abas goodarzi, ph.d., p.e. president, us hybrid sae 2014

1 SAE 2014 Hybrid and Electric Vehicle Technologies Symposium 1

Abas Goodarzi, Ph.D., P.E. President, US Hybrid SAE 2014 Hybrid and Electric Vehicle Technologies Symposium


US Hybrid HQ: Torrance, CA

Year

Established 1999

Core

Competency

Electric Powertrain for

Electric, Hybrid and Fuel

Cell Heavy Duty Vehicles

Magmotor Corporation Worcester, MA

Year

Established 1876

(Acquired by US Hybrid in 2008)

Core

Competency

Servo Motors and Drives

Automation, Robotic and

Semiconductor Mfg.

US Hybrid Group www.ushybrid.com

Honolulu, HI

www.magmotor.com

US FuelCell South Windsor, CT

Year

Established 2013

Core

Competency

Fuel Cell

Power Plant

Worcester, MA

Torrance, CA

South Windsor, CT

Torrance, CA

www.usfuelcell.com


US Hybrid’s Fuel Cell Commercial Vehicles Experience


Leader in Fuel Cell Vehicles Integration

2013

US Hybrid Acquired UTC PEM Fuel Cell

Over 50 years of Technology

Research & Product Development

Apollo

1960s 2000s 1990s 1980s 1970s 2010s

Demos: Homes, Buildings

Utilities

Space Shuttle Orbiter

200/400 kW Commercial Production

R12 Refueler

20kW Fuel Cell Bus 60kW FC Cargo Van

FC BOP

BOP to UTC

Isolated DC-DC Transit Bus

H2 Ride Shuttle Bus FC Shuttle and Truck Commercialization

Utility Van

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Dump Truck

30kW FC

Specialty Trucks and Transit

http://fuelcellsworks.com/news/2012/05/22/mass-transportation-authority-mta-unveiles-its-new-hydrogen-fuel-cell-bus-and-opened-their-alternative-fuel-facility-in-grand-blanc-township/

http://www.newflyer.com/index

http://www.handtrucksystems.com/food service.htm

http://www.bauersit.com/transit/


Electric Powertrain Components

0

100

200

300

400

500

600

6 7 8 9 10 11 12

Ou

tpu

t C

urr

en

t A

Isolated Power kW

0

100

200

300

400

500

600

0 20 40 60 80 100 120 140 160

Inp

ut

Cu

rre

nt

A

Output Power kW

320kW

240kW

200kW

DC-DC Converters

http://students.sae.org/chapters/collegiate/saelogos.htm


Plug-In Fuel Cell Shuttle Bus

Shuttle Bus (GVWR=8,850 kg) Drive Cycle: Volcano National Park Hawaii


Energy Usage Summary

Drive (miles)

Local or

FWY

H2 Used

Kg

Battery kWhr used

Total Energy used kWhr

Miles /kg H2

kWh /Mile

Expected Range miles

40.4 Local 3.15 5.88 53.1 12.8 1.32 126

16.8 4.7+12.1 1.42 -0.84 20.5 11.8 1.22 136

25.3 20+5.2 1.46 6.72 28.6 17.3 1.13 146

50 fwy 2.62 16.52 55.8 19.1 1.12 148

34 fwy 1.44 12.32 33.9 23.6 1.00 166 0.0

5.0

10.0

15.0

20.0

25.0

Local 1 Local 4 fwy 1 fwy 2 fwy 3

Energy Efficiency Miles/kg of H2


Drive Cycle: Chain of Craters

Duty Cycle • 2x27=54 miles round trip • 4000’ elevation • 2x15=30 bus stops • 1 minute dwell time at each bus stop • 2x20 minutes dwell time at visitor center • Total idle time=70 minutes • Drive Cycle 1: Vmax=30 mph (uphill) • Drive Cycle 2: Vmax=20 mph (uphill) • amax=1 m/s2 (uphill) • Vmax=40 mph (downhill)

Hotel Load A/C=4.4 kW DC/DC=2kW Other loads=0.6kW Total hotel load=7 kW

Hawaii Volcanoes National Park

Chain of Craters Road with a left onto Crater Rim Drive to Visitors Center


-400

-300

-200

-100

0

100

200

0 1 2 3 4 5 6 7 8 9 10 11

Elev

atio

n (

ft.)

