEV). Prognostics play an important role in improving the lifetime and reducing maintenance costs of PEMFC by predicting the degradation trend. In this paper, the degradation prediction of PEMFC is based on a novel model-driven method which combines the Unscented Kalman Filter (UKF) algorithm with the proposed voltage degradation model. The experimental data originated from the FCEVs which achieve postal delivery mission in the real road are used for construction and validation of the proposed model-driven prognostic method. At our best knowledge, this is the first application which uses field-based data for FC health prognosis. The influence of different lengths of measured voltage data on degradation prediction of PEMFC, and the degradation prediction performance of PEMFC in different FCEVs are also investigated by the proposed method. Test results show that the proposed model-driven method is able to accurately estimate the voltage degradation trend of PEMFC in the FCEV. When more data are applied to learning the degradation of PEMFC, the mean Relative Error (RE) in the prediction phase will decrease. Especially, when the learning data exceeds 45 h, the mean RE in prediction phase is reduced to 0.68%. Considering that the maximum mean RE in the prediction phase is 2.03% for 3 postal FCEVs, the proposed method can be applied in the degradation trend prediction of PEMFC in FCEV under real conditions.     

MPPT controller for an interleaved boost dc–dc converter used in fuel cell electric vehicles

Fuel cell electric vehicle (FCEV) has recently attracted increasing research interest. This paper investigates the performances of MPPT-FC generators supplying electric vehicle power train through an interleaved boost DC/DC converter (IBC). The accent is made on forcing the FC generator to operate at its maximum power point by using perturb and observe (P&O) algorithm integrated to the IBC control. However, the MPPT-FC control creates rapid changes in the power output from the fuel cell, which cause serious life shortening, severe cell degradation, and decrease the system efficiency. To overcome these shortcomings, the control of air generation system was designed to improve the power quality and to prevent fuel starvation phenomenon during rapid power transitions. The work involves the modeling and the simulation of the fuel cell power train in the vehicular application using the experimental data obtained in previous works. The experimental part of the proposed FCEV is based on a low-cost, low-power consumption microcontroller, which controls the IBC and performs the MPPT-FC operation. A microcontroller is used to measure the FC output power and to change the duty ratio of the IBC control signals.     

Optimized rule-based energy management for a polymer electrolyte membrane fuel cell/battery hybrid power system using a genetic algorithm

The polymer electrolyte membrane fuel cell (PEMFC) coupled with the battery is a promising hybrid power system for future energy supply application. Fuel cell durability, battery charge sustenance, and fuel consumption strongly rely on the energy management strategy (EMS). This paper puts forward an optimized rule-based EMS using genetic algorithm (GA) to optimally allocate the power between the fuel cell and the battery system. Control variables in real-time rule-based EMS are optimally adjusted with single objective of battery charge sustenance considering the fuel cell durability and efficiency. The proposed optimized rule-based EMS is simulated and experimentally verified via MATLAB/Simulink and LabVIEW-based experimental rig, respectively. The conventional rule-based EMS, fuzzy logic EMS, and dynamic programming (DP) EMS are also examined for comparison. The comparison results elucidate that the optimized rule-based EMS realizes a large performance improvement over the conventional rule-based and fuzzy logic EMSs. Near optimal performance is verified compared with DP EMS in terms of fuel economy, battery charge sustenance, fuel cell efficiency, and system durability. The combination of rule-based EMS and GA optimization algorithm has the advantage of having expert experience and global optimization properties, realizing optimal power allocation in real-time application with lower computation burden, which could be applied easily to other EMS system without loss of validity.     

