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1、FuelCellHybridDriveTrainMasterThesisinEnergyEngineeringJanuary2021PatrykKinnSupervisors:JoachimLindstromAzraSelimovic1.arsBackstromExaminatior:RobertEklundAbstractThisthesispresentsafuelcellhybriddrivetrainstudyofa26tondistributiontruckregardingthefuelconsumption.Theinvestigationismadeusingamodelimp
2、lementedinSimulink.TheconceptvehicleisaVolvoFM9,wheretheconventionaldieselpowertrainisreplacedbyanelectricaldrivesystem.TheelectricalpropulsionmotorispoweredbyaprotonexchangemembranefuelcellassistedbyaLi-ionpoweroptimisedbattery.Thepowerratingsoftheinvestigatedfuelcellsarebetween150kWand350kWandthei
3、nvestigatedbatterycapacitiesrangefrom4.5kWhto22.6kWh.Twodrivecycles,whereonerepresentsurbandistributionwithnoroadinclineandtheotherrepresentssuburbandistributionincludingroadinclineareused.Byimplementingthreedifferentpowercontrolstrategies,itisshownthatthefuelconsumptioncanbereducedbyupto56%compared
4、totheconventionaldieselreferencevehicle.Theurbandistributiondrivecycleisfoundmoresuitableforthefuelcellvehicleapplication.A250kWfuelcelland13.6kWhbatteryconfigurationissuggestedfortheurbandistributiondrivecycle,reducingthefuelconsumptionby53%.Forthesuburbandistributiondrivecyclethesuggestedconfigura
5、tionconsistsofa350kWfuelcellanda17.8kWhbattery,reducingthefuelconsumptionby25%.AcknowledgementsThereareseveralpeoplethatIwouldliketomentionandthankexplicitlyfortheircontributionsduringthisthesiswork.Thesepeopleare: JoachimJindstromwhosupervisedmeandcontributedgreatlybyhisknowledgeandexperiencewithin
6、thefieldofelectricmachines.Iamgratefulforhiswarm,experiencedandopenmindedguidanceduringtheentireworkingprocessandsupportduringthefinalisationofthereport. AzraSelimovic,foransweringthatveryphonecallduringhertimeabroadthatledtotheworkonthisthesisandforinitiatingthisproject.Iappreciateheradviceduringmy
7、work. AndreasBoden,whotogetherwhitAzrainitiatedthisprojectandhandleditovertotheexperiencedguidanceofJoachim. PaulAdamswhocontributedwithexpertiseonissuesregardinghydrogenstorageandtheEnglishlanguage. JensGrootwhoprovidedthebatterymodelandpatientlyansweredallmyquestions. MikaelHolber,forcompanionship
8、andinterestingconversationsaboutfuelcelltechnology,martialartsandargentinetango. Theentiregroup6120forthewarmwelcomingIreceived,forcontinuouslyansweringmyquestionsandforgenerouslyprovidingabroadspectrumofexpertise.NomenclatureAA/FIwheelgSJ-IhHEVICEI-SAM1wheelioK1.HVdiesel1.HVh2IfactorMMH2MairmFrontA
9、reaofthevehicleTafelequationconstantVehicleaccelerationFuelcellstackareaDragcoefficientRollingfrictionElectricalVehicleFaradayconstantFuelCellVehicleDragforceForceduetomomentofinertiaofthewheelsForceduetogravityForceduetorollingresistanceSumoftheexternalforcesTractionforceAccelerationofgravityGibbsf
10、reeenergyTotalhydrogenconsumptionHybridElectricVehicleInternalCombustionEngineIntegratedStarterAlternatorMotorMomentofinertiaofthewheelsMomentofinertiaofthemotorCurrentdensityExchangecurrentdensitySpecificheatratio1.owerheatingvalueofdiesel1.owerheatingvalueofhydrogen1.engthfactorVehicleMassMolarmas
11、sofhydrogenMolarmassofairMasstransportconstantmMasstransportconstantnNumberofcellsCompressorinletpressureCompressoroutletpressureCompressorpowerPowerenteringthefuelcellPowerdeliveredbythefuelcellMotorpowerMaximummotorpowerWheelpowerAmbientpressurePartialpressuresofhydrogenPartialpressuresofwatervapo
12、urSaturationpressureofwaterP2RrrfSOCTTwheellllTm,naxTinTmodeKniaxVocVoOCVVbaseVmaxXgearS0CVohinactVmassTfc,system(icdciselo9h2PartialpressuresofoxygenGasconstantWheelradiusArea-specificresistanceStateofchargeTemperatureWheeltorqueMotortorqueMaximummotortorqueInlettemperatureMaximumoriginaloutputtorq
