An experimental study of a PEM fuel cell power train for urban bus application

An experimental study was carried out on a fuel cell propulsion system for minibus application with the aim to investigate the main issues of energy management within the system in dynamic conditions. The fuel cell system (FCS), based on a 20 kW PEM stack, was integrated into the power train comprising DC–DC converter, Pb batteries as energy storage systems and asynchronous electric drive of 30 kW. As reference vehicle a minibus for public transportation in historical centres was adopted. A preliminary experimental analysis was conducted on the FCS connected to a resistive load through a DC–DC converter, in order to verify the stack dynamic performance varying its power acceleration from 0.5 kW s⁻¹ to about 4 kW s⁻¹. The experiments on the power train were conducted on a test bench able to simulate the vehicle parameters and road characteristics on specific driving cycles, in particular the European R40 cycle was adopted as reference. The “soft hybrid” configuration, which permitted the utilization of a minimum size energy storage system and implied the use of FCS mainly in dynamic operation, was compared with the “hard hybrid” solution, characterized by FCS operation at limited power in stationary conditions. Different control strategies of power flows between fuel cells, electric energy storage system and electric drive were adopted in order to verify the two above hybrid approaches during the vehicle mission, in terms of efficiencies of individual components and of the overall power train.     

Hydrogen release properties of lithium alanate for application to fuel cell propulsion systems

In this paper the results of an experimental study on LiAlH₄ (lithium alanate) as hydrogen source for fuel cell propulsion systems are reported. The compound examined in this work was selected as reference material for light metal hydrides, because of its high hydrogen content (10.5 wt.%) and interesting desorption kinetic properties at moderate temperatures. Thermal dynamic and kinetic of hydrogen release from this hydride were investigated using a fixed bed reactor to evaluate the effect of heating procedure, carrier gas flow rate and sample form. The aim of this study was to characterize the lithium alanate decomposition through the reaction steps leading to the formation of Li₃AlH₆ and LiH. A hydrogen tank was designed and realized to contain pellets of lithium alanate as feeding for a fuel cell propulsion system based on a 2-kW Polymeric Electrolyte Fuel Cell (PEFC) stack. The fuel cell system was integrated into the power train comprising DC-DC converter, energy storage systems and electric drive for moped applications (3 kW). The experiments on the power train were conducted on a test bench able to simulate the vehicle behaviour and road characteristics on specific driving cycles. In particular the efficiencies of individual components and overall power train were analyzed evidencing the energy requirements of the hydrogen storage material.     

Experimental assessment of energy-management strategies in fuel-cell propulsion systems

The limitations of electric vehicles equipped with electrochemical batteries justify strong research interest for new solutions, based on hydrogen fuel-cell technology that are able to improve vehicle range, and reduce battery recharging time, while maintaining the crucial advantages of high efficiency and local zero emissions. The best working of a fuel-cell propulsion system, in terms of optimum efficiency and performance, is based on specific strategies of energy management, that are designed to regulate the power flows between the fuel cells, electric energy-storage systems and electric drive during the vehicle mission. An experimental study has been carried out on a small-size electric propulsion system based on a 2.5-kW proton exchange membrane fuel cell stack and a 2.5-kW electric drive. The fuel-cell system has been integrated into a powertrain comprising a dc–dc converter, a lead–acid battery pack, and brushless electric drive. The experiments are conducted on a test bench that is able to simulate the vehicle behaviour and road characteristics on specific driving cycles. The experimental runs are carried out on the European R40 driving cycle using different energy-management procedures and both dynamic performance and energy consumption are evaluated.     

Hydrogen fuel cell hybrid vehicles (HFCHV) for Birmingham campus

The design of a campus mail delivery vehicle powered by 350 bar hydrogen feeding a 1.2 kW PEM fuel cell to charge a lead acid battery pack is described. Five vehicles supplied to the campus at the University of Birmingham to measure the performance and to evaluate relevance to fleet operations are discussed. It is shown that the performance is better than that of a standard diesel van in two drive cycles, one following an academic circuit around the campus, the other doing multiple mail delivery stops. The acceleration and drive cycle compliance are found to be adequate on campus and the efficiency is significantly better than the diesel. The need for extension of range and increase in power and acceleration to meet standard urban drive cycles is clearly demonstrated.     

