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HySYS: Fuel Cell Hybrid Vehicle System
Component Development
Project Overview
Final Event
22.09.2010 Stuttgart, Germany
Jörg Wind
Daimler AG
Wind, Daimler HySYS Final Event September 22nd, 2010
HySYS - Fuel Cell Hybrid Vehicle System Component Development
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
Wind, Daimler HySYS Final Event September 22nd, 20103
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, 20104
HySYS - Fuel Cell Hybrid Vehicle System Component Development
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
Motivation
Objective
• Improved low cost FC-system components (air supply, hydrogen supply,
humidifier, H2-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)
Wind, Daimler HySYS Final Event September 22nd, 2010
HySYS - Fuel Cell Hybrid Vehicle System Component Development
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
Wind, Daimler HySYS Final Event September 22nd, 2010
HySYS - Fuel Cell Hybrid Vehicle System Component Development
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
Wind, Daimler HySYS Final Event September 22nd, 20107
HySYS - Fuel Cell Hybrid Vehicle System Component Development
35%
N/A
0-80km/h < 21 s
0-100 km/h < 37 s
130 km/h @ grade 0%
> 300 km
<= 2.7 t / 3.5 t
30 – 50 kW, 2 kWh
One gear ratio
80 kW
70/100 kW
DAIMLER Validator
(MB-Sprinter)
Not foreseenBatterie LiIon
One gear ratioGearbox
60 kW (nominal)–75 kW (peak)Fuel Cell Power
40/75 kWMotor Power (cont/Peak)
0-50km/h < 7 s
0-100 km/h < 15 s
Acceleration
140 km/h @ grade 0%Vmax
Vmax continuous
23 %
> 80 km/h
Climbing ability fully loaded
Vmax at ½ load on 4% slope
250 kmRange at ½ load
1.4 t / 1.7 tWeight empty/fully loaded
CRF Validator
(FIAT Panda)
Parameter
Definition of Vehicle Requirements
Wind, Daimler HySYS Final Event September 22nd, 20108
HySYS - Fuel Cell Hybrid Vehicle System Component Development
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 systemHySYS Base FC System for Daimler validator
Wind, Daimler HySYS Final Event September 22nd, 20109
HySYS - Fuel Cell Hybrid Vehicle System Component Development
HV Battery Air supply
Validator Vehicle: Mercedes Benz FC-Sprinter
H2 StorageDrive Train
Converters
FC Stack
HV Battery
Vehicle Integration –DAIMLER Validator:
Packaging Concept
Wind, Daimler HySYS Final Event September 22nd, 201010
HySYS - Fuel Cell Hybrid Vehicle System Component Development
Validator Vehicle: FIAT Panda
H2 Storage
E motor
HRB
HMD
FC Stack
Air supply
VEHICLE INTEGRATION – CRF VALIDATOR:
Packaging Concept
Wind, Daimler HySYS Final Event September 22nd, 201011
HySYS - Fuel Cell Hybrid Vehicle System Component Development
Fuel Cell System Components, #1
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
Air supply
Current Technology: Screw-Compressor
Innovative Technology: Electrical Turbocharger
• High Efficiency• Low Cost, volume& weight• High Dynamic response• Noise reduction
Involved partner: Fischer, Daimler, Bosch Involved partner: Fumatech, Daimler, CRF, Rivoira
Wind, Daimler HySYS Final Event September 22nd, 201012
HySYS - Fuel Cell Hybrid Vehicle System Component Development
Fuel Cell System Components, #2
Hydrogen Sensors
Current Technology: electrochemical sensors, semiconductorsensors, 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, CNM, Univ. Montpellier
Involved partner: Bosch, CRF
Wind, Daimler HySYS Final Event September 22nd, 201013
HySYS - Fuel Cell Hybrid Vehicle System Component Development
E-Drive Components
E-Drive System
Current Technology: AC induction and PM brushless with low liquidcooling 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
InverterE-motor
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
HySYS Battery SystemHySYS Battery Module
Involved partner: CRF, Eldor, Daimler, PSA, ContiTemic, ATB, Univ. Maribor
Involved partner: Saft, Daimler, PSA, ContiTemic,Magna, ENEA
HySYS Final Event September 22nd, 201014
HySYS - Fuel Cell Hybrid Vehicle System Component Development
HYSYS WP 5100, Full power Fuel Cell Van
Parameter characteristics of fuel cell system during NEDC driving cycle
-300
-240
-180
-120
-60
0
60
120
180
240
300
1
1 2
280
289
298
307
316
325
334
343
352
361
370
1
1
0
40
80
120
160
200
240
280
320
360
1
1
0
40
80
120
160
200
240
280
320
360
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
1
Requested Current
Electrical Load
Stack Voltage
Air mass flow
Stack Current
HySYS Final Event September 22nd, 201015
HySYS - Fuel Cell Hybrid Vehicle System Component Development
HYSYS WP 5100, Full power Fuel Cell Van
Fuel Cell System Efficiency Comparison
Fuel Cell system efficiency comparison
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80 90 100
Net Power [%]
eff
icie
nc
y [
%]
EUCAR TTW (V2c 07)
HySYS efficiency (Faraday)
Fuel Cell System Comparison:
HySYS fuel cell system efficiency compared with fuel cell system efficiency curve from
EUCAR WTW Study
Wind, Daimler HySYS Final Event September 22nd, 201016
HySYS - Fuel Cell Hybrid Vehicle System Component Development
More information on:
http://www.hysys.eu
Thank you very much for your attention