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
US Hybrid Group www.ushybrid.com US Hybrid HQ: Torrance, CA www.usfuelcell.com US FuelCell South Windsor, CT www.magmotor.com 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
US Hybrid s Fuel Cell Commercial Vehicles Experience SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 33
Leader in Fuel Cell Vehicles Integration 20kW Fuel Cell Bus 60kW FC Cargo Van H2 Ride Shuttle Bus FC Shuttle and Truck Commercialization 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 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
Output Current A Electric Powertrain Components Input Current A 320kW 240kW 200kW 600 500 DC-DC Converters 600 500 400 400 300 300 200 200 100 100 0 6 7 8 9 10 11 12 Isolated Power kw 0 0 20 40 60 80 100 120 140 160 Output Power kw SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 55
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
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 3.15 5.88 53.1 12.8 1.32 126 16.8 4.7+12.1 1.42-0.84 20.5 11.8 1.22 136 25.3 20+5.2 1.46 6.72 28.6 17.3 1.13 146 50 fwy 2.62 16.52 55.8 19.1 1.12 148 34 fwy 1.44 12.32 33.9 23.6 1.00 166 25.0 20.0 15.0 10.0 5.0 0.0 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
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
Grade (%) Elevation (ft.) Drive Cycle 1: Volcano National Park Driving Elevation and Grade 200 Profile Alignment 100 0-100 -200-300 -400 0 1 2 3 4 5 6 7 8 9 10 11 Bus Stop Distance (mile) 20.00 15.00 10.00 5.00 0.00-5.00-10.00-15.00-20.00 Profile Grade 0 1 2 3 4 5 6 7 8 9 10 11 Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 99
Elevation (ft.) Grade (%) Drive Cycle: Elevation and Grade 4500 4000 3500 3000 2500 2000 1500 1000 500 0 Profile Alignment Outbound Inbound Bus Stop 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) 20 15 10 5 0-5 -10-15 -20 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) Profile Grade SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 10 10
Speed (mph) Speed (mph) 45 40 35 30 25 20 15 10 5 0 Drive Cycle 2: Speed versus Time and Distance V max = 20 mph Speed vs. Time 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 Time (s) 45 40 35 30 25 20 15 10 5 0 Speed vs. Distance 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 11 11
SOC Energy (kwh) Simulation Results for Battery Pack 25 Outbound Available Energy Inbound 20 15 10 5 0 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) State of Charge 1.5 1 0.5 0 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 12 12
Power (kw) Power (kw) Simulation Results: Power 200 100 Power Battery Fuel Cell 0-100 -200 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) 60 40 Average Power Over Time Total Battery Fuel Cell 20 0-20 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 13 13
Energy (kwh) Energy/Distance (kwh/mile) Simulation Results: Energy 100 80 Consumed Energy 60 40 20 0 Total Battery Fuel Cell -20 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) 3.5 3 2.5 2 1.5 1 0.5 Energy used per mile Total Battery Fuel Cell 0 0 5 10 15 20 25 30 35 40 45 50 55 Distance (mile) SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 14 14
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
R12 Refueler top level Specification SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 16 16
Fuel Cells Dynamic and Static Performance SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 17 17
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) 2/7/2013 11 400 0.7 15.7 18% 6.1 2/7/2013 12 400 0.7 16.4 13% 4.4 2/8/2013 28 1000 2.0 14.3 38% 12.9 2/12/2013 11 300 0.6 17.5 12% 4.1 Total 115 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 18 18
Fuel Cell Powered TUG SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 19 19
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
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 gal @5000 psi, or 11 gal @5000psi 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 0.004 kwh/kg, Lead Acid 0.025 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
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
Commercial Product Planning for durability, cost, volume and weight improvement >70% volume reduction in 5 years Power Rating Availability Year 135 kw 2014-2015 75 kw 2017 200 kw 2016 Power Rating 135kW 75kW 200kW Dynamic Response kw/s 100 75 125 Market Segment Transit Bus People movers Specialty Trucks Construction Military Mining Commercial Deploy 2015 2016 2016 Target Life (hrs. /Years) 20,000/10 10,000/6 5,000/6 PC58 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 23 23
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
Fuel Cell Power Plant Performance Status NREL Technical Report NREL/TO-5600-55367 2013 fleet leader >16,000 Hr, as of Dec 2013 and going FCEB and Diesel Bus Comparative Availability FCEB Category % # Days Planned work days 1,943 631 Days Available 1,087 56 498 79 Unavailable 856 100 133 100 Fuel cell propulsion 99 12 Hybrid propulsion 30 3 Traction battery issues 160 19 Bus maintenance 557 65 133 100 Fueling unavailable 10 1 Maintenance Cost $/Mile $1.30 100% $0.79 60% 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
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
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