Stabilised control strategy for PEM fuel cell and supercapacitor propulsion system for a city bus

Fuel Cell (FC) buses have been developed as a long term zero emission solution for city transportation and have reached levels of maturity to supplement the coming London 2020 Ultra low emission zone implementation. This research developed a scaled laboratory Fuel Cell/Supercapacitor hybrid drivetrain implementing DC/DC converters to maintain the common busbar voltage and control the balance of power. A novel and simple hybrid control strategy based on balancing the currents on the common busbar whilst maintaining a stable FC output has been developed. It has been demonstrated that the FC power output can be controlled at a user defined value for both steady state and transient load conditions. The proposed control strategy holds the promise of extending FC life, downsizing power systems and improving the FC operating efficiency.     

Energy storage devices for future hybrid electric vehicles

Powertrain hybridization as well as electrical energy management are imposing new requirements on electrical storage systems in vehicles. This paper characterizes the associated vehicle attributes and, in particular, the various levels of hybrids. New requirements for the electrical storage system are derived, including: shallow-cycle life, high dynamic charge acceptance particularly for regenerative braking and robust service life in sustained partial-state-of-charge usage. Lead/acid, either with liquid or absorptive glass-fibre mat electrolyte, is expected to remain the predominant battery technology for 14 V systems, including micro-hybrids, and with a cost-effective battery monitoring system for demanding applications. Advanced AGM batteries may be considered for mild or even medium hybrids once they have proven robustness under real-world conditions, particularly with respect to cycle life at partial-states-of-charge and dynamic charge acceptance. For the foreseeable future, NiMH and Li-ion are the dominating current and potential battery technologies for higher-functionality HEVs. Li-ion, currently at development and demonstration stages, offers attractive opportunities for improvements in performance and cost. Supercapacitors may be considered for pulse power applications. Aside from cell technologies, attention to the issue of system integration of the battery into the powertrain and vehicle is growing. Opportunities and challenges for potential “battery pack” system suppliers are discussed.     

Development strategies to satisfy corporate average CO2 emission regulations of light duty vehicles (LDVs) in Korea

In the present study, we generated vehicle dynamic based light-duty vehicle (LDV) models and investigated some technical strategies in order to meet the corporate average CO₂ emission (CACE) regulations of Korea, which will be applied from 2016 to 2020. Seven types of LDV simulation models (including gasoline, diesel, and hybrid cars) were generated based on the AVL CRUISE program and the LDV sales ratio was used to estimate the CACE value of five companies in Korea. The prediction accuracy of the LDV models was validated using chassis dynamometer test data. Then, the effectiveness of the CACE reduction strategies was investigated based on the developed LDV simulation models. From the results of this study, it was revealed that all of the companies cannot satisfy the 2020 CACE regulation by just adopting a single strategy. In order to solve this problem, two types of CACE plans that combined several strategies (reducing the mass drag and fuel consumption rate, and adding a hybrid module, etc.) were proposed. After implementing the two types of CACE plan, it was predicted that five companies will be able to satisfy the 2020 CACE regulation.     

混合动力汽车发动机调速系统研究

调速系统不但能改善混合动力汽车发动机自身的转速品质,还可以降低发动机和电机的不同步产生的振动和噪声,从而提高整车舒适性。采用改进的PID控制算法建立了电控直喷汽油机调速系统控制模型,并根据发动机转速响应特性,对比例、积分和微分参数进行整定。调速试验表明,该PID调速系统降低了发动机转速振荡,减少系统响应时间,有效地提高了整车的性能。     