Experimental study of a fuel cell power train for road transport application

The development of fuel cell electric vehicles requires the on-board integration of fuel cell systems and electric energy storage devices, with an appropriate energy management system. The optimization of performance and efficiency needs an experimental analysis of the power train, which has to be effected in both stationary and transient conditions (including standard driving cycles).In this paper experimental results concerning the performance of a fuel cell power train are reported and discussed. In particular characterization results for a small sized fuel cell system (FCS), based on a 2.5 kW PEM stack, alone and coupled to an electric propulsion chain of 3.7 kW are presented and discussed. The control unit of the FCS allowed the main stack operative parameters (stoichiometric ratio, hydrogen and air pressure, temperature) to be varied and regulated in order to obtain optimized polarization and efficiency curves. Experimental runs effected on the power train during standard driving cycles have allowed the performance and efficiency of the individual components (fuel cell stack and auxiliaries, dc–dc converter, traction batteries, electric engine) to be evaluated, evidencing the role of output current and voltage of the dc–dc converter in directing the energy flows within the propulsion system.     

Fuel cell-battery hybrid powered light electric vehicle (golf cart): Influence of fuel cell on the driving performance

A light electric vehicle (golf cart, 5 kW nominal motor power) was integrated with a commercial 1.2 kW PEM fuel cell system, and fuelled by compressed hydrogen (two composite cylinders, 6.8 L/300 bar each). Comparative driving tests in the battery and hybrid (battery + fuel cell) powering modes were performed. The introduction of the fuel cell was shown to result in extending the driving range by 63–110%, when the amount of the stored H₂ fuel varied within 55–100% of the maximum capacity. The operation in the hybrid mode resulted in more stable driving performances, as well as in the increase of the total energy both withdrawn by the vehicle and returned to the vehicle battery during the driving. Statistical analysis of the power patterns taken during the driving in the battery and hybrid-powering modes showed that the latter provided stable operation in a wider power range, including higher frequency and higher average values of the peak power.     

Directly connected series coupled HTPEM fuel cell stacks to a Li-ion battery DC bus for a fuel cell electrical vehicle

The work presented in this paper examines the use of pure hydrogen fuelled high temperature polymer electrolyte membrane (HTPEM) fuel cell stacks in an electrical car, charging a Li-ion battery pack. The car is equipped with two branches of two series coupled 1 kW fuel cell stacks which are connected directly parallel to the battery pack during operation. This enables efficient charging of the batteries for increased driving range. With no power electronics used, the fuel cell stacks follow the battery pack voltage, and charge the batteries passively. This saves the electrical and economical losses related to these components and their added system complexity. The new car battery pack consists of 23 Li-ion battery cells and the charging and discharging are monitored by a battery management system (BMS) which ensures safe operating conditions for the batteries. The direct connection of the fuel cell stacks to the batteries can only be made if the stacks are carefully dimensioned to the battery voltage. The experimental results of stationary fuel cell charging are presented, showing stable and efficient operation.     

Lithium polymer batteries and proton exchange membrane fuel cells as energy sources in hydrogen electric vehicles

This paper deals with the application of lithium ion polymer batteries as electric energy storage systems for hydrogen fuel cell power trains. The experimental study was firstly effected in steady state conditions, to evidence the basic features of these systems in view of their application in the automotive field, in particular charge-discharge experiments were carried at different rates (varying the current between 8 and 100 A). A comparison with conventional lead acid batteries evidenced the superior features of lithium systems in terms of both higher discharge rate capability and minor resistance in charge mode. Dynamic experiments were carried out on the overall power train equipped with PEM fuel cell stack (2 kW) and lithium batteries (47.5 V, 40 Ah) on the European R47 driving cycle. The usage of lithium ion polymer batteries permitted to follow the high dynamic requirement of this cycle in hard hybrid configuration, with a hydrogen consumption reduction of about 6% with respect to the same power train equipped with lead acid batteries.     