Distance (mile)

Profile Alignment

Drive Cycle 1: Volcano National Park Driving Elevation and Grade

Bus Stop

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

20.00

0 1 2 3 4 5 6 7 8 9 10 11Gra

de

(%)

Distance (mile)

Profile Grade


Drive Cycle: Elevation and Grade

Bus Stop

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0 5 10 15 20 25 30 35 40 45 50 55

Elev

atio

n (

ft.)

Distance (mile)

Profile Alignment

-20

-15

-10

-5

0

5

10

15

20

0 5 10 15 20 25 30 35 40 45 50 55Gra

de

(%)

Distance (mile)

Profile Grade

Outbound Inbound


0

5

10

15

20

25

30

35

40

45

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

Spe

ed

(m

ph

)

Time (s)

Speed vs. Time

Drive Cycle 2: Speed versus Time and Distance

Vmax = 20 mph

0

5

10

15

20

25

30

35

40

45

0 5 10 15 20 25 30 35 40 45 50 55

Spe

ed

(m

ph

)

Distance (mile)

Speed vs. Distance


0 5 10 15 20 25 30 35 40 45 50 550

5

10

15

20

25

Distance (mile)

En

erg

y (

kW

h)

Available Energy

Simulation Results for Battery Pack

Outbound Inbound

0 5 10 15 20 25 30 35 40 45 50 550

0.5

1

1.5

Distance (mile)

SO

C

State of Charge


Simulation Results: Power

0 5 10 15 20 25 30 35 40 45 50 55-200

-100

0

100

200

Distance (mile)

Po

we

r (k

W)

Power

Battery

Fuel Cell

0 5 10 15 20 25 30 35 40 45 50 55-20

0

20

40

60

Distance (mile)

Po

we

r (k

W)

Average Power Over Time

Total

Battery

Fuel Cell


Simulation Results: Energy

0 5 10 15 20 25 30 35 40 45 50 55-20

0

20

40

60

80

100

Distance (mile)

En

erg

y (

kW

h)

Consumed Energy

Total

Battery

Fuel Cell

0 5 10 15 20 25 30 35 40 45 50 550

0.5

1

1.5

2

2.5

3

3.5

Distance (mile)

En

erg

y/D

ista

nce

(kW

h/m

ile

)

Energy used per mile

Total

Battery

Fuel Cell


Fuel Cell Plug-In hybrid Electric Refueler (R12) Fuel Cell Plug-In Hybrid Electric Re-Fueler (R12)

Hydrogen Fueling and Defueling, Diagnostics and Telematics Interface

3 * (HD16 +CV12) in parallel


R12 Refueler top level Specification


Fuel Cells Dynamic and Static Performance


R12- Performance Summary

Fuel Cell Hybrid R12 Test Drive Summary

H2 Tank Pressure Net

Drop (psi)

H2 Net Consumption

(kg) Miles/kg

Battery Pack (380V, 90 Ahr, 34 kWhr)

Battery consumption in SOC

Battery consumption (kWhr) Date

Miles Driven

2/7/2013 11 400 0.7 15.7 18% 6.1

2/7/2013 12 400 0.7 16.4 13% 4.4

2/8/2013 28 1000 2.0 14.3 38% 12.9

2/12/2013 11 300 0.6 17.5 12% 4.1

Total 115


Fuel Cell Powered TUG


Li-Ion Battery

Electric Driven Steering

and Brake

Plug-In Hybrid Fuel Cell Class 8 Dump Truck

Hydrogenics 30kW

single fuel Cell Plant H2 Fuel System

10kg)

240kW

Drive

iDrive

Charger

J1772 CV35

DC-DC


Comparable Energy Density

Diesel: 37.1 kwh/gal (Energy content), Engine Output:, 15kWh/gal, 4.5 kWh/kg

Gasoline: 32.9 kWh/gal, (Energy content), Engine Output: 11.8 kWh/gal, 2.8 kWh/kg