A robust online energy management strategy for fuel cell/battery hybrid electric vehicles

Traditional optimization-based energy management strategies (EMSs) do not consider the uncertainty of driving cycle induced by the change of traffic conditions, this paper proposes a robust online EMS (ROEMS) for fuel cell hybrid electric vehicles (FCHEV) to handle the uncertain driving cycles. The energy consumption model of the FCHEV is built by considering the power loss of fuel cell, battery, electric motor, and brake. An offline linear programming-based method is proposed to produce the benchmark solution. The ROEMS instantaneously minimizes the equivalent power of fuel cell and battery, where an equivalent efficiency of battery is defined as the efficiency of hydrogen energy transforming to battery energy. To control the state of charge of battery, two control coefficients are introduced to adjust the power of battery in objective function. Another penalty coefficient is used to amend the power of fuel cell, which reduces the load change of fuel cell so as to slow the degradation of fuel cell. The simulation results indicate that ROEMS has good performance in both fuel economy and load change control of fuel cell. The most important advantage of ROEMS is its robustness and adaptivity, because it almost produces the optimal solution without changing the control parameters when driving cycles are changed.     

Analyses of the holistic energy balance of different fuel cell powertrains under realistic boundary conditions and user behaviors

Based on increasing component efficiencies and the ongoing drivetrain electrification the influence of the auxiliary load raises. Up to now, the effect of the additional energy consumption of auxiliary loads, such as the HVAC system, is often not investigated in detail. To close this gap for various fuel cell based drivetrains this paper applies a novel approach of Hollweck [1] and analyzes the holistic energy demand under realistic boundary conditions with a validated total vehicle simulation model. Thereby the drivetrains of a midsized fuel cell electric vehicle (FCEV), fuel cell plug-in electric vehicle (FC-PHEV) as well as the fuel cell range-extended electric vehicle (FC-REEV) are considered. In a first step, the novel approach, which regards the influence of the user behavior, the vehicle properties, the climate boundaries and the starting conditions is introduced. In a second step, the total vehicle simulation model consisting of the vehicle architecture, the drivetrain topology with its electrical and mechanical components, the thermal management of the drivetrain and the thermal management of the vehicle cabin is explained, verified and parameterized. In a final step, the seasonal and yearly energy demand for different driving profiles (urban, rural and motorway) and German weather conditions as well as the influence of colder winter conditions is analyzed. The detected varying auxiliary loads' influence on the different fuel cell based drivetrains is shown and discussed. Thereby, one of the results is that the auxiliary loads’ impact on FCEVs is moderate, while the impact on FC-PHEVs and FC-REEVs - driven in battery - mode is significant. Especially in cold winter conditions this effect is substantial.     

A new cost-minimizing power-allocating strategy for the hybrid electric bus with fuel cell/battery health-aware control

The two primary challenges preventing the commercialization of fuel cell hybrid electric vehicles (FCHEV) are their high cost and limited lifespan. Improper use usage can could also hasten the breakdown of proton exchange membrane fuel cell (PEMFC). This paper proposes a new cost-minimizing power-allocating technique with fuel cell/battery health-aware control to optimize the economic potential of fuel cell/battery hybrid buses. The proposed framework quantifies the fuel cell (FC) deterioration of the whole working zone in a real hybrid electric bus using a long short-term memory network (LSTM), which reduces the time required to get the key lifetime parameters. A new FC lifespan model is embedded into the control framework, together with a battery aging model, to balance hydrogen consumption and energy source durability. In addition, in the speed prediction step, an enhanced online Markov prediction approach with stochastic disturbances is presented to increase the forecast accuracy for future disturbances. Finally, comparative analysis is used to verify the efficacy of the suggested approach, which shows that when compared to the benchmark method, the proposed strategy may extend the FC lifetime and lower operating costs by 5.04% and 3.76%, respectively.     

Multi-mode control strategy for fuel cell electric vehicles regarding fuel economy and durability

A proton electrolyte membrane (PEM) fuel cell system and a Li-ion battery (LIB) are two power sources in a fuel cell electric vehicle (FCEV). The fuel cell system is composed of a fuel cell stack and subsystems for air/hydrogen supply and cooling water. The operation procedure of the fuel cell system can be generally separated into several processes, e.g. starting up, normal/abnormal working and shutting down. In this paper, a multi-mode real-time control strategy for a FCEV is proposed. The strategy is established based on three typical processes (starting up, normal working, shutting down) of the fuel cell system, taking the fuel economy and system durability into consideration. The strategy is applied into a platform vehicle for the 12th 5-year project of “the next generation technologies of fuel cell city buses”. Experiments of the “China city bus typical cycle” on a test bench for the bus were carried out. Results show that, the fuel economy is 7.6 kg (100 km)⁻¹ in the battery charge-sustaining status. In a practical situation, a total driving mileage of more than 270 km can be achieved. Cycle testing also showed that, the degradation rate of the fuel cell was reduced to half of the original level. No performance degradation of the LIB system was observed in the cycling test.     