II. A combined model for determining capacity usage and battery size for hybrid and plug-in hybrid electric vehicles

We combine a detailed battery model with a simple vehicle model to examine the battery size and capacity usage of a Li_xC₆/Li_y+0.16Mn_1.84O₄ cell (with a normal and artificially flat equilibrium potential) and a Li_4+3xTi₅O₁₂/Li_yFePO₄ cell. The features of cell chemistry we are concerned with are the magnitude and shape of the cell equilibrium potential and internal resistance. Our key findings include that a battery for a hybrid electric vehicle application has a capacity usage from 15 to 25% (for a minimum separator area size), and as one moves from a HEV battery to a plug-in hybrid electric vehicle battery there is a change in the slope of the separator area vs. equivalent-electric range curve due to the shape of the pulse-power capability. We also find that defining the resistance using the HPPC protocol has limitations because in general the pulse resistance depends on the applied current and pulse duration. Our detailed, combined model also shows that the benefits of a flat-potential system may be limited because of the relative positions of a flat and sloped equilibrium potential, and the lack of a driving force for the relaxation of solid-phase concentration gradients throughout the electrode. That latter effect is shown to be more significant for electrodes with a non-uniform current distribution.     

I. A simplified model for determining capacity usage and battery size for hybrid and plug-in hybrid electric vehicles

We develop a simplified model to examine the effect of the shape and magnitude of the battery pulse-power capability on capacity usage and battery size. The simplified model expresses the capacity usage and a dimensionless battery area in terms of a dimensionless energy-to-power ratio and a parameter that characterizes the shape of the pulse-power capability. We also present dimensional results that show how the capacity usage depends on the equivalent-electric range and separator area, and how the battery area depends on the equivalent-electric range. Key results include the presence of a Langmuir-like relationship between the capacity usage and the dimensionless energy-to-power ratio, and a linear relationship between the dimensionless energy-to-power ratio and a dimensionless area, with a slope and offset that depend on the shape of the pulse-power capability. We also found that a flat pulse-power capability curve increases capacity usage and decreases battery size, and that two important parameters for battery design are (U − V_min)V_min/R, which reflects the maximum power capability, and Q〈V〉, which reflects the battery energy. The results and analysis contained herein are used to help interpret the results from a combined battery and vehicle model, presented in a companion paper.     

An innovative optimal power allocation strategy for fuel cell, battery and supercapacitor hybrid electric vehicle

An optimal design of a three-component hybrid fuel cell electric vehicle comprised of fuel cells, battery, and supercapacitors is presented. First, the benefits of using this hybrid combination are analyzed, and then the article describes an active power-flow control strategy from each energy source based on optimal control theory to meet the demand of different vehicle loads while optimizing total energy cost, battery life and other possible objectives at the same time. A cost function that minimizes the square error between the desired variable settings and the current sensed values is developed. A gain sequence developed compels the choice of power drawn from all devices to follow an optimal path, which makes trade-offs among different targets and minimizes the total energy spent. A new method is introduced to make the global optimization into a real-time based control. A model is also presented to simulate the individual energy storage systems and compare this invention to existing control strategies, the simulation results show that the total energy spent is well saved over the long driving cycles, also the fuel cell and batteries are kept operating in a healthy way.     

Multiple model predictive control for a hybrid proton exchange membrane fuel cell system

This paper presents a hierarchical predictive control strategy to optimize both power utilization and oxygen control simultaneously for a hybrid proton exchange membrane fuel cell/ultracapacitor system. The control employs fuzzy clustering-based modeling, constrained model predictive control, and adaptive switching among multiple models. The strategy has three major advantages. First, by employing multiple piecewise linear models of the nonlinear system, we are able to use linear models in the model predictive control, which significantly simplifies implementation and can handle multiple constraints. Second, the control algorithm is able to perform global optimization for both the power allocation and oxygen control. As a result, we can achieve the optimization from the entire system viewpoint, and a good tradeoff between transient performance of the fuel cell and the ultracapacitor can be obtained. Third, models of the hybrid system are identified using real-world data from the hybrid fuel cell system, and models are updated online. Therefore, the modeling mismatch is minimized and high control accuracy is achieved. Study results demonstrate that the control strategy is able to appropriately split power between fuel cell and ultracapacitor, avoid oxygen starvation, and so enhance the transient performance and extend the operating life of the hybrid system.     

