Abas Goodarzi, Ph.D., P.E. President, US Hybrid SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 1
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1 Abas Goodarzi, Ph.D., P.E. President, US Hybrid SAE 2014 Hybrid and Electric Vehicle Technologies Symposium SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 1 1
2 US Hybrid Group US Hybrid HQ: Torrance, CA US FuelCell South Windsor, CT Magmotor Corporation Worcester, MA Year Established 1999 Year Established 2013 Year Established 1876 (Acquired by US Hybrid in 2008) Core Competency Electric Powertrain for Electric, Hybrid and Fuel Cell Heavy Duty Vehicles Core Competency Fuel Cell Power Plant Core Competency Servo Motors and Drives Automation, Robotic and Semiconductor Mfg. Torrance, CA South Windsor, CT Worcester, MA Torrance, CA Honolulu, HI SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 22
3 US Hybrid s Fuel Cell Commercial Vehicles Experience SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 33
4 Leader in Fuel Cell Vehicles Integration 20kW Fuel Cell Bus 60kW FC Cargo Van H2 Ride Shuttle Bus FC Shuttle and Truck Commercialization FC BOP 30kW FC Utility Van Isolated DC-DC Transit Bus BOP to UTC R12 Refueler Dump Truck Specialty Trucks and Transit 1960s 1970s 1980s 1990s 2000s 2010s 2013 US Hybrid Acquired UTC PEM Fuel Cell Apollo Demos: Homes, Buildings Utilities Space Shuttle Orbiter 200/400 kw Commercial Production Over 50 years of Technology Research & Product Development SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 44
5 Output Current A Electric Powertrain Components Input Current A 320kW 240kW 200kW DC-DC Converters Isolated Power kw Output Power kw SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 55
6 Plug-In Fuel Cell Shuttle Bus Shuttle Bus (GVWR=8,850 kg) Drive Cycle: Volcano National Park Hawaii SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 66
7 Energy Usage Summary Drive (miles) Local or FWY H2 Used Kg Battery kwhr used Total Energy used kwhr Miles /kg H2 kwh /Mile Expected Range miles 40.4 Local fwy fwy Energy Efficiency Miles/kg of H2 Local 1 Local 4 fwy 1 fwy 2 fwy 3 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 77
8 Drive Cycle: Chain of Craters Hawaii Volcanoes National Park Duty Cycle 2x27=54 miles round trip 4000 elevation 2x15=30 bus stops 1 minute dwell time at each bus stop 2x20 minutes dwell time at visitor center Total idle time=70 minutes Drive Cycle 1: V max =30 mph (uphill) Drive Cycle 2: V max =20 mph (uphill) a max =1 m/s 2 (uphill) V max =40 mph (downhill) Chain of Craters Road with a left onto Crater Rim Drive to Visitors Center Hotel Load A/C=4.4 kw DC/DC=2kW Other loads=0.6kw Total hotel load=7 kw SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 88
9 Grade (%) Elevation (ft.) Drive Cycle 1: Volcano National Park Driving Elevation and Grade 200 Profile Alignment Bus Stop Distance (mile) Profile Grade Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 99
10 Elevation (ft.) Grade (%) Drive Cycle: Elevation and Grade Profile Alignment Outbound Inbound Bus Stop Distance (mile) Distance (mile) Profile Grade SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 10 10
11 Speed (mph) Speed (mph) Drive Cycle 2: Speed versus Time and Distance V max = 20 mph Speed vs. Time Time (s) Speed vs. Distance Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 11 11
12 SOC Energy (kwh) Simulation Results for Battery Pack 25 Outbound Available Energy Inbound Distance (mile) State of Charge Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 12 12
13 Power (kw) Power (kw) Simulation Results: Power Power Battery Fuel Cell Distance (mile) Average Power Over Time Total Battery Fuel Cell Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 13 13
14 Energy (kwh) Energy/Distance (kwh/mile) Simulation Results: Energy Consumed Energy Total Battery Fuel Cell Distance (mile) Energy used per mile Total Battery Fuel Cell Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 14 14
15 Fuel Cell Plug-In Hybrid hybrid Electric Re-Fueler Refueler (R12) (R12) 3 * (HD16 +CV12) in parallel Hydrogen Fueling and Defueling, Diagnostics and Telematics Interface SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 15 15