Dynamic behaviour of hydrogen fuel cells for automotive application

An experimental analysis was conducted on a 30 kW fuel cell power train with the aim to elucidate specific concerns of dynamic behaviour of hydrogen fuel cells in automotive applications. The study was conducted on a dynamic test bench able to simulate the behaviour of the reference vehicle, a minibus for historical centres collective service, on predefined driving cycle. The transient performance of the fuel cell system was firstly investigated without electric drive, using as load electric resistances electronically controlled. Experimental data were collected during warmup phases characterized by two acceleration slopes (150 W/s and 1500 W/s) and during a sequence of dynamic test cycles characterized by a very high acceleration slope of about 6 kW/s. The role of reactant feeding, humidification and cooling systems was investigated during all tests evaluating the performance during the transient steps in terms of cell voltage uniformity, expressed by the coefficient of variation C_v, used as statistical indicator. A driving cycle characterized by stop-and-go pattern and acceleration slopes compatible with a real utilization of the reference vehicle was finally adopted for tests on the overall power train. The results demonstrated a very good dynamic performance of the fuel cell stack as evidenced by the analysis of C_v, which resulted lower than 2.5% in all investigated working conditions, and by the overall power train efficiency which resulted about 30% with fuel cell system efficiency close to 50%.     

Performance optimization of hybrid hydrogen fuel cell-electric vehicles in real driving cycles

In this research study, a fuel cell-electric hybrid car is studied. This car includes an electric motor that is connected to a fuel cell and a complex which includes a battery pack and an Ultracapacitor. The assessment of this hybrid vehicle is conducted by using various driving cycles such as FTP-75 driving cycle, NEDC driving cycle and SFTP-SC03 driving cycle. Battery state of charge (SoC) and hydrogen fuel consumption are the effective parameters influencing the vehicle performance. For analysing the performance of this vehicle, an innovative computational model is considered. In this innovative computational model, an accurate control strategy is considered in order to control the power demand, staying the battery packs and the Ultracapacitor state of charge in a limited domain. Results show that in NEDC driving cycle, by means of using Ultracapacitor in this model, 3.3% reduction in fuel consumption and 20.2% decrease in the difference between initial and final State of Charge (SoC) in battery pack can be achieved. In addition, a robust regenerative braking control strategy is used in order to recover some parts of the wasted energy in braking driving modes.     

Fuel processor-battery-fuel cell hybrid drivetrain for extended range operation of passenger vehicles

Power required to run auxiliary systems on a passenger car, such as those for air conditioning and advanced vehicle control, reduces the driving range of a vehicle equipped with a hybrid drive train. Under practical driving conditions, a significant amount of additional energy is required at low power levels compared to the rated power of the drive unit. In the present study, we consider a fuel cell-battery drive train augmented by an on-board fuel (ethanol) processor to provide the motoring power requirements of a car. Using systematic driving cycle simulations that take account of power-to-weight, energy-to-weight and power-to-efficiency factors of on-board power sources under simulated load conditions, we show that a combination of steadily-operated compact ethanol reformer, a low-power battery continuously charged by excess reformer capacity and a high-power fuel cell powered by conservatively-used hydrogen from cylinder can increase the range of hybrid fuel cell drivetrains to about 750 km. Although the overall energy consumption of the three-way hybrid is more than that of fuel cell-battery hybrid, lesser use of stored hydrogen improves the fuel economy of the hybrid drivetrain. While the system complexity is increased, long-range distressed mode operation becomes feasible with the added fuel processor.     

Experimental assessment of fuel cell/supercapacitor hybrid system for scooters

This paper presents an experimental assessment of fuel cell hybrid propulsion systems for scooters based on a modular 1.2 kW PEM fuel cell. The tests of the hybrid system are carried out using a programmable electronic load. Different configurations of the fuel cell/battery and the fuel cell/supercapacitor hybrid systems are explored. Both systems demonstrate their ability to deliver the requested load satisfactorily. The distributions of the fuel cell power delivery, although different between the two systems, are within the region where the fuel cell efficiency is approximately constant. As a result, the rates of fuel consumption show no discernable difference between the two systems for all three driving cycles considered. In addition to the fuel consumption, considerations including bus voltage, cost and packaging issues suggest that the supercapacitor has advantages over the battery for the use as secondary energy storage in fuel cell hybrid propulsion system for scooters.     