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.     

Fault tree analysis for PEM fuel cell degradation process modelling

For transportation applications, Proton Exchange Membrane fuel cells (PEMFC) are considered to be the most promising fuel cell technology due to their low operating temperature and pressure resulting in a possible quick start-up. However, to implement them in transportation systems, their reliability should be improved. In the present work, a single fuel cell is considered. It is composed of a membrane, catalyst layers (anode and cathode electrodes) and diffusion layers (anode and cathode electrodes). Those layers are considered as the critical components of the cell. Modelling the process degradations of those components is a great issue. In this work, Fault Tree (FT) is used for this modelling for two main reasons. At first, FT helps to model clearly and intuitively the different causal relations of the degradation mechanisms. Secondly, FT allows quantifying components specific degradations, and their effects on the global degradation of the cell. The cell is considered non repairable. Degradation modelling needs knowledge about mechanisms involving components failures. For 1000 simulations of 100 h operation in cycling conditions, the results of the FT show the most important degradations effects on the global degradation of the cell. This work also proposes degradation probability estimates for some specific events.     

Lithium polymer batteries and proton exchange membrane fuel cells as energy sources in hydrogen electric vehicles

This paper deals with the application of lithium ion polymer batteries as electric energy storage systems for hydrogen fuel cell power trains. The experimental study was firstly effected in steady state conditions, to evidence the basic features of these systems in view of their application in the automotive field, in particular charge-discharge experiments were carried at different rates (varying the current between 8 and 100 A). A comparison with conventional lead acid batteries evidenced the superior features of lithium systems in terms of both higher discharge rate capability and minor resistance in charge mode. Dynamic experiments were carried out on the overall power train equipped with PEM fuel cell stack (2 kW) and lithium batteries (47.5 V, 40 Ah) on the European R47 driving cycle. The usage of lithium ion polymer batteries permitted to follow the high dynamic requirement of this cycle in hard hybrid configuration, with a hydrogen consumption reduction of about 6% with respect to the same power train equipped with lead acid batteries.     

Performance simulation and analysis of a fuel cell/battery hybrid forklift truck

The performance of a forklift truck powered by a hybrid system consisting of a PEM fuel cell and a lead acid battery is modeled and investigated by conducting a parametric study. Various combinations of fuel cell size and battery capacity are employed in conjunction with two distinct control strategies to study their effect on hydrogen consumption and battery state-of-charge for two drive cycles characterized by different operating speeds and forklift loads. The results show that for all case studies, the combination of a 110 cell stack with two strings of 55 Ah batteries is the most economical choice for the hybrid system based on system size and hydrogen consumption. In addition, it is observed that hydrogen consumption decreases by about 24% when the maximum speed of the drive cycle is decreased from 4.5 to 3 m/s. Similarly, by decreasing the forklift load from 2.5 to 1.5 ton, the hydrogen consumption decreases by over 20%.     

Remodeling of a commercial plug-in battery electric vehicle to a hybrid configuration with a PEM fuel cell

In the present research, a commercial battery-powered pure electric vehicle was suitably modified to convert it into a hybrid one integrating a PEMFC stack. The hydrogen supply system to the stack included a passive recirculation system based on a Ventury-type ejector. Besides, in order to achieve an optimum operation of the PEMFC stack, a discrete state machine model was considered in its control system. The inclusion of a rehabilitation operating mode prevented the stack from possible failures, increasing its lifetime. It was verified that for the rated operating point when supplying power to the vehicle (2.5 kW) the hydrogen consumption decreased, and the actual efficiency (47.9%) PEMFC was increased close to 1%. Field tests performed demonstrate that the range of the hybrid electric vehicle was increased by 78% when compared to the one of the original battery electric car. Also, under the tested experimental conditions in hybrid mode, 34% of the total energy demanded by the electric machine of the vehicle was supplied by the PEMFC stack.     

