HySYS: Fuel Cell Hybrid Vehicle System Component Development Project Overview Final Event 22.09.2010 Stuttgart, Germany Jörg Wind Daimler AG
FC Hybrid Vehicle System Component Development FACTS Coordinator: Daimler AG Total budget: 22.7 M EC-Funding: 11.2 M Partners: 28 (17 Industry, 2 SMEs, 4 Institutes, 5 Universities) Countries: 8 EC Member States and Switzerland Duration: 01.12.2005 30.11.2010
HySYS - Fuel Cell Hybrid Vehicle System Component Development IP-Partners 6 OEM s 14 Suppliers 3 Institutes 5 Universities Wind, Daimler HySYS Final Event September 22nd, 2010 3
Motivation Motivation, Objectives Improvement of system components for FC-hybrid vehicles is necessary to meet all necessary requirements for mass production Involve supplier industry more deeply in FC- and ICE Hybrid component development by cooperation in a European project Close cooperation of car industry with suppliers is needed for a successful market introduction of FC-vehicles Objective Improved low cost FC-system components (air supply, hydrogen supply, humidifier, H 2 -sensors) suitable for mass production Improved low cost E-drive components (E-motor, power electronics, battery) suitable for mass production Optimised system architecture for low energy consumption and high performance All achievements will be validated in vehicles (2 validators) 4
Project Goals Improvement of fuel cell system components for market readiness Improvement of electric drive train components (Synergies FC and ICE-hybrids) for market readiness Optimisation of system architecture for low energy consumption, high performance, high durability and reliability Optimisation of energy management, enhanced FC-drive train efficiency Development of low cost components for mass production Validation of component and system performance on FC Vehicles
Regarded Components Low cost automotive electrical turbochargers for air supply with high efficiency and high dynamics Low cost humidifiers with high packaging density Low cost hydrogen sensors for automotive use Effective low cost hydrogen supply line High efficient, high power density electric drive train Low cost high power Li-Ion batteries
Definition of Vehicle Requirements Parameter Motor Power (cont/peak) Fuel Cell Power Gearbox Batterie LiIon Weight empty/fully loaded Range at ½ load Vmax Vmax continuous DAIMLER Validator (MB-Sprinter) 70/100 kw 80 kw One gear ratio 30 50 kw, 2 kwh <= 2.7 t / 3.5 t > 300 km 130 km/h @ grade 0% CRF Validator (FIAT Panda) 40/75 kw 60 kw (nominal) 75 kw (peak) One gear ratio Not foreseen 1.4 t / 1.7 t 250 km 140 km/h @ grade 0% Acceleration Climbing ability fully loaded Vmax at ½ load on 4% slope 0-80km/h < 21 s 0-100 km/h < 37 s 35% N/A 0-50km/h < 7 s 0-100 km/h < 15 s 23 % > 80 km/h 7
HYSYS component integration The HySYS validators use different base fuel cell systems and e-drive train components Some major components are replaced by those which are developed in HySYS HySYS components which are integrated in the validators: Air suppply: electric turbo charger and integrated air sensor Hydrogen Metering Device Hydrogen humidification system Electric Motor Inverter DC/DC converter Li-Ion battery system HySYS Base FC System for Daimler validator 8
Validator Vehicle: Mercedes Benz FC-Sprinter Vehicle Integration DAIMLER Validator: Packaging Concept Converters HV Battery HV Battery Air supply Drive Train H2 Storage FC Stack 9
Validator Vehicle: FIAT Panda VEHICLE INTEGRATION CRF VALIDATOR: Packaging Concept HRB Air supply H2 Storage HMD FC Stack E motor 10
Fuel Cell System Components, #1 Air supply Current Technology: Screw-Compressor Innovative Technology: Electrical Turbocharger High Efficiency Low Cost, volume& weight High Dynamic response Noise reduction Humidifier Current Technology: Contact humidifier Innovative Technology: Gas-to-gas humidifier high packaging density high humidification efficiency low degradation tendency low cost materials easy production technology Involved partner: Fischer, Daimler, Bosch Involved partner: Fumatech, Daimler, Wind, Daimler HySYS Final Event CRF, September Rivoira 22nd, 2010 11
Fuel Cell System Components, #2 Hydrogen Sensors Current Technology: electrochemical sensors, semiconductor sensors, catalytic bed sensor Innovative Technology: Palladium Nanostructure Low cost, weight&volume Fast response No calibration needed High gas selectivity Integrated design Hydrogen supply line Current Technology: standard H2 line with pressure regulator valves Innovative Technology: Fully automated H2 line with Hydrogen Metering Device dual stage pressure reduction fully automatic operation flexible regulating FC stack pressure fail safe with failure recovery improved lifetime of FC system Involved partner: EPFL, MiCS, PSA, Involved partner: Bosch, CRF CNM, Wind, Univ. Daimler Montpellier HySYS Final Event September 22nd, 2010 12
E-Drive Components E-Drive System Current Technology: AC induction and PM brushless with low liquid cooling temperature (55-60 C) power electronics Innovative Technology: Buried PM synchronous and mixed motors e-motor: higher specific torque-power and efficiency power electronics: higher integration and cooling temperature (up to 90 C) HV-HV DC/DC converter: modular solution with high power density Battery System Current Technology: Ni-MeH Innovative Technology: Li-ion higher specific power: from 1.35 to 2 kw/kg higher specific energy: from 46 to 63 Wh/kg higher efficiency: from 85 to 95% improved lifetime: from 8 to 15 years E-motor Inverter HySYS Battery Module HySYS Battery System Involved partner: CRF, Eldor, Daimler, PSA, Involved partner: Saft, Daimler, PSA, ContiTemic, ContiTemic, ATB, Univ. Maribor Magna, ENEA 13
HYSYS WP 5100, Full power Fuel Cell Van Parameter characteristics of fuel cell system during NEDC driving cycle 300 Requested Current Electrical Load 240 180 120 60 0-60 -120-180 -240-300 1 370 361 1 2 Stack Voltage 352 343 334 325 316 307 298 289 280 1 360 320 1 Air mass flow 280 240 200 160 120 80 40 1 Stack Current 0 1 360 320 280 240 200 160 120 80 40 0 1 1 50s 1m 40s 2m 30s 3m 20s 4m 10s 5m 0s 5m 50s 6m 40s 7m 30s 8m 20s 9m 10s 10m 0s 10m 50s 11m 40s 12m 30s 13m 20s 14m 10s 15m 0s 15m 50s 16m 40s 17m 30s 18m 20s 19m 10s HySYS Final Event September 22nd, 2010 14
HYSYS WP 5100, Full power Fuel Cell Van Fuel Cell System Efficiency Comparison Fuel Cell system efficiency comparison 70 60 efficiency [%] 50 40 30 20 10 0 EUCAR TTW (V2c 07) HySYS efficiency (Faraday) 0 10 20 30 40 50 60 70 80 90 100 Net Power [%] Fuel Cell System Comparison: HySYS fuel cell system efficiency compared with fuel cell system efficiency curve from EUCAR WTW Study HySYS Final Event September 22nd, 2010 15
Thank you very much for your attention More information on: http://www.hysys.eu 16