13、ueOpencircuitvoltageOpencircuitvoltageatstandardpressureandtemperatureVehiclespeedVehiclespeedcorrespondingtomotorbasespeedMaximumvehiclespeedGearratioDeltastareofchargeOhmicresistancelossesActivationlossesMasstransportationlossesFuelcellsystemefficiencyDC/DCconverterefficiencyIsentropicefficiencyEl
14、ectricefficiencyTotalmechanicalderivelineefficiencyInclineangleMolarflowofhydrogenairPairPdieselCOm(OnunotorCOtiuixtWheeICOwheeI(0wleelMolarflowofairAirdensityDieseldensityMotorspeedMaximummotorspeedMaximumwheelspeedWheelspeedWheelaccelerationTableofcontentIntroduction1Thefuelcellvehicle1Prerequisit
15、es3Purposeandgoal3Conceptvehicle3Dataandperformancespecification4Drivecycles4Sizing5Performance7Drivecycle10Themodelandcomponents11Thedriver11Thefuelcellsystem11Thefueltank12Thefuelcell13Thecompressor16Theauxiliaryload17Theelectricmotor17Thefinalgear19Thevehiclebody19Thebattery20Thecontroller20Contr
16、olstrategy20Powerdemand21Simulations21Batteryandfuelcellsizes21DeltaSOCcorrection22Performanceandfuelconsumption22Results24Performance24Fuelconsumption33Discussion43Performance43Fuelconsumption43General45Conclusions46Futurework47References48IntroductionTheemissionandfuelconsumptionfavourableoperatio
17、noftheHybridElectricVehicles(HEVs)haveresultedintremendouspopularityincreaseofthesevehiclesduringthelasttwodecays1.Theelectricvehicleishowevernotanewconceptandthemanufacturingofsuchvehiclesstartedasearlyasbefore1900.FerdinandPorsche,sfirsthybridvehicleproducedin1899wasforinstancepropelledbyfourwheel
18、-mountedelectricmotorswithaseriesdrivelinesolution1.Thelackofinsightinthefinitenatureandintheenvironmentalimpactofthefossilfuels,aswellasthefastdevelopmentoftheinternalcombustionengine(ICE)duringtheFirsWordWarandthelowfuelprices,pushedtheelectricvehiclesaside2.Sincethen,theICEvehicleshavedominatedth
19、eroadsandhavenowprobablydonethatfarlongerthananyofthosedrivingthemtodaycanremember.Theinfrastructure,performancedemands,manufacturingprocessandmanyotheraspectshavebeeninfluencedandformedbythisdominance.Nowhowever,whentheenvironmentalimpactofthetrafficcausedpollutionisbecomingvisibleandthefossilfuelr
20、eserveofthisplanetfadesrapidly,newpossibilitiestodevelopedalternativepowertrainconceptsarise.Thisdevelopmentmayevenbeconsideredasnecessaryifthefreedomofusingfastandflexiblepersonalandgoodstransportsarenottobeabandonedmeanwhiletheplanetsenvironmentispreservedforthefuturegenerations.Asubstantialamount
21、ofresearchanddevelopmenttime,aswellasfinancialmeansisnowinvestedbythemanufacturersandpoliticalorgansinordertomeetthedemandsfromaconstantlymoreawarepublic.Eveniflargeadvancehasalreadybeenmade,therearestillmanyaspectstobeconsideredandproblemstobesolvedregardingtheHEVsbeforetheycanbefullycommercialized
22、.Twosuchaspectsarethecostandperformanceofthesevehicles.Becauseeveniftheenvironmentalconcernhasbeenbroughttoattention,thecustomersmustbeabletoaffordtheproductandtheproductneedstofulfilitspurpose.Anotheraspectistheoriginofasubstitutionfuelanditsdistribution.Variousresearchanddevelopmentactivitieshaver
23、esultedinavarietyofdifferenthybridsolutions,fromtheelectricmotorassistedbicyclestomoreadvancedpluginhybridcarsandthefuelcellvehicles(FCV).ThisthesesaimstocontributetoageneraleffortofHEVstudybyinvestigatingthefuelconsumptionofafuelcellbaseddrivelinesolutionfora26tonnedistributiontruck.Thefuelcellvehi
24、cleWhenthereareatleasttwoformsofenergystoredonboardavehiclethatcanbeusedforpropulsionandiftheenergyinatleastoneofthecasesiselectric,suchavehiclequalifiestobecalledaHEV.SincethisisthecasefortheFCV,wherethepropulsionenergycanbetakenfromthehydrogensuppliedtothefuelcellorfromtheelectricenergystoredinthe
