Battery and FC vehicles A concept to increase efficiency and range Prof. Dr.-Ing. Thomas von Unwerth, Dipl.-Ing. Christoph Danzer Department for Advanced Powertrains 13.12.2013 European Fuel Cell Rome, Italy
Driver for Electrification Society: - increasing awareness of ecologic/economic issues - climatic changes - lobbyists Legislation: Advanced powertrains / Electrification - emissions / fuel consumption - incentives / tax benefits - driving bans / city-charges - ZEV-Legislation Energy sector: - Fuel availability and local dependencies - shortage of ressources - decreasing oil production Competition: - increased activities - more launches of series vehicles - market positioning. 2
Efficiencies compared (exemplary) Efficiency pathways Wind power Hydrogen Fuel Cell Electric vehicle H 2 Efficiencies: 50% 70% 90% 50% 80% = 12.6% Windpower Battery Electric vehicle Li-Ion Efficiencies: 50% 95% 90% 80% = 34.2% 3
Volume and weight for 500 km range Diesel Compressed Hydrogen Li-Ion battery 400 kwh chemical energy 6 kg H2 @700 bar = 200 kwh chemical energy 100 kwh electrical energy system fuel system fuel system fuel 43 kg 33 kg 125 kg 6 kg 830 kg 540 kg 46 L 37 L 260 L 170 L 670 L 360 L (Ref.: CEP) 4
Electric vehicles filling duration electricity high power plug 10 kw hydrogen filling station 2.000 kw (ca. 1 kg/min) gasoline filling station 27.000 kw (ca. 50 l/min) 1 min filling = 1 km driving 1 min filling = 100 km driving 1 min filling = 1.000 km driving SS2010 / Dr.-Ing. 5 T.von Unwerth 0-5
Infrastructure for electric vehicles Charging and filling Charging stations at Lisboa (Source: zeitonline.de) Hydrogen filling station at Berlin (Source: cleanenergypartnership.de) Charging station at Berlin (Source berlin.de) HFS at NYC (Source: dailytech) Honda Solar H2-Station at LA (Source: Honda) SS2010 / Dr.-Ing. 6 T.von Unwerth 0-6
Energy path with electricity coal, gas nuclear wind water solar mix mix public charging stations at work at home 7
Energy path with hydrogen coal, gas nuclear wind solar water electricity electricity electricity electricity electricity Hydrogen Filling Station Electric Vehicles with Fuel Cells 8
Sample battery electric vehicle Electric A/C 9
Sample battery electric vehicle 270 Nm torque 50 kw (85 kw peak) electric motor 26,5 kwh Battery Capacity 150 km range (w/o A/C) 10
Sample Fuel cell drivetrain 11
Sample Fuel cell drivetrain FC-System w/ eletric charging compressor hydrogen storage Li-Ion-battery 80 kw FC-system 6,4 kg H2 @ 700 bar 55 kw (peak 100 kw) Electric motor Electric A/C electric motor 1,47 kwh Battery Capacity 12
Fuel Cell powertrain - efficiency Example NEDC η = 65 % FC-stack η = 60 % FC-system FC-system compressor cool-pump recirculation Bat. overall efficiency 25 % of FCstack energy η = 95 % η = 45 % tank to wheel PDU PDC à consumption 0,9 1,1 kg H 2 /100 km relation Diesel 21 25 % Otto 17 19 % FU M 80 % of E brake η = 85 % η = 85 % (incl. η Bat.) 25 % of FCstack energy A/C BN 5 % of FCstack energy 13
ESD Efficient Synergy Drive System Today H2 ESD-System H2 Traction Battery Fuel Cell system Traction Battery Fuel Cell system DC/AC EM2 Air compressor DC/AC EM1 Gearbox EM1 EM2 Gearbox Air compressor Dual utilization of an expanded air compressor motor for Fuel cell charging and driving at partial-load ranges Optimal power split between both electric motors to minimize power losses in all driving situations Synergistic effect of two electric motors provide powershiftable multi-speed gearboxes High system efficiency due to elimination of lossy friction clutches and hydraulics 14
ESD Efficient Synergy Drive Draft Design Study (1) Main EM-housing (2) Power electronics (3) Belt drive (4) Planetary gearset 1 (5) Twinstage output (6) Dog clutch K0/K1 5 (7) Dog clutch B0 3 EM1 3 EM2 2 7 6 4 15
ESD Efficient Synergy Drive Intelligent Power Management Exemplary Driving Situation v = 50 km/h a P Road = 7.5 kw = 0.25 m/s² P Comp. = 1.0 kw Torque [Nm] Efficiency map of EM1 including INV1 95.2% wheels Standard EV Powertrain: P EM1 = 7.5 kw P EM2 = 1.0 kw Low utilization of EM maps Low powertrain efficiency Lower cruising range Speed [rpm] EM1 Continuously variable torque ESD Powertrain: P EM1 = 0.0 kw P EM2 = 8.5 kw Intelligent map utilization High powertrain efficiency Higher cruising range Comp. EM2 Torque [Nm] Efficiency map of EM2 including INV2 95.8% Speed [rpm] 16
ESD Efficient Synergy Drive Intelligent Power Management Exemplary Driving Situation v = 50 km/h a P Road = 7.5 kw = 0.25 m/s² P Comp. = 0.5 kw Torque [Nm] Efficiency map of EM1 including INV1 95.2% wheels Standard EV Powertrain: P EM1 = 7.5 kw P EM2 = 1.0 kw η EM1 = 75 % η EM2 = 90 % P Losses = 1.98 kw Speed [rpm] EM1 Continuously variable torque ESD Powertrain: P EM1 = 0.0 kw P EM2 = 8.5 kw η EM1 = 30 % η EM2 = 95 % P Losses = 0.43 kw Comp. EM2 Torque [Nm] Efficiency map of EM2 including INV2 95.8% Speed [rpm] 17
ESD Efficient Synergy Drive Concept Features: Dual use of an expanded compressor drive for fuel cell charging and partialload driving Cruising-range extension through efficiency-optimized power split Powershiftable two-speed gearbox Active synchronization Simple, cost-efficient and low-loss electromechanical shifting actuator Fully integrated system drive for minimal packaging CAD Design Draft 18
Thank you for your attention ESD Efficient Synergy Drive Contact: Prof. Dr.-Ing. T. von Unwerth Chemnitz University of Technology Faculty for Mechanical Engineering Department for Advanced Powertrains Reichenhainer Str.70 09126 Chemnitz Germany Phone: +49 371 531-23550 E-mail: thomas.von-unwerth@mb.tu-chemnitz.de 19