7/19/2011

Fuel Cell Electric Hybrid Motorcycle

Principle Investigator: Prof. Paul Erickson
Associate Professor, Mechanical Engineering Department, University of California - Davis

Presented by: Aaron Sanders (M.S, M.E, 2011) Karan Jhaveri (Ph.D., M.E, 2013) Joseph Lee (B.S, M.E., 2011)

Outline
Project Scope And Overview Modeling And Analysis System Design
o Power-train
Fuel Cell Batteries Motor And Motor Controller Electrical system

o Sensors And instrumentation o Fuel delivery o Integration

Insights

Small Hybrid Project / May 2011 / UC Davis

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Project Scope and Overview

Problem statement
o Convert an all-electric motorcycle with 4 kW-hr battery into a Fuel-cell hybrid with final energy storage capacity greater than 4 kW-hr o The converted bike must be able to run at 10, 20 and 30 mph for 5 minutes

Small Hybrid Project / May 2011 / UC Davis

Project Scope and Overview

Hydrogen as a fuel / ADVANTAGES:

Specific Energy comparison [ONLY FUEL]

Small Hybrid Project / May 2011 / UC Davis

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Project Scope and Overview

Hydrogen as a fuel / DISADVANTAGES:

Energy Density comparison [ONLY FUEL]

Small Hybrid Project / May 2011 / UC Davis

Project Scope and Overview

PEM (Proton Exchange Membrane) fuel cell operation

Small Hybrid Project / May 2011 / UC Davis

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Project Scope and Overview

Voltage polarization curve for Fuel Cells

Small Hybrid Project / May 2011 / UC Davis

Project Scope and Overview

Fuel Cell Series Hybrid configuration

Small Hybrid Project / May 2011 / UC Davis

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Outline
Project Scope and Overview Modeling and Analysis System Design
o Power-train
Fuel Cell Batteries Motor and Motor Controller High Voltage circuit Low Voltage circuit

o Sensors and instrumentation o Fuel delivery o Integration

Insights
Small Hybrid Project / May 2011 / UC Davis 9

Modeling and Analysis

Objective
o Build power-train model of the existing motorcycle to simulate performance and extract sizing and control related information for hybrid system

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Modeling and Analysis

Motor model
o Extracted performance and efficiency information from manufacturers charts o Model calibrated with experimental data obtained from test runs

Small Hybrid Project / May 2011 / UC Davis

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Modeling and Analysis

Analysis over urban drive cycle (FTP 75)

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Outline
Project Scope and Overview Modeling and Analysis System Design
o Power-train
Fuel Cell Batteries Motor and Motor Controller High Voltage circuit Low Voltage circuit

o Sensors and instrumentation o Fuel delivery o Integration

Insights
Small Hybrid Project / May 2011 / UC Davis 13

System Design/ Powertrain

Fuel Cell
o o o o o 48 cell, PEM Fuel cell 2kW rated power @ 40% efficiency Max. stack temperature 65 C Weight with controller 8 kg Startup to rated power 2 min

52% @ 1.2kW

Small Hybrid Project / May 2011 / UC Davis

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System Design/ Powertrain

Fuel cell / H2 storage selection

0.02
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System Design/ Powertrain

Battery
o o o o o o o o Li-Polymer Each cell 22.2 V and 5 A-hr Pack 2 cells in series (44.4 V) per branch, 5 branches in parallel Total pack voltage 44.4 V Total pack capacity 5 A-hr Total Energy 1.1 kW-hr Steady discharge 5C per cell = 625 A Pack charging time 7 hours

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System Design/ Powertrain

Control
o Arduino MEGA o Fuel cell acts as a range extender providing a maximum of 2kW power as per demand and a minimum of all auxiliary power demand (~0.6 kW) at all other times o Power demand calculated from current measurements -> required fuel cell current obtained from look-up table -> Boost converter commanded to impose desired current limit o Always in the 50 60 % efficiency range

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System Design/ Powertrain

Electrical System

Drive System

Fuel Cell

Boost Converter

Batteries Auxiliary System

Small Hybrid Project / May 2011 / UC Davis

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System Design/ Powertrain

Motor controller (AXE-4855)
o Controls motor current o First line of defense against over discharging batteries o Reprogrammed to cut off outside of 38-54 VDC

Small Hybrid Project / May 2011 / UC Davis

System Design/ Powertrain

Boost converter: Zahn DCDC6350-SU-ADJ
o Fuel cell voltage drops to 36V under load o Boost converter steps voltage up to 50 VDC

Small Hybrid Project / May 2011 / UC Davis

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System Design/ Powertrain

Step down converters (Sevcon 622/11084)
o Auxiliary systems require 12 VDC power o Step down DC/DC converters take 48VDC input and output 12 VDC

Small Hybrid Project / May 2011 / UC Davis

System Design/ Instrumentation

Temperature sensors
o Monitor battery and motor temperature and control cooling fans

Pressure sensor
o Monitor tank pressure

Current sensors
o Measure battery, motor and auxiliary load currents o Used to control fuel cell output and calculate battery state of charge

Relays
o Activate contactors, enable motor controller

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System Design/ Fuel Delivery

Quarter turn valves

Equivalent to 3 kW-hr electrical energy output from Fuel Cell

Rigid tubing for high pressure

Flexible tubing after first regulator - low pressure ~ 30 psi

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System Design/ Integration

Components to be mounted
o o o o o o o o o o DC-DC Converters (2) DC-DC Step-up converter (1) Batteries (10) Hydrogen Fuel Cell Hydrogen Tanks (2) Pressure Regulators (2) Fuel Cell Controller Arduino Box LCD Box Fuse Box

Design Criteria
Functionality o All components must fit on motorcycle and interface well with each other. Safety o All stresses in mounting hardware should be at allowable levels as calculated though FEA analysis and vibrations should be minimized. Weight o Minimize weight addition Stability o Maintain low center of gravity, minimize moments by having components mounted symmetrically
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Small Hybrid Project / May 2011 / UC Davis

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System Design/ Integration

Hydrogen tanks

Fuel cell

Battery Box

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System Design/ Integration

Full CAD Assembly Completed assembly

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Outline
Project Scope and Overview Modeling and Analysis System Design
o Power-train
Fuel Cell Batteries Motor and Motor Controller High Voltage circuit Low Voltage circuit

o Sensors and instrumentation o Fuel delivery o Integration

Insights
Small Hybrid Project / May 2011 / UC Davis 27

Insights
For U.A.V kind of an application
o Low heat signature
Fuel cell stack and exhaust temperature much lower than I.C. engine

o Low acoustic signature

Only noise sources are fans, pumps, etc. No high intensity pressure wave due to combustion to deal with

o Possible to achieve acceptable flight duration

Fuel cells are very good for low steady-state power operation. Can use ultra-caps or batteries for take-off and cruise mainly on fuel cell power

o Fueling
Significant challenge

o Reliability
Can be made comparable to incumbent technologies through focused development

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Team UC Davis!!
Principle Investigator Dr. Paul Erickson Organizers Karan Jhaveri Aaron Sanders Electrical and Controls Bernard Balak James Dewberry Jonathan Harris Adam Kistler Elijah Rosas Modeling and Simulation Christopher Gruenwald Michael James Javier Jonathan Sokolov Fuel System Team Ronald Joshua Academia Robert Lapp Joseph Lee Kevin Uy System Integration Team Gary Rossetto Michael Corsetto Nicholas Prsha Jared Jones Mechacnical Design and Fabrication John Barnes Rocher Mach Peter Taylor

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Thank you! Q&A

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