25、battery,thesevehiclescanberegardedasHEVs.ThedrivelineoftheHEVisusuallyoneofthreebasictypes.Onetypeistheseriesdrivelineimposingthatonlyoneenergyformisusedtopowerthepropulsion.Theothertwotypesaretheparallelandcomplexdrivelinesolutions2.Theparalleldrivelineimposethattwoenergyformscanbeusedatthesametime
26、andthecomplexdrivelineimposethatboththeseriesandparalleldrivelinesareimplementedandthatachoiceismadewhichsolutiontouseinacertainsituation.Allthesedrivelinesolutionshavetheirprosandconswhencomparedtooneanother.However,sincetheenergyusedtopowerthepropulsionmotoroftheFCViselectric,theseriesdrivelinesol
27、utionisonlyonestudiedinthefollowingwork.SincetheFCVispropelledbyelectricenergy,thistypeofvehiclepossesthesamepotentialofemissionfavourabletransportationasthebatterysourcedelectricvehicle(EV).Thefuelcellhowever,givesthebenefitofextendedtravelleddistanceforthesameorevensmallerbatterysize.Thisreduction
28、inbatterydependenceisdesirablesincethebattery,atpresent,canberegardedastheAchillesheelinallhybrids3duetoe.g.lowlifetimeandhighcost.Thefuelcelltechnologyhoweverintroducesotherchallengingaspects.Oneissueistheabsenceoffueldistributioninfrastructure,makingithardtocommercializethefuelcellvehicle.Todealwi
29、ththisproblemthereareseveraldemonstrationprojectsofhydrogenhighwaysaroundtheworldandongoingresearchonstoragepossibilities.Inasensethisissueispartiallyaddressedinthisthesis,wherethefuelconsumptionandstoragecapacityisinvestigated.Naturallyithastobekeptinmindthatforthisemissionfavourableconcepttobecome
30、reality,thehydrogenneedstobeproducedanddistributedinequallyemissionfavourableway.Intheidealcasealsothemanufacturingprocess,serviceandtherecyclingprocessallneedtobeemissionfavourable.EveniftheseissuesareofgreatimportanceandstronglyrelatedtotheenvironmentalbenefitsoftheFCVandothertypesHEVs,theyarenotc
31、onsideredinthistextandleftforotherinspiredinvestigatorsandfuturestudies.PrerequisitesInthissectionthepurposeandthegoalofthethesesarepresented.Theconceptvehicle,theperformancerequirementsandthedrivecycleschosenarealsopresented.Thefirstsubsectiondealwhitthepurposeandgoalandisfollowedbyamotivationofthe
32、vehicleselection.Thefollowingsubsectionsintroducethevehicledata,theperformancerequirementsandthedrivecycleschosenforthefuelconsumptionsimulations.PurposeandgoalThepurposeofthisthesisistoconductaprestudyonahydrogenbasedfuelcellserieshybriddrivetrainforamedium-heavydistributiontruck.Thefocusofthestudy
33、istosimulateandevaluatedifferentsystemlayoutsforthedrivetrainanddefineprosandconsforeachconceptdefinedregardingmainlythefueleconomy.Thebasiccasewillbeanequivalentconventionaldieseldrivenvehicle.Otherimportantpartsoftheworkaretodefineandscalethecomponentsofthesystemsuchashydrogenstorage,battery,elect
34、ricmachineandfuelcell.Importantaspectsherearetodefinethepowerbalancebetweenthefuelcell,electricmachineandthebattery.Thegoalwiththisthesisistodeliveramodeltakingmostoftheimportantaspectsofthedrivetrainintoaccount.Themodellevelshouldbeaccurateenoughtodeliverreliableresultsforbasicvehicleanalysis.There
35、sultsarecomparedwiththoseofaconventionaldrivetrainaswellasstateoftheartdiesel-electricparallelhybriddrivetrain.ConceptvehicleThevehiclechosenforthisstudyistheVolvoFM9illustratedinFigure1.Thevehiclechoiceisprimarymotivatedbytwofactors.Thefirstfactoristhelargeamountofreferencematerialandvehicledataspe
36、cifiedinthereportontheI-SAMproject4.Thereferencematerialincludesfuelconsumptionoftheconventionalversionofthisvehicle.ThesecondfactormotivatingthechoiceofthevehicleisthepossibilityofusingtheVolvoFM9forcitydeliveryapplications,whichwastheinitialproposalofthetheses.Duringtheliteraturestudyintheinitialp