Comparative study of energy management systems for a hybrid fuel cell electric vehicle - A novel mutative fuzzy logic controller to prolong fuel cell lifetime

Hybrid fuel cell battery electric vehicles require complex energy management systems (EMS) in order to operate effectively. Poor EMS can result in a hybrid system that has low efficiency and a high rate of degradation of the fuel cell and battery pack. Many different types of EMS have been reported in the literature, such as equivalent consumption minimisation strategy and fuzzy logic controllers, which typically focus on a single objective optimisations, such as minimisation of H₂ usage. Different vehicle and system specifications make the comparison of EMSs difficult and can often lead to misleading claims about system performance. This paper aims to compare different EMSs, against a range of performance metrics such as charge sustaining ability and fuel cell degradation, using a common modelling framework developed in MATLAB/Simulink - the Electric Vehicle Simulation tool-Kit (EV-SimKit). A novel fuzzy logic controller is also presented which mutates the output membership function depending on fuel cell degradation to prolong fuel cell lifetime – the Mutative Fuzzy Logic Controller (MFLC). It was found that while certain EMSs may perform well at reducing H₂ consumption, this may have a significant impact on fuel cell degradation, dramatically reducing the fuel cell lifetime. How the behaviour of common EMS results in fuel cell degradation is also explored. Finally, by mutating the fuzzy logic membership functions, the MFLC was predicted to extend fuel cell lifetime by up to 32.8%.     

Performance assessment of thermal management systems for electric and hybrid electric vehicles

Thermal management systems (TMS) are one of the key components of electric and hybrid electric vehicles to achieve high vehicle efficiency and performance under all operating conditions. Current improvements in electric battery technology allow vehicles to have relatively long ranges, fast acceleration, and long life while keeping low‐maintenance costs and considerably lower emissions. However, the vehicle performance is significantly affected by the battery operating conditions. Moreover, the cell life cycle, safety, and possibility of thermal runaway significantly depend on peak temperature rise and temperature uniformity of the battery. Therefore, various TMSs are created to keep batteries within ideal operating ranges. In this article, three different TMS systems—passive cabin cooling (via air), active moderate liquid circulation (via refrigerant), and active liquid circulation (via refrigerant and coolant)—are analyzed and compared with electric and hybrid electric vehicles. A second law analysis is used to examine the areas of low exergy efficiency in each system and minimize the entropy generation based on the system configuration. Moreover, TMS systems are compared on the basis of battery temperature increase and temperature uniformity. Various parametric studies are conducted to compare the TMS in different ambient and operating conditions. On the basis of the analysis, the active liquid circulation (via refrigerant and coolant) is determined to have the lowest battery temperature increase (3.9 °C in 30 min) and most cell temperature uniformity (2.5 °C median) as well as the lowest entropy generation rate (0.0121 W/K) among the compared systems. Copyright © 2012 John Wiley & Sons, Ltd.     

Modeling,control and power management of hybrid photovoltaic fuel cells with battery bank supplying electric vehicle

In this paper, modeling, control and power management (PM) of hybrid Photovoltaic Fuel cell/Battery bank system supplying electric vehicle is presented. The HPS is used to produce energy without interruption. It consists of a photovoltaic generator (PV), a proton exchange membrane fuel cell (PEMFC), and a battery bank supplying an electric vehicle of 3 kW. In our work, PV and PEMFC systems work in parallel via DC/DC converter and the battery bank is used to store the excess of energy. The mathematical model topology and it power management of HPS with battery bank system supplying electric vehicle (EV) are the significant contribution of this paper. Obtained results under Matlab/Simulink and some experimental ones are presented and discussed.     