Design and development of a multipurpose utility AWD electric vehicle with a hybrid powertrain based on PEM fuel cells and batteries

This paper presents the results obtained on the research project CIT-370000-2008-11, entitled “Multi-purpose remote-controlled all-wheel-drive tool-vehicle powered by fuel cells” funded by the Spanish Ministry of Science and Technology. A new concept multipurpose electric vehicle has been designed and manufactured, based on three basic features: a hybrid power system consisting in PEM fuel cells + batteries, an all-wheel-drive traction system, and the capability of being either on-site driven or remote-controlled. The vehicle is formed by two frames connected by a two-degree of freedom joint, and is powered by two 2.5 kW DC motors, one in each axle. All the electric circuits for the suitable control of the power hybrid system have been developed in our Laboratory, allowing a large flexibility. After the different tests performed, it has been verified that the vehicle presents good maneuverability, a good traction performance in off-road driving, as well as a good slope-climbing capability. Under the experimental conditions tested, the vehicle reached a maximum speed of 11 km/h on flat surface, keeping the maximum power consumption always around 3 kW.     

Analysis of Adverse Effects on Performance due to Battery Deterioration Installed in BEV and HEV

This paper reports the results of investigating the permissible amount of battery deterioration. An investigation was carried out using the following two types of vehicles： a BEV （battery electric vehicle） and a HEV （hybrid electric vehicle）. First, a detailed evaluation was carried out to identify how the vehicle performance was adversely affected as the lithium-ion batteries installed in the vehicles deteriorated. Next, an attempt was made to determine the permissible amount of deterioration for the vehicle-mounted lithium-ion batteries. In the case of the BEV, the driving distance declined by 20% when the capacity maintenance rate was approximately 80%. Therefore, this was specified as the permissible amount of battery deterioration for the BEV. In the case of the HEV, the fuel consumption increased by 20% when the maximum battery output maintenance rate was approximately 40%. Therefore, this was specified as the permissible amount of battery deterioration for the HEV.     

An improved energy management strategy for FC/UC hybrid electric vehicles propelled by motor-wheels

The hybridization of the fuel-cell electric-vehicle (FCEV) by a second energy source has the advantage of improving the system's dynamic response and efficiency. Indeed, an ultra-capacitor (UC) system used as an energy storage device fulfills the FC slowest dynamics during fast power transitions and recovers the braking energy. In FC/UC hybrid vehicles, the search for a suitable power management approach is one of the main objectives. In this paper, an improved control strategy managing the active power distribution between the two energy sources is proposed. The UC reference power is calculated through the DC link voltage regulation. For the FC power demand, an algorithm with five operating modes is developed. This algorithm, depending on the UC state of charge (SOC) and the vehicle speed level, minimizes the FC power demand transitions and therefore ameliorates its durability. The traction power is provided using two permanent magnetic synchronous motor-wheels to free more space in the vehicle. The models of the FC/UC vehicle system parts and the control strategy are developed using MATLAB software. Simulation results show the effectiveness of the proposed energy management strategy.     

Fuel cell-battery hybrid powered light electric vehicle (golf cart): Influence of fuel cell on the driving performance

A light electric vehicle (golf cart, 5 kW nominal motor power) was integrated with a commercial 1.2 kW PEM fuel cell system, and fuelled by compressed hydrogen (two composite cylinders, 6.8 L/300 bar each). Comparative driving tests in the battery and hybrid (battery + fuel cell) powering modes were performed. The introduction of the fuel cell was shown to result in extending the driving range by 63–110%, when the amount of the stored H₂ fuel varied within 55–100% of the maximum capacity. The operation in the hybrid mode resulted in more stable driving performances, as well as in the increase of the total energy both withdrawn by the vehicle and returned to the vehicle battery during the driving. Statistical analysis of the power patterns taken during the driving in the battery and hybrid-powering modes showed that the latter provided stable operation in a wider power range, including higher frequency and higher average values of the peak power.