37、artoftheprojectitwashoweverdiscoveredthatasimilarinvestigationhasalreadybeenperformedforalightdistributiontruck5.Beingnearlytwiceasheavyasthevehiclealreadyinvestigated(FL6),theVolvoFM9waschoseninordertocontributetotheresultsoftheexistinginvestigation.Figure1:TheVolvoFM6.Dataandperformancespecificati
38、onThephysicaldataofthevehiclearesummarizedinTable1.Table1:TheVolvoFM9dataWeight(loaded)26tonRollingfriction,Cr0.005N/NFrontarea,A9.7m2Dragcoefficient,Cd0.65Wheelradius,r0.492mAuxiliaryload4.4kWThefollowingperformancerequirementshavebeenchosenforthestudy:1.Cruisingability:Thevehicleshallbeabletocruis
39、eat100km/hatlevelground.2.Gradeability:Thevehicleshallbeabletocruiseat40km/hattheinclineof8.7%(5o).3.Acceleration:Thevehicleshallbeabletoperformmaximalaccelerationfromstandstillto100km/hatlevelground.Thevehicleshallbeabletoperformmaximalaccelerationfromstandstillto50km/hattheinclineof8.7%(5).Aswillb
40、eshownlateron,thegradeabilityrequirementisdemanding.ForcomparisonitcanbestatedthatthehighwayE6,whenpassingtheHaIlandsaseninSwedeninthesoutherndirection,hastheinclineof6%(3.43o).DrivecyclesTwodifferentdrivecycleshavebeenselectedforthestudy.Thesort3drivecycleandthesx365drivecycle.Thesort3drivecycleisa
41、syntheticcyclewithacompletelyflatroadtopologyduringtheentireduration.Itconsistsofanaccelerationsection,aconstantvelocitysection,adecelerationsectionandastandstillsectionrepeatedforthreedifferentconstantvelocities.Theconstantvelocitiesare30km/h,50km/hand60km/h.Duringonesimulationthisdrivecycleisdrive
42、ntentimes.Thesort3drivecycleisconsideredsuitableforcitydistribution4.Thesx365drivecyclecorrespondtoanactualroadintheneighbourhoodofHallerdtestgroundinSweden,itishillyandcontainsfewstops.Thesx365drivecycleisconsideredsuitableforsuburbandistribution4.DatasummeryforbothdrivecyclesispresentedinTable2.Th
43、ereferencespeedofthesort3cycleisshowninFigure2andthecorrespondingspeedofthesx365cycleisillustratedinFigure3,wheretheroadtopologyhasbeenincluded.ThefuelconsumptionofthereferencetruckandtheI-SAMtruckaregiveninTable3.Table2:DriVeCyCledaiaSUmmary4.sx365sort3Durations2150200Distancem356601450Stoptime(%7%
44、20%Averagespeedkmhl6026AveragespeedexcludedstopsknVh6549Maximalspeed(krnh9060RoutetopologyyesnoTable3:Fuelconsumptionofthereferencevehicle4.DrivecycleReferencetruckI-SAMtrucksort35.681/10km4.661/10kmsx3654.291/10km4.08(1/10kmFigure3:Speedandheightprofileofthesx365drivecycleApartfromthefactthatfuelco
45、nsumptionofthereferencevehicleforthesetwodrivecyclesisdocumented,thechoiceofsort3cycleismotivatedbythecitydeliverysuitabilitywhilethechoiceofsx365cycleismotivatedbythehillyroadtopologyandsuburbandrivingrepresentation.SizingTheinformationaboutthedrivecyclesincludesvelocityandaccelerationrequirementsa
46、swellastheslopeofthedrivewayduringtheentirecycle.Thisinformation,andtheperformancerequirementinformationstatedintheprevioussection,combinedwiththevehicledataandNewton,ssecondlowofmotioncanbeusedforanestimationoftheelectricmotorrequirementandthegearratio.TractionforceThefirststepinthissizingprocessis
47、thecomputationofthetractionforcethatisrequiredatthewheelsforpropulsionofthevehicle.AspostulatedbyNewtoninhissecondlowofmotion,themotionofthevehiclewilldependontheresultingforcefromallexternalforcesactingonthevehicle.TheseexternalforcesarethetractionforceFtr,therollingresistanceforceFrOM,thedragforceFdandthegravitationalforceFlllgx7.Whenthevehicleisacceleratingtherearealsoadditionalforcesduetothemomentofinertia.Onesuchforce,theforceFhvheelcorrespondingtothemomentofinertiaofthewheels,isincludedinthefo
