Power management system for a fuel cell/battery hybrid vehicle incorporating fuel cell and battery degradation

Optimization of fuel cell/battery hybrid vehicle systems has primarily focused on reducing fuel consumption. However, it is also necessary to focus on fuel cell and battery durability as inadequate lifespan is still a major barrier to the commercialization of fuel cell vehicles. Here, we introduce a power management strategy which concurrently accounts for fuel consumption as well as fuel cell and battery degradation. Fuel cell degradation is quantified using a simplified electrochemical model which provides an analytical solution for the decay of the electrochemical surface area (ECSA) in the fuel cell by accounting for the performance loss due to transient power load, start/stop cycles, idling and high power load. The results show that the performance loss based on remaining ECSA matches well with test data in the literature. A validated empirical model is used to relate Lithium-ion battery capacity decay to C-rate. Simulations are then conducted using a typical bus drive cycle to optimize the fuel cell/battery hybrid system. We demonstrate that including these degradation models in the objective function can effectively extend the lifetime of the fuel cell at the expense of higher battery capacity decay resulting in a lower average running cost over the lifetime of the vehicle.     

Optimization of powerplant component size on board a fuel cell/battery hybrid bus for fuel economy and system durability

The size of the individual powerplant components on board a fuel cell/battery hybrid vehicle affects the power management strategy which determines both the fuel economy and the durability of the fuel cell and the battery, and thus the average lifetime cost of the vehicle. Cost is one of the major barriers to the commercialization of fuel cell vehicles, therefore it is important to study how the sizing configuration affects overall vehicle cost. In this paper, degradation models for the fuel cell and the battery on board a fuel cell/battery hybrid bus are incorporated into the power management system to extend their lifetimes. Different sizing configurations were studied and the results reveal that the optimal size with highest lifetime and lowest average cost is highly dependent on the drive cycle. The vehicle equipped with a small fuel cell stack serving as a range extender will fail earlier and consume more fuel under drive cycles with high average power demand resulting in higher overall cost. However, the same configuration gives optimal results under a standard bus cycle with lower average power demand. At the other end of the spectrum, a fuel cell-dominant bus does not guarantee longer lifetime since the fuel cell operates mostly under low-load conditions which correspond to higher potentials reducing lifetime. Such a configuration also incurs a higher initial capital cost of the fuel cell stack resulting in a high average cost. The best configuration is a battery-dominated system with moderately-sized fuel cell stack which achieves the longest lifetime combined with the lowest average running cost throughout the lifetime of the vehicle.     

Investigation of battery end-of-life conditions for plug-in hybrid electric vehicles

Plug-in hybrid electric vehicles (PHEVs) capable of drawing tractive energy from the electric grid represent an energy efficient alternative to conventional vehicles. After several thousand charge depleting cycles, PHEV traction batteries can be subject to energy and power degradation which has the potential to affect vehicle performance and efficiency. This study seeks to understand the effect of battery degradation and the need for battery replacement in PHEVs through the experimental measurement of lithium ion battery lifetime under PHEV-type driving and charging conditions. The dynamic characteristics of the battery performance over its lifetime are then input into a vehicle performance and fuel consumption simulation to understand these effects as a function of battery degradation state, and as a function of vehicle control strategy. The results of this study show that active management of PHEV battery degradation by the vehicle control system can improve PHEV performance and fuel consumption relative to a more passive baseline. Simulation of the performance of the PHEV throughout its battery lifetime shows that battery replacement will be neither economically incentivized nor necessary to maintain performance in PHEVs. These results have important implications for techno-economic evaluations of PHEVs which have treated battery replacement and its costs with inconsistency.     

Comparative study of energy management systems for a hybrid fuel cell electric vehicle - A novel mutative fuzzy logic controller to prolong fuel cell lifetime

Hybrid fuel cell battery electric vehicles require complex energy management systems (EMS) in order to operate effectively. Poor EMS can result in a hybrid system that has low efficiency and a high rate of degradation of the fuel cell and battery pack. Many different types of EMS have been reported in the literature, such as equivalent consumption minimisation strategy and fuzzy logic controllers, which typically focus on a single objective optimisations, such as minimisation of H₂ usage. Different vehicle and system specifications make the comparison of EMSs difficult and can often lead to misleading claims about system performance. This paper aims to compare different EMSs, against a range of performance metrics such as charge sustaining ability and fuel cell degradation, using a common modelling framework developed in MATLAB/Simulink - the Electric Vehicle Simulation tool-Kit (EV-SimKit). A novel fuzzy logic controller is also presented which mutates the output membership function depending on fuel cell degradation to prolong fuel cell lifetime – the Mutative Fuzzy Logic Controller (MFLC). It was found that while certain EMSs may perform well at reducing H₂ consumption, this may have a significant impact on fuel cell degradation, dramatically reducing the fuel cell lifetime. How the behaviour of common EMS results in fuel cell degradation is also explored. Finally, by mutating the fuzzy logic membership functions, the MFLC was predicted to extend fuel cell lifetime by up to 32.8%.     

