Cost-optimal design and energy management of fuel cell electric trucks

Road freight transport on hilly routes represents a significant challenge for the advancement of fuel cell electric trucks because of the high-performance requirements for fuel consumption, vehicle lifetime, and battery charge control. Therefore, it is essential to optimize the vehicle design and energy management, which greatly influence the driving performance and total cost of ownership. This paper focuses on the cost-optimal design and energy management of fuel cell electric trucks, considering five key influencing factors: powertrain component sizing, driving cycle, vehicle weight, component degradation, and market prices. The cost optimization relies on a novel predictive energy management scheme based on dynamic programming and the systematic calibration of control parameters. The paper analyzes the simulation results to highlight three main findings for fuel cell electric trucks: 1) cost-optimal energy management is essential to define the best trade-off between fuel consumption and component degradation; 2) the total cost of ownership is significantly influenced by component sizing, driving cycles, vehicle weight, and market prices; 3) predictive energy management is highly beneficial in challenging road topographies for substantial cost-saving and lower component size requirements.     

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.     

Estimation of indirect CO2 emissions of a hydrogen‐powered medium size vehicle for the NEDC cycle

Reduction in greenhouse effect gases emission is a major source of concern nowadays. Internal combustion engines, as the most widely used power generation mean for transportation, represent a large share of such gases, which motivates active research efforts for alternative solutions. In this regard, PEM fuel cells represent a promising prospect and are thoroughly investigated, whether experimentally or through numerical simulation. The present work presents a simulation of the power potential of a PEM fuel cell, which is integrated to the full power electric traction chain of a medium size car. The cell potential is modelled by taking into account the different types of polarization. The driving performances of the vehicle and its hydrogen consumption are evaluated through a simple mathematical model and an application is performed for the New European Driving Cycle (NEDC) standard driving cycle. A preliminary sizing of the proton exchange membrane fuel cell (PEMFC) membrane area for the chosen vehicle is presented, along with that of a hydrogen storage tank for a typical autonomy. The main goal of the simulation is to estimate CO₂ indirect emissions due to the production of the needed hydrogen for the cycle via an electrolyser, compared with the case of a gasoline fueled vehicle. This is performed solely on a ‘fuel tank to wheel’ basis in order to have comparable figures. The results indicate that the environmental advantage of hydrogen cars is quite questionable if hydrogen is produced using carbon‐based energy sources. Copyright © 2009 John Wiley & Sons, Ltd.     

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.     

Influence of secondary source technologies and energy management strategies on Energy Storage System sizing for fuel cell electric vehicles

Fuel cell electric vehicles (FCEVs) have some limitation which make them less competitor to thermal ones and delay their commercialization. The most important problems as the range, the durability and the cost depend directly on the energy storage problematic issues. In this context, this work presents an optimal sizing methodology for an Energy Storage System (ESS) composed by a fuel cell and an assistant source to supply a lightweight vehicle with 700 km driving range. Firstly, a comparative study between single and hybrid source is carried out to show the benefits of hybridization according to the range in terms of weight, cost and fuel consumption. Moreover, in order to improve the hybrid source characteristics, three technologies of the secondary source are tested and evaluated to be chosen for hybridization with fuel cell system purposes. Furthermore, the influence of three Energy Management Strategies (EMSs) on ESS sizing is studied where an optimal strategy provides the most favorable dimensions of the hybrid system. Simulation results give us the best technology needed for hybridization and allow us adopting the optimal management strategy to design the hybrid source. Finally, in order to show the influence of the driving cycles on the ESS design, a comparison study using the New European Driving Cycle “NEDC” and the Assessment and Reliability of Transport Emission Models Inventory Systems (ARTEMIS) confirms that there is a slow influence of the driving cycle on the ESS sizes.     

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.     

Impact of energy supply infrastructure in life cycle analysis of hydrogen and electric systems applied to the Portuguese transportation sector

Hydrogen and electric vehicle technologies are being considered as possible solutions to mitigate environmental burdens and fossil fuel dependency. Life cycle analysis (LCA) of energy use and emissions has been used with alternative vehicle technologies to assess the Well-to-Wheel (WTW) fuel cycle or the Cradle-to-Grave (CTG) cycle of a vehicle's materials. Fuel infrastructures, however, have thus far been neglected. This study presents an approach to evaluate energy use and CO₂ emissions associated with the construction, maintenance and decommissioning of energy supply infrastructures using the Portuguese transportation system as a case study. Five light-duty vehicle technologies are considered: conventional gasoline and diesel (ICE), pure electric (EV), fuel cell hybrid (FCHEV) and fuel cell plug-in hybrid (FC-PHEV). With regard to hydrogen supply, two pathways are analysed: centralised steam methane reforming (SMR) and on-site electrolysis conversion. Fast, normal and home options are considered for electric chargers. We conclude that energy supply infrastructures for FC vehicles are the most intensive with 0.03–0.53 MJ_eq/MJ emitting 0.7–27.3 g CO_2eq/MJ of final fuel. While fossil fuel infrastructures may be considered negligible (presenting values below 2.5%), alternative technologies are not negligible when their overall LCA contribution is considered. EV and FCHEV using electrolysis report the highest infrastructure impact from emissions with approximately 8.4% and 8.3%, respectively. Overall contributions including uncertainty do not go beyond 12%.     

