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.     

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.     

Dynamic behaviour of Li batteries in hydrogen fuel cell power trains

A Li ion polymer battery pack for road vehicles (48 V, 20 Ah) was tested by charging/discharging tests at different current values, in order to evaluate its performance in comparison with a conventional Pb acid battery pack. The comparative analysis was also performed integrating the two storage systems in a hydrogen fuel cell power train for moped applications. The propulsion system comprised a fuel cell generator based on a 2.5 kW polymeric electrolyte membrane (PEM) stack, fuelled with compressed hydrogen, an electric drive of 1.8 kW as nominal power, of the same typology of that installed on commercial electric scooters (brushless electric machine and controlled bidirectional inverter). The power train was characterized making use of a test bench able to simulate the vehicle behaviour and road characteristics on driving cycles with different acceleration/deceleration rates and lengths. The power flows between fuel cell system, electric energy storage system and electric drive during the different cycles were analyzed, evidencing the effect of high battery currents on the vehicle driving range. The use of Li batteries in the fuel cell power train, adopting a range extender configuration, determined a hydrogen consumption lower than the correspondent Pb battery/fuel cell hybrid vehicle, with a major flexibility in the power management.     

PEFC stacks as power sources for hybrid propulsion systems

In this paper the performance of two polymeric electrolyte fuel cell systems (FCS) for hybrid power trains are presented and discussed. In particular, an experimental analysis was effected on 2.4 and 20 kW stacks with the aim to investigate the energy management issues of the two FCSs for utilization as power sources in electric power trains for scooter and minibus, respectively. The stack characterizations permitted the effect of the main operative variables (temperature, pressure and stoichiometric ratio) on mean power density of cells to be evaluated. The FCS efficiency was evaluated and compared for the two traction systems, individuating the optimal operative conditions for automotive application and specifying the energy losses of the auxiliary components. The efficiency of both fuel cell systems resulted higher than 40% in a wide range of loads (100–600 mA/cm²), with maximum values close to 50%. The experimental characterization of the two power trains was carried out on dynamic test benches, able to simulate the behaviour of the two vehicles on the European R40 driving cycle. The characterization of the two propulsion systems on R40 driving cycle evidenced that the overall efficiency was not affected significantly by the hybrid configuration adopted, as the efficiency values ranged from 27 to 29% in the different procedures analyzed.     

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.     

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%.     

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.     

Modeling and thermal management of proton exchange membrane fuel cell for fuel cell/battery hybrid automotive vehicle

The proton exchange membrane fuel cell (PEMFC) stack is a key component in the fuel cell/battery hybrid vehicle. Thermal management and optimized control of the PEMFC under real driving cycle remains a challenging issue. This paper presents a new hybrid vehicle model, including simulations of diver behavior, vehicle dynamic, vehicle control unit, energy control unit, PEMFC stack, cooling system, battery, DC/DC converter, and motor. The stack model had been validated against experimental results. The aim is to model and analyze the characteristics of the 30 kW PEMFC stack regulated by its cooling system under actual driving conditions. Under actual driving cycles (0–65 kW/h), 33%–50% of the total energy becomes stack heat; the heat dissipation requirements of the PEMFC stack are high and increase at high speed and acceleration. A PID control is proposed; the cooling water flow rate is adjusted; the control succeeded in stabilizing the stack temperature at 350 K at actual driving conditions. Constant and relative lower inlet cooling water temperature (340 K) improves the regulation ability of the PID control. The hybrid vehicle model can provide a theoretical basis for the thermal management of the PEMFC stack in complex vehicle driving conditions.     

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.     

