New Technologies for Fuel Cells in Future Powertrain Applications

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1 New Technologies for Fuel Cells in Future Powertrain Applications Peter PRENNINGER Wasserstoff und Brennstoffzellen-Projekte, F&E-Institutionen, Firmenstrategien und technologiepolitische Förderinstrumente in Deutschland und Österreich TechGate Vienna

2 AVL Company Profile Rethinking Propulsion. Turnover: 2006: 537 Mio AVL Powertrain Engineering Employees: 2006: 3640 AVL Advanced Simulation Technology Average R&D spending: 10 % of turnover AVL Instrumentation and Test Systems 2

3 AVL Technical Centers Rethinking Propulsion. Plymouth, Michigan Ann Arbor, Michigan Headquarters Graz New Delhi Shanghai Germany Sweden Peterborough, UK 3

4 Rethinking Propulsion. AVL Examples R&D Activities First Magnesium DI Diesel Engine First Turbocharged DI Gasoline Engine 4

5 Rethinking Propulsion. ECO Target TM ICE Hybrid Concept Mid-Class Passenger Car (1350 kg) Mild Hybrid Concept with 3-Cylinder DI Diesel Engine CO 2 -g/km NOx - g/km g/km Achievement of CO 2 Emissions < 100 g/km Downsizing and conventional HSDI Diesel combustion Hybridization (idle shut-off, regenerative braking, electrical boosting) Alternative Diesel combustion Potential of thermal encapsulation 5

6 Rethinking Propulsion. AVL Selected A3 Projects SOFC Auxiliary Power Unit PTSU TM Fuel Cell Vehicle Controller for the HyLite Project Stack Monitoring Technique AVL-THDA TM 6

7 SOFC Auxiliary Power Unit PTSU TM Rethinking Propulsion. Motivation: Reduction of heavy duty truck idling costs and emissions Offer and Implementation! Development partnership of AVL and leading fuel cell manufacturer Topsoe Fuel Cell (TOFC)! Prototype development! Sub-system and single component development! Integration and economic feasibility studies! HiL test bench for system and component development Solution SOFC Stack - TOFC (1) PTSU AVL Diesel ATR/CPOX Reformer! Stand alone and highly integrated concept PTSU TM(1) developed! Solid oxide fuel cell technology, fuel: Diesel! Cabin climatisation, electrification, engine pre-heating and exhaust gas after treatment! End-consumer pay back period below 2 years! Modular design of 2 concepts (1 manufacturing line for 2 products)! Significant reduction of idling noise and emissions 7

8 SOFC Auxiliary Power Unit PTSU TM Rethinking Propulsion. 1 kw SOFC Stack (TOFC) Reformer Cathode HEX 8

9 SOFC Auxiliary Power Unit PTSU TM Rethinking Propulsion. 37% System Efficiency (compared to 35% design target) 600 SOFC APU Load Profile Test P_demand P_gross P_net System Efficiency % Peak Efficiency electric Power [W] Efficiency [-] 92% Fuel Utilization time [s]

10 Rethinking Propulsion. HyLite PEMFC-Battery Hybrid EV HyLite - a consortium of 10 automotive supplier industry partners. The partners built a hydrogen fuelled PEM fuel cell battery hybrid energy system for an electrical driven vehicle. Targets Development of optimised components for fuel cells systems i.e. in particular air and fuel supply subsystems, thermal and energy management systems Build up of an open testing platform for fuel cell and electrical driven power trains. 10

11 HyLite PEMFC-Battery Hybrid EV Rethinking Propulsion. driving conditions city propulsion power highway extra-urban Detection of Vehicle Driving State and Driver Demand regenerative power area energy management unit state of charge actual SOC SOC target VMU principle R D N P Energy Management considering SOC and FC State PEFC system 15kW net gas. H2 tank battery pack NiMH,, 8kW DC DC DC AC ASM Testing of Operation Strategy with Vehicle Simulation Model 11

12 HyLite PEMFC-Battery Hybrid EV Rethinking Propulsion. Vehicle vehicle speed wheel speed wheel torque motor speed motor torque efficiencies Powertrain Control electric power demand drive Further Further Elements Elements Driver drive torque brake torque Electric Control electric power demand FC fuel cell power limit reference pressure hydrogen reference mass flow hydrogen Anode BOP Control Pressure Control Pressure Sensor Driver sensor reading anode pressure reference HMD signal HMD Driver Hydrogen Path actuator output PEMFC Model from CDL-FCS TU Graz E-Drive Pressure Sensor HMD FC-HEV Powertrain System Target System: dspace Microautobox Implementation in AVL-MCU TM Brake pedal Acceleration pedal Basis for RT-HIL Model in EU Project HySys HIL Demonstrator at AVL Exhibition 12

13 Rethinking Propulsion. Stack Monitoring Technique AVL-THDA TM AVL THDA TOTAL HARMONIC DISTORTION ANALYSIS cell voltage, V area of linear transfer function 0.9 typ. V/I curve critical cell no 0.7 distortion time harmonic distortion i thda (t) Effects resulting from voltage drifts are analyzed instead of voltage drift measurement operating point stack current, A time If defects or critical conditions occur in one or few cells, local nonlinearities in the transfer function distort a superimposed signal and form harmonics Extra spectral components (i.e. harmonics) are detectable in the entire stack sum voltage Reduced measurement effort: stack voltage & stack current only Low cost approach (2 channel instrumentation) THDA Total Harmonic Distortion Analysis* *patented, registered trademark 13

14 Rethinking Propulsion. Stack Monitoring Technique AVL-THDA TM battery pack inverters, converters, ect. & signal modulation fuel cell system i FC i AC a. DC DC DC AC DC DC +12V FC control w/ THDA b. M a. Modulation of specific current signal pattern by converter b. Embedded signal distortion analysis by existing FC controller (SW function) " cost reduction to minimum 14

15 Rethinking Propulsion. Stack Monitoring Technique AVL-THDA TM 5kW PEMFC System: Varying Air Supply Conditions Load = 2.5kW, AVL List GmbH cell voltage [V] air lambda [-] cell voltage [V] air lambda CVM (~100 channels) THDA CVM (~100 channels) THDA time scale [s] 5kW PEMFC System: Dead End Operation with Delayed Anode-Purge load = 2.4kW; AVL List GmbH 2007 H2 purge H2 purge H2 purge THDA level THDA level THDA level is indicating on-line critical voltage drifts (somewhere) in the stack time scale [s] 15

16 Rethinking Propulsion. Stack Monitoring Technique AVL-THDA TM impedance [] EIS: electrical impedance spectroscopy Dead End t=230s Low hydrogen partial pressure p=0.25 Low air stoichiometry =1.4 Normal operation CDL PEMFC V2: 25cm² standard MEA&GDL f THDA1 f THDA2 f THDA3 f Membrane frequency [Hz] Changes in impedances are differently influenced by several critical conditions " correlates to harmonic distortion effects # Basis for separation of cathode/anode effects with THDA 16

17 Rethinking Propulsion. AVL Selected A3 Projects SOFC Auxiliary Power Unit PTSU TM Fuel Cell Vehicle Controller for the HyLite Project Stack Monitoring Technique AVL-THDA TM 17

18 Kontakt Rethinking Propulsion. Dr. Peter Prenninger AVL List GmbH Anschrift: Hans List Platz Graz Tel: Fax: web: peter.prenninger@avl.com 18