Efficiencies of hydrogen storage systems onboard fuel cell vehicles

Energy efficiency, vehicle weight, driving range, and fuel economy are compared among fuel cell vehicles (FCV) with different types of fuel storage and battery-powered electric vehicles. Three options for onboard fuel storage are examined and compared in order to evaluate the most energy efficient option of storing fuel in fuel cell vehicles: compressed hydrogen gas storage, metal hydride storage, and onboard reformer of methanol. Solar energy is considered the primary source for fair comparison of efficiencies for true zero emission vehicles. Component efficiencies are from the literature. The battery powered electric vehicle has the highest efficiency of conversion from solar energy for a driving range of 300 miles. Among the fuel cell vehicles, the most efficient is the vehicle with onboard compressed hydrogen storage. The compressed gas FCV is also the leader in four other categories: vehicle weight for a given range, driving range for a given weight, efficiency starting with fossil fuels, and miles per gallon equivalent (about equal to a hybrid electric) on urban and highway driving cycles.     

Hybrid polymer electrolyte membrane fuel cell–lithium‐ion battery powertrain testing platform – hybrid fuel cell electric vehicle emulator

A testing and validation platform for hybrid fuel cell (FC)–lithium‐ion battery (LIB) powertrain systems is investigated. The hybrid FC electric vehicle emulator enables testing of hybrid system components and complete hybrid power modules up to 25 kW for application in electric light‐duty vehicles, light electric vehicles and so forth. A hybrid system comprising a 10‐kW_el low‐temperature polymer electrolyte membrane FC stack and an 11.5‐kWh LIB pack is installed. The system supplies power to a 20‐kW permanent magnet synchronous motor and a 25‐kW alternating current asynchronous, electrically programmable dynamometer is used to simulate the vehicle load during testing at dynamic drive cycle. The steady‐state performance tests of the direct current (DC) motor, DC/DC converter, low‐temperature polymer electrolyte membrane FC stack and LIB are performed as well as dynamic tests of the complete hybrid system. The Economic Commission for Europe driving cycle is selected as a reference cycle to validate the investigated hybrid FC–LIB powertrain. An efficiency of 83% and 95% is measured for electric motor and DC/DC converter, respectively. An average stack efficiency of 50% is achieved. An average hydrogen consumption of 3.9 g * km^?1 is reached during the Economic Commission for Europe driving cycle test. Copyright © 2017 John Wiley & Sons, Ltd.     

Energy management of a fuel cell hybrid ultra-energy efficient vehicle

This paper focuses on energy management in an ultra-energy efficient vehicle powered by a hydrogen fuel cell with rated power of 1 kW. The vehicle is especially developed for the student competition Shell Eco-marathon in the Urban Concept category. In order to minimize the driving energy consumption a simulation model of the vehicle and the electric propulsion is developed. The model is based on vehicle dynamics and real motor efficiency as constant DC/DC, motor controllers and transmission efficiency were considered. Based on that model five propulsion schemes and driving strategies were evaluated. The fuel cell output parameters were experimentally determined. Then, the driving energy demand and hydrogen consumption was estimated for each of the propulsion schemes. Finally, an experimental study on fuel cell output power and hydrogen consumption was conducted for two propulsion schemes in case of hybrid and non-hybrid power source. In the hybrid propulsion scheme, supercapacitors were used as energy storage as they were charged from the fuel cell with constant current of 10 A.     