16 R12 Refueler top level Specification SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 16 16
17 Fuel Cells Dynamic and Static Performance SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 17 17
18 R12- Performance Summary Fuel Cell Hybrid R12 Test Drive Summary Date Miles Driven H2 Tank Pressure Net Drop (psi) H2 Net Consumption (kg) Miles/kg Battery Pack (380V, 90 Ahr, 34 kwhr) Battery consumption in SOC Battery consumption (kwhr) 2/7/ % 6.1 2/7/ % 4.4 2/8/ % /12/ % 4.1 Total 115 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 18 18
19 Fuel Cell Powered TUG SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 19 19
20 Plug-In Hybrid Fuel Cell Class 8 Dump Truck Li-Ion Battery Hydrogenics 30kW single fuel Cell Plant H2 Fuel System 10kg) Charger J1772 CV35 DC-DC Electric Driven Steering and Brake idrive 240kW Drive SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 20 20
21 Comparable Energy Density Diesel: 37.1 kwh/gal (Energy content), Engine Output:, 15kWh/gal, 4.5 kwh/kg Gasoline: 32.9 kwh/gal, (Energy content), Engine Output: 11.8 kwh/gal, 2.8 kwh/kg Hydrogen: 39.7 kwh/kg, (Energy content), (1kg H2 =11 psi, or 11 tank is same as 2 gal of diesel fuel) Total Energy Density (Electric output power) per kg: 15 kwh/kg Mixed Fuels: Ethanol(E100) = 22.1 kwh/gal, (M85) 85% Methanol, 15% Gasoline = 18.6 kwh/gal Energy Storage Devices have much lower energy density: Ultra Capacitors kwh/kg, Lead Acid kwh/kg NiMh 0.06 kwh/kg Li-Ion 0.11 kwh/kg 1kg of H2 (7.8miles/kg) > 2-Gallons Diesel (3.8mpg) 40 Transit Bus 1kg of H2 (6miles/kg) > 2-Gallons Diesel (2.4mpg) Drayage Truck 1kg of H2 (12miles/kg) > 2.5-Gallons Gasoline (5 mpg) Shuttle Bus SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 21 21
22 US Hybrid acquired UTC PEM Transportation assets and IP License PureMotion 120kW FC power plant is the most robust fuel cell for transit applications with millions of miles logged. Generation2; 150kW Fuel Cell Power plant has the following advantages: SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 22 22
23 Commercial Product Planning for durability, cost, volume and weight improvement >70% volume reduction in 5 years Power Rating Availability Year 135 kw kw kw 2016 Power Rating 135kW 75kW 200kW Dynamic Response kw/s Market Segment Transit Bus People movers Specialty Trucks Construction Military Mining Commercial Deploy Target Life (hrs. /Years) 20,000/10 10,000/6 5,000/6 PC58 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 23 23
24 FCPP/BOP DFMA & Cost Reduction Controller Vehicle Electrical Center Frame and Enclosure Harnessing Power Distribution Module (PDM) Electrical Control System Cell Stack Assemblies Thermal Management System Fuel Processing System Air Processing System SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 24 24
25 Fuel Cell Power Plant Performance Status NREL Technical Report NREL/TO fleet leader >16,000 Hr, as of Dec 2013 and going FCEB and Diesel Bus Comparative Availability FCEB Category % # Days Planned work days 1, Days Available 1, Unavailable Fuel cell propulsion Hybrid propulsion 30 3 Traction battery issues Bus maintenance Fueling unavailable 10 1 Maintenance Cost $/Mile $ % $ % Comments: Most cost is due to learning curve Bus Maintenance and Battery are major items Fuel Cell Technician labor rate is higher than Diesel Diesel # Days % Fuel cell power plants can provide better or comparable reliability and maintenance costs to Diesel engines with after-treatment. SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 25 25
26 Hydrogen Fuel Cells Market Focus Public Transit People Mover Pilot Production Special Purpose Military Vehicles Special Applications Commercial Trucks Production SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 26 26
27 Summary and Conclusions Electric Traction will be the main stream Hybrid technology Enables traffic decoupling Fuel Engineering Technology is the research trend Hydrogen Fuel Cell appears to be future mainstream SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 27 27
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