Hydrogen: 39.7 kWh/kg, (Energy content),

(1kg H2 =11 gal @5000 psi, or 11 gal @5000psi tank is same as 2 gal of diesel fuel)

Total Energy Density (Electric output power) per kg: 15 kWh/kg

Mixed Fuels:

Ethanol(E100) = 22.1 kWh/gal,

(M85) 85% Methanol, 15% Gasoline = 18.6 kWh/gal

Energy Storage Devices have much lower energy density:

Ultra Capacitors 0.004 kWh/kg,

Lead Acid 0.025 kWh/Kg

NiMh 0.06 kWh/Kg

Li-Ion 0.11 kWh/Kg

1kg of H2 (7.8miles/kg) > 2-Gallons Diesel (3.8mpg) 40’ Transit Bus

1kg of H2 (6miles/kg) > 2-Gallons Diesel (2.4mpg) Drayage Truck

1kg of H2 (12miles/kg) > 2.5-Gallons Gasoline (5 mpg) Shuttle Bus


US Hybrid acquired UTC PEM Transportation assets and IP License

• PureMotion 120kW FC power plant is the most robust fuel cell for transit applications with millions of miles logged.

• Generation2; 150kW Fuel Cell Power plant has the following advantages:


Commercial Product Planning for durability, cost, volume and weight improvement

Power Rating Availability Year

135 kW 2014-2015

75 kW 2017

200 kW 2016

Power Rating 135kW 75kW 200kW

Dynamic Response kW/S 100 75 125

Market Segment Transit Bus

People movers Specialty Trucks

Construction Military Mining

Commercial Deploy 2015 2016 2016

Target Life (hrs. /Years) 20,000/10 10,000/6 5,000/6

PC58

>70% volume reduction in 5 years


FCPP/BOP DFMA & Cost Reduction

Electrical Control System

Controller

Vehicle Electrical

Center

Power Distribution

Module (PDM)

Harnessing

Cell Stack Assemblies

Air Processing System Fuel Processing System

Thermal Management System

Frame and Enclosure


Fuel Cell Power Plant Performance Status

NREL Technical Report NREL/TO-5600-55367

FCEB

# Days

Planned work days 1,943 631

Days Available 1,087 56 498 79

Unavailable 856 100 133 100

Fuel cell propulsion 99 12

Hybrid propulsion 30 3

Traction battery issues 160 19

Bus maintenance 557 65 133 100

Fueling unavailable 10 1

Maintenance Cost $/Mile $1.30 100% $0.79 60%

Comments: Most cost is due to learning curveBus Maintenance and Battery are major itemsFuel Cell Technician labor rate is higher than Diesel

Category % Diesel

# Days%

FCEB and Diesel Bus Comparative Availability

Fuel cell power plants can provide better or comparable reliability and maintenance

costs to Diesel engines with after-treatment.

2013 fleet leader >16,000 Hr, as of Dec 2013 and going


Hydrogen Fuel Cells Market Focus

Special Applications

Commercial Trucks Production

Special Purpose Military Vehicles

Public Transit

People Mover Pilot Production

http://www.bauersit.com/transit/

http://www.transportationissuesdaily.com/usdot-awards-13-1-million-to-advance-adoption-of-clean-green-energy-for-transit/

http://www.handtrucksystems.com/food service.htm

http://lyle.smu.edu/emis/design/?p=1371

http://www.armyrecognition.com/sofex_2012_show_daily_news_pictures_video/oshkosh_defense_showcases_special_forces_vehicle_expertise_at_sofex_2012_in_jordan_0605122.html


Summary and Conclusions

• Electric Traction will be the main stream

• Hybrid technology Enables traffic decoupling

• Fuel Engineering Technology is the research trend

• Hydrogen Fuel Cell appears to be future mainstream

abas goodarzi, ph.d., p.e. president, us hybrid sae 2014

Documents