Fuel Cell Electric Drivetrain for 500km Range of 4.6t LCV in Zero Emission Municipal Application

Authors

Dipl.-Ing. Dr. techn. E. Wahlmüller, Dipl.-Ing. (FH) W. Rumpl MSc, Dipl.-Ing. M. Friedl, S. J. Jones PhD MSc, Plastic Omnium New Energies Wels GmbH, Wels; Prof. Dr. R. Wörner, S. Hegde MEng, Y. Wiese BEng, Prof. Dr.-Ing W. T. Czarnetzki, Institute for Sustainable Energy Technology and Mobility (INEM), Esslingen University; B. Beutel BEng, R. Ritter, EFA-S GmbH, Zell unter Aichelberg:

Year

2023

Print Info

Production/Publication ÖVK

Summary

One of the first 4.6t zero emission vehicles with a towing capacity of 2.5t in Europe was developed by integration of a modular battery and hydrogen fuel cell powertrain to increase the range towards 500km in all weather conditions. The highly efficient range extender powertrain developed in this project meets these requirements and is suitable for 60-70% of the total European light commercial vehicle market [1]. The lithium iron phosphate (LFP) batteries used, with a total energy capacity of 40kWh and a maximum discharge rate of 3C, operate at a voltage level of 400V. The 50kW PEM fuel cell system with integrated DC/DC converter achieves an overall efficiency of up to 56%. The J1939 interface enables standardized control and embedding of the module in the overall vehicle environment. Two Type IV hydrogen tanks with a total capacity of 8.6kg at 700bar allow refueling times of less than 5 minutes. Analyzing real driving cycles of commercial and municipal vehicles and the application of simulation methods supported development of the energy management system. The optimal operating point of the fuel cell is controlled by real-time analysis of system variables such as driving behavior, temperature-dependent de-rating and state of charge of the battery. The aim is to keep the state of charge of the battery in the range of 60-80% in order to minimize the losses in the overall battery-fuel cell system and maximize the lifetime of the components. The results of the static and dynamic tests of the vehicle under practical load and weather conditions (especially cold winter temperatures) confirm the achievement of the set goals and the versatility of the developed technology.

ISBN

978-3-9504969-2-5