Control strategy of a fuel-cell power module for electric forklift

Fuel cell-battery hybrid systems for the powertrain, which have the advantage of emission-free power generation and adapt to material transport and emission reduction, are investigated. Based on the characteristics of the fuel cell system and the characteristics of the electric forklift truck powertrain system, this work defines the design principle of the control strategy to improve overall performance and economy. A simulation platform for fuel cell and electric vehicles has been established. The optimal performance of the fuel cell stack and the battery capacity were defined for the specific application. An energy control strategy was defined for different operating cycles and operating conditions. Model validation involved comparing simulation results with experimental data obtained during VDI60 test protocol. The main parameters that influence the forklift performance were defined and evaluated, such as energy loss, fuel cell operating conditions and different battery charging cycles. The optimal size of the fuel cell stack of 11 kW and the battery of 10 Ah was determined for the specific load profile with the proposed control strategy. The results obtained in this work forms the basis for an in-depth study of the energy management of fuel cell battery drive trains for forklift trucks.     

Numerical prediction on an automotive fuel cell driving system

Mathematical models were applied to predict the results of different strategies to improve automotive fuel cell driving systems. First, a fuel cell system was optimized on the base of a fuel cell stack model. Then calculations about the utilization of recovered energy from air exhaust steam were carried out. Two methods to combine the turbocharger with an electric compressor, namely in series and in parallel, were evaluated for a fuel cell system. Finally, research on the effect of removing the big power DC/DC converter, which is located between the fuel cell system and the driving motor, was conducted for a fuel cell driving system. The main results show that it is highly advantageous to connect the turbocharger with an electric compressor in series than in parallel; and that the fuel cell driving system without DC/DC converter before its motor could reach much higher performance characteristics, and even be so in lower power range while the cell voltage was designated to be lower.     

Design and energy efficiency analysis of a pure fuel cell vehicle for Shell eco racer

The target of Shell Eco‐marathon competition of vehicle is to drive a fixed distance with the lowest quantity of fuel. To win the competition, the fuel cell‐powered propulsion system needs to be ultra efficient since the fuel cell system and transmission system are the key effects on the performance of the fuel cell‐powered propulsion system. In this study, a high‐efficiency fuel cell propulsion system has been designed and integrated in a prototype vehicle to participate the Shell Eco‐marathon Asia 2018 race. To achieve that, the vehicle dynamic is modeled to make the selection of the key components, and some experiments have been conducted to obtain the properly vehicle driving strategy. Based on the results of vehicle dynamic analysis, a high specific power proton‐exchange membrane fuel cell (PEMFC) stack with 1000 W and a high‐performance direct current (DC) brushless motor (1000 W) are selected to build the propulsion system of the Shell Eco‐marathon vehicle. Based on the experimental result, the racing time (1300‐1440 seconds) and varied range of racing speed (23‐27 km/h) are selected as the driving strategy. Finally, the efficiency of the fuel cell‐powered vehicle is analyzed. In the race at the year of 2018, the designed vehicle won the first place.     

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.     

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.     

Robust low frequency current ripple elimination algorithm for grid-connected fuel cell systems with power balancing technique

The low frequency current ripple in grid-connected fuel cell systems is generated from dc–ac inverter operation, which generates 60 Hz fundamental component, and gives harmful effects on fuel cell stack itself, such as making cathode surface responses slower, causing an increase of more than 10% in the fuel consumption, creating oxygen starvation, causing a reduction in the operating lifetime, and incurring a nuisance tripping such as overload situation. With these reasons, low frequency current ripple makes fuel cell system unstable and lifetime of fuel cell stack itself short. This paper presents a fast and robust control algorithm to eliminate low frequency current ripple in grid-connected fuel cell systems. Compared with the conventional methods, in the proposed control algorithm, dc link voltage controller is shifted from dc–dc converter to dc–ac inverter, resulting that dc–ac inverter handles dc link voltage control and output current control simultaneously with help of power balancing technique. The results indicate that the proposed algorithm can not only completely eliminate current ripple but also significantly reduce the overshoot or undershoot during transient states without any extra hardware. The validity of the proposed algorithm is verified by computer simulations and also by experiments with a 1 kW laboratory prototype.     