Fuzzy control based engine sizing optimization for a fuel cell/battery hybrid mini-bus

The fuel cell/battery hybrid vehicle has been focused for the alternative engine of the existing internal-combustion engine due to the following advantages of the fuel cell and the battery. Firstly, the fuel cell is highly efficient and eco-friendly. Secondly, the battery has the fast response for the changeable power demand. However, the competitive efficiency of the hybrid fuel cell vehicle is necessary to successfully alternate the conventional vehicles with the fuel cell hybrid vehicle. The most relevant factor which affects the overall efficiency of the hybrid fuel cell vehicle is the relative engine sizing between the fuel cell and the battery. Therefore the design method to optimize the engine sizing of the fuel cell hybrid vehicle has been proposed. The target system is the fuel cell/battery hybrid mini-bus and its power distribution is controlled based on the fuzzy logic. The optimal engine sizes are determined based on the simulator developed in this paper. The simulator includes the several models for the fuel cell, the battery, and the major balance of plants. After the engine sizing, the system efficiency and the stability of the power distribution are verified based on the well-known driving schedule. Consequently, the optimally designed mini-bus shows good performance.     

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.     

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.     

Electric buses – An energy efficient urban transportation means

Bus transit systems with electric traction are an important contribution to the post fossil fuel mobility. Most renewable energy sources provide energy in the form of electricity. Electric motors thus have promise in the development of the way “beyond oil”. The reactivation of trolley bus systems – grid bounded but also catenary free for short distances – paves this way. The design of modern trolley bus operations overcomes the existing disadvantages of conventional buses using fossil fuel. Germany has an efficient industry in this field, that offers braking energy recuperation and energy storage in modern supercapacitors as well as technical and organisational innovations for a local emission free and a low noise transit system. Gentle but powerful when starting and braking, the trolley bus is cost effective and easy to integrate into an existing infrastructure. Such an electric bus system is ecological, customer-friendly and suitable for cities. It has a high economic efficiency and it also expands the traffic planning field towards an ecological future technology. This paper shows examples at home and abroad how electric buses achieve an energy solving modern urban traffic. It gives insights into technical developments of electric vehicle equipment, cateneries with fast driving handling characteristics and the use of plain electric and hybrid powertrains.     

The computer-aided analysis for the driving stability of a plug-in fuel cell vehicle using a proton exchange membrane fuel cell

In order to analyze the driving stability of a plug-in fuel cell vehicle (PFCV), a computer-aided simulator for PFCVs has been developed. PFCVs have been introduced around the world to achieve early commercialization of an eco-friendly and highly efficient fuel cell vehicle. The plug-in option, which allows the battery to be recharged from the electricity grid, enables a reduction in size of the fuel cell system (FCS) and an improvement of its durability. As such, the existing limitations of the fuel cell - such as its high cost, poor durability, and the insufficient hydrogen infrastructure – can be overcome. During the design phase of PFCV development, simulation-based driving stability test is necessary to determine the sizes of the electric engine of the FCS and the battery. The developed simulator is very useful for analyzing the driving stability of the PFCV with respect to the capacities of the FCS and battery. The simulation results are in fact very close to those obtained from a real system, since the estimation accuracy of PFCV component models used in this simulator, such as the fuel cell stack, battery, electric vehicle, and the other balance of plants (BOPs), are verified by the experiments, and the simulator uses the newly-proposed power distribution control logic and the pre-confirmed real driving schedule. Using these results, we can study which one will be the best in terms of driving stability.     

Hydraulic/electric synergy system (HESS) design for heavy hybrid vehicles

Energy storage source is one of the key factors constraining the development of hybrid drive technology. Single energy storage source is difficult to satisfy the hybrid vehicle’s requirements for both energy density and power density. This paper presents a hydraulic/electric synergy system (HESS) for heavy hybrid vehicles to overcome the existing drawbacks of single energy storage source. The key components in the synergy system are sized to improve the fuel economy potential while satisfying the vehicle performance constraints. In order to achieve optimal fuel economy, energy control strategy tailored specially to the synergy system is designed to manage the power distribution between multiple energy sources based on theirs characteristics. The experiments and simulations demonstrate that the proposed synergy system can provide good fuel economy and overall system efficiency.     