Comparative analysis of battery electric,hydrogen fuel cell and hybrid vehicles in a future sustainable road transport system

This paper compares battery electric vehicles (BEV) to hydrogen fuel cell electric vehicles (FCEV) and hydrogen fuel cell plug-in hybrid vehicles (FCHEV). Qualitative comparisons of technologies and infrastructural requirements, and quantitative comparisons of the lifecycle cost of the powertrain over 100,000 mile are undertaken, accounting for capital and fuel costs. A common vehicle platform is assumed. The 2030 scenario is discussed and compared to a conventional gasoline-fuelled internal combustion engine (ICE) powertrain. A comprehensive sensitivity analysis shows that in 2030 FCEVs could achieve lifecycle cost parity with conventional gasoline vehicles. However, both the BEV and FCHEV have significantly lower lifecycle costs. In the 2030 scenario, powertrain lifecycle costs of FCEVs range from $7360 to $22,580, whereas those for BEVs range from $6460 to $11,420 and FCHEVs, from $4310 to $12,540. All vehicle platforms exhibit significant cost sensitivity to powertrain capital cost. The BEV and FCHEV are relatively insensitive to electricity costs but the FCHEV and FCV are sensitive to hydrogen cost. The BEV and FCHEV are reasonably similar in lifecycle cost and one may offer an advantage over the other depending on driving patterns. A key conclusion is that the best path for future development of FCEVs is the FCHEV.     

Intensifying vehicular proton exchange membrane fuel cells for safer and durable,design and operation

The explosion in a proton exchange membrane fuel cell (PEMFC) powered forklift in Louisiana, USA in May 2018 and the resulting fatality highlights the need for the improved safety of this technology. Apart from the safety concerns, PEMFC durability has been an important issue towards its further commercialization. Both the safety and durability concerns associated with this technology can be attributed to the temporal degradation of its components. In this study, we have developed a mathematical model that relates the microscale PEMFC degradation to the probability of a macroscale explosion in a Fuel Cell Electric Vehicle (FCEV). Using the model and the inherent safety principle of intensification, it was observed that increasing the operating temperature of the PEMFC system can significantly improve both its safety and durability while intensifying membrane design parameters i.e. membrane thickness and membrane conductivity do not provide any significant improvements. A key inference from this study is that the durability (expressed in voltage loss) and safety (expressed in explosion probability) of a PEMFC system are not perfectly correlated.     

Experimental investigation of supercapacitor based regenerative energy storage for a fuel cell vehicle equipped with an alternator

Recently, researchers have devoted more attention to supercapacitors (SCs) to integrate with batteries in energy storage systems (ESSs) for vehicle applications. In this study, we attempted to characterize the use of SCs in the ESS for a PEM fuel cell vehicle equipped with an alternator to maximize the performance of regenerative braking. We applied lithium-ion batteries (LIBs) and SCs as energy storage devices to examine their effect on ESS. Then we used a hysteresis brake to apply controllable braking force on the flywheel to form hybrid braking (HB) and made efforts to study its behavior to suggest a braking control strategy. We also ran the whole system over the rotational speed to cover the range of driving speed. At last, we sized the SCs for the most commonly used fuel cell electric vehicle (FCEV) in Korea, i.e., Hyundai NEXO, based on the results obtained from the above study by alternator efficiencies.     

The development of a PEMFC hybrid power electric vehicle with automatic sodium borohydride hydrogen generation

This paper describes the development of a hybrid Proton Exchange Membrane Fuel Cell (PEMFC) electric vehicle consisting of a 3 kW PEMFC, PV arrays, secondary battery sets, and a chemical hydrogen generation system. We first integrate a hybrid PEMFC electric vehicle and design power management strategies. The on-board hydrogen generation system can provide sufficient hydrogen for continuous operation of the PEMFC, and the performance tests demonstrate the effectiveness of the integrated system in providing sustainable power for driving. We then use Matlab/SimPowerSystem? to develop a simulation model and adjust the model parameters using experimental data. The results indicated that the model can effectively predict system responses and can be used for performance evaluation. We also use the simulation model to estimate the mileage and costs of the developed electric vehicle, and we discuss the impacts of component sizes on system costs and travelling ranges.