Exploitation of vehicle's kinetic energy in power management of tow -wheel drive electric vehicles based on ANFIS DTC-SVM comparative study

The concept of the hybrid power system in electric vehicles means that there are many sources in this electric vehicle. The electric vehicle of two-wheel drives motors doesn't exploit the two front wheel; this kind of electric vehicle prompted us to propose using the front wheels in electric vehicle energy management, which creates another energy source. The hybrid vehicle can associate more than one source to each other to secure a long time working. The two rear wheels are generally controlled by classical controllers as the DTC-SVM controller that is one of many methods to control a motor's speed. It Based on three classical controllers. We want to replace the PI speed controller with an intelligent controller and show the possibility of integrating it in this kind of control. In this paper, we exploit the electric vehicle's Kinetic energy in energy management by combining the permanent magnet synchronous generator in the vehicle's front wheels, and integrating the ANFIS controller with back motors. The generator's power represents about 19% of the total electric vehicle power. The ANFIS management strategy gave the best résults 96.6 as efficiency and the smallest consumption of Air/fuel compared with the others methods about 55.75–199 (Ipm).     

Optimized rule-based energy management for a polymer electrolyte membrane fuel cell/battery hybrid power system using a genetic algorithm

The polymer electrolyte membrane fuel cell (PEMFC) coupled with the battery is a promising hybrid power system for future energy supply application. Fuel cell durability, battery charge sustenance, and fuel consumption strongly rely on the energy management strategy (EMS). This paper puts forward an optimized rule-based EMS using genetic algorithm (GA) to optimally allocate the power between the fuel cell and the battery system. Control variables in real-time rule-based EMS are optimally adjusted with single objective of battery charge sustenance considering the fuel cell durability and efficiency. The proposed optimized rule-based EMS is simulated and experimentally verified via MATLAB/Simulink and LabVIEW-based experimental rig, respectively. The conventional rule-based EMS, fuzzy logic EMS, and dynamic programming (DP) EMS are also examined for comparison. The comparison results elucidate that the optimized rule-based EMS realizes a large performance improvement over the conventional rule-based and fuzzy logic EMSs. Near optimal performance is verified compared with DP EMS in terms of fuel economy, battery charge sustenance, fuel cell efficiency, and system durability. The combination of rule-based EMS and GA optimization algorithm has the advantage of having expert experience and global optimization properties, realizing optimal power allocation in real-time application with lower computation burden, which could be applied easily to other EMS system without loss of validity.     

Degradation-oriented real-time power control of fuel cell hybrid vehicles under uncertain driving conditions

This work provides a real-time power allocation algorithm to address uncertain actual driving situations for fuel cell hybrid vehicles. To predict the vehicle speed under nondeterministic driving conditions, a fusion prediction model is developed based on the advantages of the Markov chain and neural network. The optimal power splitting decision in each receding horizon is then solved using the Pontryagin's minimum principle (PMP) method, considering fuel consumption, State of Charge (SOC), and performance degradation. A degradation model of electrochemical active surface area (ECSA) based on Pt catalyst dissolution was developed. Then the effect of the energy management algorithm on fuel cell degradation was evaluated using the degradation model. Compared with the two conventional real-time power splitting strategies, the approach suggested in this research can better reduce the fuel consumption and maintain the stability of battery SOC with a lower fluctuation while taking into account the degradation of the fuel cell.     

Energy management strategy based on fuzzy logic for a fuel cell hybrid bus

Fuel cell vehicles, as a substitute for internal-combustion-engine vehicles, have become a research hotspot for most automobile manufacturers all over the world. Fuel cell systems have disadvantages, such as high cost, slow response and no regenerative energy recovery during braking; hybridization can be a solution to these drawbacks. This paper presents a fuel cell hybrid bus which is equipped with a fuel cell system and two energy storage devices, i.e., a battery and an ultracapacitor. An energy management strategy based on fuzzy logic, which is employed to control the power flow of the vehicular power train, is described. This strategy is capable of determining the desired output power of the fuel cell system, battery and ultracapacitor according to the propulsion power and recuperated braking power. Some tests to verify the strategy were developed, and the results of the tests show the effectiveness of the proposed energy management strategy and the good performance of the fuel cell hybrid bus.     