Numerical analysis of an energy storage system based on a metal hydride hydrogen tank and a lithium-ion battery pack for a plug-in fuel cell electric scooter

This work investigates on the performance of a hybrid energy storage system made of a metal hydride tank for hydrogen storage and a lithium-ion battery pack, specifically conceived to replace the conventional battery pack in a plug-in fuel cell electric scooter. The concept behind this solution is to take advantage of the endothermic hydrogen desorption in metal hydrides to provide cooling to the battery pack during operation.The analysis is conducted numerically by means of a finite element model developed in order to assess the thermal management capabilities of the proposed solution under realistic operating conditions.The results show that the hybrid energy storage system is effectively capable of passively controlling the temperature of the battery pack, while enhancing at the same time the on-board storage energy density. The maximum temperature rise experienced by the battery pack is around 12 °C when the thermal management is provided by the hydrogen desorption in metal hydrides, against a value above 30 °C obtained for the same case without thermal management. Moreover, the hybrid energy storage system provides the 16% of the total mass of hydrogen requested by the fuel cell stack during operation, which corresponds to a significant enhancement of the hydrogen storage capability on-board of the vehicle.     

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.     

Experimental investigation on the dynamic performance of a hybrid PEM fuel cell/battery system for lightweight electric vehicle application

A hybrid system combining a 2 kW air-blowing proton exchange membrane fuel cell (PEMFC) stack and a lead–acid battery pack is developed for a lightweight cruising vehicle. The dynamic performances of this PEMFC system with and without the assistance of the batteries are systematically investigated in a series of laboratory and road tests. The stack current and voltage have timely dynamic responses to the load variations. Particularly, the current overshoot and voltage undershoot both happen during the step-up load tests. These phenomena are closely related to the charge double-layer effect and the mass transfer mechanisms such as the water and gas transport and distribution in the fuel cell. When the external load is beyond the range of the fuel cell system, the battery immediately participates in power output with a higher transient discharging current especially in the accelerating and climbing processes. The DC–DC converter exhibits a satisfying performance in adaptive modulation. It helps rectify the voltage output in a rigid manner and prevent the fuel cell system from being overloaded. The dynamic responses of other operating parameters such as the anodic operating pressure and the inlet and outlet temperatures are also investigated. The results show that such a hybrid system is able to dynamically satisfy the vehicular power demand.     

Energy distribution analyses of an additional traction battery on hydrogen fuel cell hybrid electric vehicle

Hydrogen is the most abundant element in the world and produces only water vapor as a result of chemical reaction that occurred in fuel cells. Therefore, fuel cell electric vehicles, which use hydrogen as fuel, continue its growing trend in the sector. In this study, an energy distribution comparison is carried out between fuel cell electric vehicle and fuel cell hybrid electric vehicle. Hybridization of fuel cell electric vehicle is designed by equipped a traction battery (15 kW). Modeled vehicles were prepared under AVL Cruise program with similar chassis and same fuel cell stacks for regular determining process. Numerical analyses were presented and graphed with instantaneous results in terms of sankey diagrams with a comparison task. WLTP driving cycle is selected for both vehicles and energy input/output values given with detailed analyses. The average consumption results of electric and hydrogen usage is found out as 4.07 kWh and 1.125 kg/100 km respectively for fuel cell electric vehicle. On the other hand, fuel cell hybrid electric vehicle’s average consumption results figured out as 3.701 kWh for electric and 0.701 kg/100 km for hydrogen consumption. As a result of this study, fuel cell hybrid electric vehicle was obtained better results rather than fuel cell electric vehicle according to energy and hydrogen consumption with 8% and 32%, respectively.     

Voltage balancing: Long-term experience with the 250 V supercapacitor module of the hybrid fuel cell vehicle HY-LIGHT

On the occasion of the “Challenge Bibendum” 2004 in Shanghai, the hybrid fuel cell—supercapacitor vehicle HY-LIGHT, a joint project of Conception et Développement Michelin and the Paul Scherrer Institut, was presented to the public. The drive train of this vehicle comprises a 30 kW polymer electrolyte fuel cell (PEFC) and a 250 V supercapacitor (SC) module for energy recuperation and boost power during short acceleration and start-up processes. The supercapacitor module was deliberately constructed without continuous voltage balancing units. The performance of the supercapacitor module was monitored over the 2 years of operation particularly with respect to voltage balancing of the large number of SC cells connected in series. During the investigated period of 19 months and about 7000 km driving, the voltage imbalance within the supercapacitor module proved negligible. The maximum deviation between best and worst SC was always below 120 mV and the capacitor with the highest voltage never exceeded the nominal voltage by more than 40 mV.