Fuel cell power trains for road traffic

Legal regulations, especially the low emission vehicle (LEV) laws in California, are the driving forces for more intensive technological developments with respect to a global automobile market. In the future, high efficient vehicles at very low emission levels will include low temperature fuel cell systems (e.g., polymer electrolyte fuel cell (PEFC)) as units of hydrogen-, methanol- or gasoline-based electric power trains. In the case of methanol or gasoline/diesel, hydrogen has to be produced on-board using heated steam or partial oxidation reformers as well as catalytic burners and gas cleaning units. Methanol could also be used for direct electricity generation inside the fuel cell (direct methanol fuel cell (DMFC)). The development potentials and the results achieved so far for these concepts differ extremely. Based on the experience gained so far, the goals for the next few years include cost and weight reductions as well as optimizations in terms of the energy management of power trains with PEFC systems. At the same time, questions of fuel specification, fuel cycle management, materials balances and environmental assessment will have to be discussed more intensively. On the basis of process engineering analyses for net electricity generation in PEFC-powered power trains as well as on assumptions for both electric power trains and vehicle configurations, overall balances have been carried out. They will lead not only to specific energy demand data and specific emission levels (CO₂, CO, VOC, NO_x) for the vehicle but will also present data of its full fuel cycle (FFC) in comparison to those of FFCs including internal combustion engines (ICE) after the year 2005. Depending on the development status (today or in 2010) and the FFC benchmark results, the advantages of balances results of FFC with PEFC vehicles are small in terms of specific energy demand and CO₂ emissions, but very high with respect to local emission levels.     

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.     

Fuel cell hybrid powertrains for use in Southern Italian railways

This paper analyses the use of a fuel cell hybrid powertrain for different uses on rail. Four vehicles are numerically tested on suitable tracks. The implemented model calculates the vehicle power demand, starting from track altitude, train speed and vehicle characteristics. For each track, a powertrain composed of a fuel cell system and an energy storage system, battery and/or supercapacitor, is used, suitable for the purpose. Each component is modelled separately and is validated. It should be underlined that the whole system is validated, by means of experimental data found in the literature. A comparison analysis between the simulation results is done: the H₂ consumption varies between 5 kg/cycle and 160 kg/cycle, according to the track energy consumption, while the fuel cell efficiency is between 50% and 47%, since the fuel cell works at different power rates.     

Hydrogen as a fuel

Hydrogen, used as fuel, has a number of attractive features that make it a leading candidate in the search for an alternative to the dwindling and progressively less reliable supply of fluid hydrocarbon fuels. Hydrogen produced by electrolysis using hydro- or nuclear-generated electricity will be available in Canada at prices competitive with other portable forms of energy before the end of the century. This paper examines the use of carbon-free electrolytic hydrogen as a motor vehicle fuel and as a fuel for fuel cells. A review of onboard hydrogen storage systems indicates that the propulsion power unit of hydrogen-fueled vehicles must be considerably more efficient than present gasoline-fueled internal combustion engines in order to compensate for the larger size and greater weight of hydrogen storage systems. Hydrogen-fueled internal combustion engines are more efficient than similar gasoline-fueled engines, but the improvement is not sufficient to offset the storage system limitation. Fuel cells operate with much higher efficiency than internal combustion engines, especially at partial loads. A comparison between H₃PO₄ and KOH fuel cells show that where carbon-free hydrogen is available from the onboard storage system, the KOH fuel cell offers the higher level of performance.     

Optimal energy management strategy of fuel-cell battery hybrid electric mining truck to achieve minimum lifecycle operation costs

Proton exchange membrane fuel cell (PEMFC) electric vehicle is an effective solution for improving fuel efficiency and onboard emissions, taking advantage of the high energy density and short refuelling time. However, the higher cost and short life of the PEMFC system and battery in an electric vehicle prohibit the fuel cell electric vehicle (FCEV) from becoming the mainstream transportation solution. The fuel efficiency-oriented energy management strategy (EMS) cannot guarantee the improvement of total operating costs. This paper proposes an EMS to minimize the overall operation costs of FCEVs, including the cost of hydrogen fuel, as well as the cost associated with the degradations of the PEMFC system and battery energy storage system (ESS). Based on the PEMFC and battery performance degradation models, their remaining useful life (RUL) models are introduced. The control parameters of the EMS are then optimized using a meta-model based global optimization algorithm. This study presents a new optimal control method for a large mining truck operating on a real closed-road operation cycle, using the combined energy efficiency and performance degradation cost measures of the PEMFC system and lithium-ion battery ESS. Simulation results showed that the proposed EMS could improve the total operating costs and the life of the FCEV.     

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.     

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.