Fuzzy control based engine sizing optimization for a fuel cell/battery hybrid mini-bus

The fuel cell/battery hybrid vehicle has been focused for the alternative engine of the existing internal-combustion engine due to the following advantages of the fuel cell and the battery. Firstly, the fuel cell is highly efficient and eco-friendly. Secondly, the battery has the fast response for the changeable power demand. However, the competitive efficiency of the hybrid fuel cell vehicle is necessary to successfully alternate the conventional vehicles with the fuel cell hybrid vehicle. The most relevant factor which affects the overall efficiency of the hybrid fuel cell vehicle is the relative engine sizing between the fuel cell and the battery. Therefore the design method to optimize the engine sizing of the fuel cell hybrid vehicle has been proposed. The target system is the fuel cell/battery hybrid mini-bus and its power distribution is controlled based on the fuzzy logic. The optimal engine sizes are determined based on the simulator developed in this paper. The simulator includes the several models for the fuel cell, the battery, and the major balance of plants. After the engine sizing, the system efficiency and the stability of the power distribution are verified based on the well-known driving schedule. Consequently, the optimally designed mini-bus shows good performance.     

Fuel economy and life-cycle cost analysis of a fuel cell hybrid vehicle

The most promising vehicle engine that can overcome the problem of present internal combustion is the hydrogen fuel cell. Fuel cells are devices that change chemical energy directly into electrical energy without combustion. Pure fuel cell vehicles and fuel cell hybrid vehicles (i.e. a combination of fuel cell and battery) as energy sources are studied. Considerations of efficiency, fuel economy, and the characteristics of power output in hybridization of fuel cell vehicle are necessary. In the case of Federal Urban Driving Schedule (FUDS) cycle simulation, hybridization is more efficient than a pure fuel cell vehicle. The reason is that it is possible to capture regenerative braking energy and to operate the fuel cell system within a more efficient range by using battery.Life-cycle cost is largely affected by the fuel cell size, fuel cell cost, and hydrogen cost. When the cost of fuel cell is high, hybridization is profitable, but when the cost of fuel cell is less than 400 US$/kW, a pure fuel cell vehicle is more profitable.     

Energy management of fuel cell/battery/ultracapacitor in electrical hybrid vehicle

This paper describes an energy management algorithm for an electrical hybrid vehicle. The proposed hybrid vehicle presents a fuel cell as the main energy source and the storage system, composed of a battery and a supercapacitor as the secondary energy source. The main source must produce the necessary energy to the electrical vehicle. The secondary energy source produces the lacking power in acceleration and absorbs excess power in braking operation. The addition of a supercapacitor and battery in fuel cell-based vehicles has a great potential because it allows a significant reduction of the hydrogen consumption and an improvement of the vehicle efficiency. Other the energy sources, the electrical vehicle composed of a traction motor drive, Inverter and power conditioning. The last is composed of three DC/DC converters: the first converter interfaces the fuel cell and the DC link. For the second and the third converter, two buck boost are used in order to interface respectively the ultracapacitor and the battery with the DC link. The energy management algorithm determines the currents of the converters in order to regulate accurately the power provided from the three electrical sources. This algorithm is simulated with MATLAB_Simulink and implemented experimentally with a real-time system controller based on dSPACE. In this paper, the proposed algorithm is evaluated for the New European Driving Cycle (NEDC). The experimental results validate the effectiveness of the proposed energy management algorithm.     

Dynamic behaviour of Li batteries in hydrogen fuel cell power trains

A Li ion polymer battery pack for road vehicles (48 V, 20 Ah) was tested by charging/discharging tests at different current values, in order to evaluate its performance in comparison with a conventional Pb acid battery pack. The comparative analysis was also performed integrating the two storage systems in a hydrogen fuel cell power train for moped applications. The propulsion system comprised a fuel cell generator based on a 2.5 kW polymeric electrolyte membrane (PEM) stack, fuelled with compressed hydrogen, an electric drive of 1.8 kW as nominal power, of the same typology of that installed on commercial electric scooters (brushless electric machine and controlled bidirectional inverter). The power train was characterized making use of a test bench able to simulate the vehicle behaviour and road characteristics on driving cycles with different acceleration/deceleration rates and lengths. The power flows between fuel cell system, electric energy storage system and electric drive during the different cycles were analyzed, evidencing the effect of high battery currents on the vehicle driving range. The use of Li batteries in the fuel cell power train, adopting a range extender configuration, determined a hydrogen consumption lower than the correspondent Pb battery/fuel cell hybrid vehicle, with a major flexibility in the power management.     