Optimization and efficiency analysis of methanol SOFC-PEMFC hybrid system

In order to improve the power generation efficiency of fuel cell systems employing liquid fuels, a hybrid system consisting of solid oxide fuel cell (SOFC) and proton exchange membrane fuel cell (PEMFC) is proposed. Utilize the high temperature heat generated by SOFC to reform as much methanol as possible to improve the overall energy efficiency of the system. When SOFC has a stable output of 100 kW, the amount of hydrogen after reforming is changed by changing the methanol flow rate. Three hybrid systems are proposed to compare and select the best system process suitable for different situations. The results show that the combined combustion system has the highest power generation, which can reach 350 kW and the total electrical efficiency is 57%. When the power of the tail gas preheating system is 160 kW, the electrical efficiency can reach 75%. The PEM water preheating system has the most balanced performance, with the electric power of 300 kW and the efficiency of 66%.     

Road testing of a three-wheeler driven by a 5 kW PEM fuel cell in the absence and presence of batteries

The road testing and demonstration of a three-wheeler vehicle driven by a 5 kW proton exchange membrane fuel cell (PEMFC) was carried out in the absence and presence of lead acid batteries. Prior to integrating the PEMFC module and batteries in the three-wheeler, they were tested and demonstrated separately. The PEMFC module had a very fast response as the load was manually or, especially, automatically changed and it could supply a continuous power when the reactant was supplied continuously. In contrast, the 5 kW lead acid batteries alone could supply power for no longer than 300 s. In the presence of both the PEMFC module and batteries, when the drawing power was in the range of the PEMFC module capacity the propulsion motor gained its energy from the PEMFC module only, whilst the stack power output at all conditions was greater than the setting power of approximately 400 W. After integrating the PEMFC module and batteries into the three-wheeler, both energy sources were found to power the vehicle effectively. The motor power as well as the stack power changed as a linear proportion to the throttle. The motor consumed more power in case of high speed driving, take off or hill climbing, while it used only 0.354 kW in the absence of throttle. The hybrid system can achieve a maximum speed in this three-wheeler of around 24.9 km/h with a hydrogen consumption of 11 g H₂/km (71 g H₂/kWh) and an operating cost of 1.99 USD/km. The thermodynamic efficiency of the vehicle was 42.9%.     

Optimization of hydrogen feeding procedure in PEM fuel cell systems for transportation

The hydrogen feeding sub-system is one of balance of plant (BOP) components necessary for the correct operation of a fuel cell system (FCS). In this paper the performance of a 6 kW PEM (Proton Exchange Membrane) FCS, able to work with two fuel feeding procedures (dead-end or flow-through), was experimentally evaluated with the aim to highlight the effect of the anode operation mode on stack efficiency and durability. The FCS operated at low reactant pressure (<50 kPa) and temperature (<330 K), without external humidification. The experiments were performed in both steady state and dynamic conditions. The performance of some cells in dead-end mode worsened during transient phases, while a more stable working was observed with fuel recirculation. This behavior evidenced the positive role of the flow-through procedure in controlling flooding phenomena, with the additional advantage to simplify the management issues related to hydrogen purge and air stoichiometric ratio. The flow-through modality resulted a useful way to optimize the stack efficiency and to reduce the risks of fast degradation due to reactant starvation during transient operative phases.     

Economic energy management strategy design and simulation for a dual-stack fuel cell electric vehicle

This paper presents the design and simulation validation of two energy management strategies for dual-stack fuel cell electric vehicles. With growing concerns about environmental issues and the fossil energy crisis, finding alternative methods for vehicle propulsion is necessary. Proton exchange membrane (PEM) fuel cell systems are now considered to be one of the most promising alternative energy sources. In this work, the challenge of further improving the fuel economy and extending the driving range of a fuel cell vehicle is addressed by a dual-stack fuel cell system with specific energy management strategies. An efficiency optimization strategy and an instantaneous optimization strategy are proposed. Simulation validation for each strategy is conducted based on a dual-stack fuel cell electric vehicle model which follows the new European driving cycle (NEDC). Simulation results show that a dual-stack fuel cell system with proposed energy management strategies can significantly improve the fuel economy of a fuel cell vehicle and thus lengthen the driving range while being able to keep the start-stop frequency of the fuel cell stack within a reasonable range.