Effects of drivetrain hybridization on fuel economy,performance and costs of a fuel cell hybrid electric vehicle

Fuel cell hybrid electric vehicles (FCHEVs) are considered to be the most attractive long-term option for passenger cars. Several barriers, such as cost, durability and hydrogen refueling infrastructure, must be overcome for a wider use of FCHEVs. In this paper, a mid-sized FCHEV is modeled and simulated in ADVISOR to analyze the influence of hybridization factor on vehicle performance and costs. The results are compared with those of the Toyota Mirai in order to find the optimum size of the fuel cell stack and the number of battery modules that meet various driving requirements, minimize hydrogen consumption and vehicle cost. The best results are obtained by reducing the fuel cell stack power by 58%. A 7.7% increase in equivalent fuel economy (71.6 MPGe) and a reduction of 25% in the vehicle cost is achieved.     

Experimental investigation on the online fuzzy energy management of hybrid fuel cell/battery power system for UAVs

The hybrid powerplant combining a fuel cell and a battery has become one of the most promising alternative power systems for electric unmanned aerial vehicles (UAVs). To enhance the fuel efficiency and battery service life, highly effective and robust online energy management strategies are needed in real applications.In this work, an energy management system is designed to control the hybrid fuel cell and battery power system for electric UAVs. To reduce the weight, only one programmable direct-current to direct-current (dcdc) converter is used as the critical power split component to implement the power management strategy. The output voltage and current of the dcdc is controlled by an independent energy management controller. An executable process of online fuzzy energy management strategy is proposed and established. According to the demand power and battery state of charge, the online fuzzy energy management strategy produces the current command for the dcdc to directly control the output current of the fuel cell and to indirectly control the charge/discharge current of the battery based on the power balance principle.Another two online strategies, the passive control strategy and the state machine strategy, are also employed to compare with the proposed online fuzzy strategy in terms of the battery management and fuel efficiency. To evaluate and compare the feasibility of the online energy management strategies in application, experiments with three types of missions are carried out using the hybrid power system test-bench, which consists of a commercial fuel cell EOS600, a Lipo battery, a programmable dcdc converter, an energy management controller, and an electric load. The experimental investigation shows that the proposed online fuzzy strategy prefers to use the most power from the battery and consumes the least amount of hydrogen fuel compared with the other two online energy management strategies.     

Analysis of air conditioning system impact on a fuel cell vehicle performance based on a realistic model under actual urban conditions

In this study, a practical fuel cell vehicle considering the Heating, Ventilation, and Air conditioning system is considered to analyze hydrogen consumption under different working conditions. As a prevalent hydrogen-fueled vehicle, Toyota Mirai has been meticulously modeled in Simecenter Amesim software. The simulated model covers all of the vehicle's components with a concentration on Heating, Ventilation, and Air conditioning system. Since the air temperature and ‘weather conditions can significantly impact the vehicle's overall performance, various environmental conditions, including temperature variations, humidity, and varied solar fluxes, are taken into account. Furthermore, New York City is chosen as a densely populated megacity to simulate the dynamic behavior of the fuel cell vehicle under actual driving circumstances. The results illustrate that the Heating, Ventilation, and Air conditioning system can notably alter hydrogen consumption under real driving conditions. In this regard, turning on the Heating, Ventilation, and Air Conditioning system results in a 19% increase in fuel consumption. Moreover, the degradation phenomenon, which is a typical result of using fuel cell vehicles under urban driving conditions, impacts the vehicle's mileage and hydrogen consumption. The simulation results indicate that a fresh fuel cell stack consumes 80 g of hydrogen, while for 2500 and 5500 working hours fuel cells, the stack consumes 89.6 and 107 g of hydrogen, respectively. Based on the obtained results, a 33.75% increase in fuel consumption occurs by implementing a degraded fuel cell stack under real driving conditions.     

Development of new energy management strategy for a household fuel cell/battery hybrid system

This work aims to construct an efficient and robust fuel cell/battery hybrid operating system for a household application. The ability to dispatch the power demands, sustain the state of charge (SOC) of battery, optimize the power consumption, and more importantly, ensure the durability as well as extend the lifetime of a fuel cell system is the basic requirements of the hybrid operating system. New power management strategy based on fuzzy logical combined state machine control is developed, and its effectiveness is compared with various strategies such as dynamic programming (DP), state machine control, and fuzzy logical control with simulation. Experimental results are also presented, except for DP because of difficulties in achieving real‐time implementation and much faster response to load variation. The given current from the energy management system (EMS) as a reference of the fuel cell output current is determined by filtering out various harmful signals. The new power management strategy is applied to a 1‐kW stationary fuel cell/battery hybrid system. Results show that the fuel cell hybrid system can run much smoothly with prolonged lifetime.     

A hierarchical energy management strategy for fuel cell/battery/supercapacitor hybrid electric vehicles

In this paper, a hierarchical energy management strategy (EMS) based on low-pass filter and equivalent consumption minimization strategy (ECMS) is proposed in order to lift energy sources lifespan, power performance and fuel economy for hybrid electrical vehicles equipped with fuel cell, battery and supercapacitor. As for the considered powertrain configuration, fuel cell serves as main energy source, and battery and supercapacitor are regarded as energy support and storage system. Supercapacitor with high power density and dynamic response acts during great power fluctuations, which relives stress on fuel cell and battery. Meanwhile, battery is used to lift the economy of hydrogen fuel. In higher layer strategy of the proposed EMS, supercapacitor is employed to supply peak power and recycle braking energy by using the adaptive low-pass filter method. Meantime, an ECMS is designed to allocate power of fuel cell and battery such that fuel cell can work in a high efficient range to minimize hydrogen consumption in lower layer. The proposed EMS for hybrid electrical vehicles is modeled and verified by advisor-simulink and experiment bench. Simulation and experiment results are given to confirm effectiveness of the proposed EMS of this paper.     

Cost-optimal design and energy management of fuel cell electric trucks

Road freight transport on hilly routes represents a significant challenge for the advancement of fuel cell electric trucks because of the high-performance requirements for fuel consumption, vehicle lifetime, and battery charge control. Therefore, it is essential to optimize the vehicle design and energy management, which greatly influence the driving performance and total cost of ownership. This paper focuses on the cost-optimal design and energy management of fuel cell electric trucks, considering five key influencing factors: powertrain component sizing, driving cycle, vehicle weight, component degradation, and market prices. The cost optimization relies on a novel predictive energy management scheme based on dynamic programming and the systematic calibration of control parameters. The paper analyzes the simulation results to highlight three main findings for fuel cell electric trucks: 1) cost-optimal energy management is essential to define the best trade-off between fuel consumption and component degradation; 2) the total cost of ownership is significantly influenced by component sizing, driving cycles, vehicle weight, and market prices; 3) predictive energy management is highly beneficial in challenging road topographies for substantial cost-saving and lower component size requirements.     

Hybrid electric vehicles and electrochemical storage systems — a technology push–pull couple

In the advance of fuel cell electric vehicles (EV), hybrid electric vehicles (HEV) can contribute to reduced emissions and energy consumption of personal cars as a short term solution. Trade-offs reveal better emission control for series hybrid vehicles, while parallel hybrid vehicles with different drive trains may significantly reduce fuel consumption as well. At present, costs and marketing considerations favor parallel hybrid vehicles making use of small, high power batteries. With ultra high power density cells in development, exceeding 1 kW/kg, high power batteries can be provided by adapting a technology closely related to consumer cell production. Energy consumption and emissions may benefit from regenerative braking and smoothing of the internal combustion engine (ICE) response as well, with limited additional battery weight. High power supercapacitors may assist the achievement of this goal. Problems to be solved in practice comprise battery management to assure equilibration of individual cell state-of-charge for long battery life without maintenance, and efficient strategies for low energy consumption.     

Performance and cost of fuel cells for urban air mobility

Several companies are developing enabling elements of urban air mobility (UAM) for air taxis, including prototypes of electric vertical take-off and landing (eVTOL) vehicles. These prototypes incorporate electric and hybrid powertrains for multi-rotor and tilt-rotor crafts. Many eVTOLS are using batteries for propulsion and charging them rapidly between the flights or swapping them for slow charging overnight. Rapid charging degrades the battery cycle life while swapping requires multiple batteries and charging stations. This study has conducted a technoeconomic evaluation of the eVTOL air taxis with alternate powertrains using hydrogen fuel cell systems being developed for light-duty and heavy-duty vehicles. We consider performance metrics such as fuel cell engine power, weight, and durability; hydrogen consumption and weight of storage system; and maximum take-off weight. The metrics for economic evaluation are capital cost, operating and maintenance cost, fuel cost, and the total cost of ownership (TCO). We compare the performance and TCO of battery, fuel cell and fuel cell – battery hybrid powertrains for multi-rotor and tilt-rotor crafts. We show that fuel cells are the only viable concept for powering multi-rotor eVTOLs on an urban scenario that requires 60-mile range, and hybrid fuel cells are superior to batteries as powertrains for tiltrotor eVTOLs.