WG2: Fuel Cell Vehicles WG

ChairpersonProf. Yoichi Hori (The University of Tokyo)

LeaderHidemi Onaka (Toyota Motor Corporation)

Role of FCV WGJHFC’s Targets

1．Targets for hydrogen infrastructure①Review and proposals of future commercialized infrastructure models②Operation of hydrogen infrastructure under actual condition of use and

clarification of tasks involved③ Drawing up of specific plans for verifying safety of hydrogen infrastructure and

reexamining regulations

2．Targets for fuel cell vehicles④Operation of fuel cell vehicles under actual condition of use and

clarification of tasks involved⑤Verification of energy saving effects (fuel efficiency) and environment impact

reduction effects

3．Targets for common areas shared by vehicle and infrastructure⑥Review of measures to be taken for all issues that should be addressed

jointly between the vehicle and infrastructure fields

4．Targets for dissemination of results/public relation/globalization/local validation⑦Public relation and educational activities⑧Identification and proposal of overseas technologies and policy trends⑨Review ideal local validation methods

5．Review of tasks in starting dissemination in 2015

1

１．Demonstration Test Details and Results(1) Mileage/efficiency demonstration：Bench fuel economy, on-road fuel economy(2) General test：①Third party fleet test

②Hokkaido cold region startability test③1,100km long distance test drive

2．Clarification of FCV Positioning (Characteristic and Compartmentalization)

3．Progress of FCV Technology・ Progress of Solutions for Technical Problems

4. Summary of JHFC2 WG2 Activities

Contents of Presentation

2

JHFC Participating Cars

Nissan X-TRAIL FCV

Mercedes BenzA-Class F-Cell GM Equinox

Toyota/Hino FCHV-BUS

Toyota FCHV-adv

Suzuki SX4-FCV

Honda FCX Clarity

Mazda Premacy RE Hybrid

3

Bench Fuel Economy and Vehicle Efficiency Tests

ObjectiveTo demonstrate improvement of FCV‘s fuel economy. This test isconducted according to Japanese fuel consumption measurement mode.When new models are introduced, their tests are conducted sequentially.

MethodThe test is conducted on the chassis dynamometer of JARI (Tsukuba) according to ISO 23828 (energy consumption measurement for fuel cell vehicles).

4

Hydrogentank

Motor

Exhaust

Precision balance

Fuel cell

Fuel Consumption Measurement System

Measuring mass variation

Hydrogen consumption is acquired by measuring mass variation of theoutboard fixed hydrogen tank which supplies hydrogen to the vehicle fortesting.

Improvement of Bench Fuel Economy andVehicle Efficiency

[ ] in graph indicates gasoline equivalent fuel consumption (km/L) : gasoline energy LHV 45.1MJ/kg, gasoline density 0.729kg/L,hydrogen energy LHV 120MJ/kg (25°C 1 atm) applied

*1 Latest demonstrated vehicles: FCHV-adv, X-TRAIL FCV (2005), FCX Clarity Vehicles not updated since initial demonstration are not included. * 2 Initial demonstrated vehicles: FCHV (2002), X-TRAIL FCV (2003), FCX (2002), A-Class F-Cell, HydroGen3, Wagon R-FCV* 3 Vehicle efficiency[%]= (Total driven work by vehicle / energy applied to vehicle) × 100Note that tire slip losses are not concerned, and battery charge/discharge difference before and after the test is less than1% in all vehicles.* 4 As the JC08 bench fuel economy test has been carried out since 2007, carried out only two models of Initial demonstrated vehicles. Not indicated due to lack of data.

Fuel economy and vehicle efficiency (*3) of latest demonstrated vehicles (*1)improves significantly compared to initial demonstrated vehicles (*2).Vehicle efficiency achieves 60%, which is a target for 2015 (NEDO road map 2008).

5

Latest demonstrated vehicles *2

Initial demonstrated vehicles *１

0

50

100

150

Ben

ch fu

el e

cono

my （km

/kg-

H2）

108.7 [29.8]

159.2 [43.6]

71.4 [19.6]

117.8 [32.3]

0

20Vehi

cle

effic

ienc

y（%）*3

40

6061.3

49.6

30.2

54.0

Target for 2015

Gas

olin

e eq

uiva

lent

fuel

co

nsum

ptio

n （km

/L）

50

40

30

20

10

0

141.0 [38.6]

111.7 [30.6]

56.1

51.4

Bench fuel economy test results Vehicle efficiency10･15 JC08 *４ 10･15 JC08 *４

On-Road Fuel Economy Test*To confirm improved fuel economy on actual street.*To identify refuelings problems by performing 9 or more refuelings in a quarter year.

Method

6

Segmental fuel consumption was calculated from routes traveled between JHFC hydrogen stations. These drives were performed on February, May, August, and November and the target travel distance for each month was 200 km. To simulate actual use, the air conditioner was turned on in February and August.

CalculationThe segmental average fuel consumption wascalculated for each travel on each route. Theseaverage fuel consumptions were calculated for eachvehicle model and the average fuel consumptionranges between upper and lower ends are illustrated

Fuel

con

sum

ptio

n

Fuel

con

sum

ptio

nAv. of A’Av. of B’Av. of C’

Initialdemonstratedvehicle

Latestdemonstratedvehicle

Av. of AAv. of BAv. of CAv. of D

Objective

Initialdemonstratedvehicle

Latestdemonstratedvehicle

Tokyo

Chiba Prefecture

Kawasaki station

Senju station

Kanagawa Prefecture

Sagamihara station

Yokohama /Asahi station

Ichihara station

（Dotted line） Local road（Solid line) Highway Funabashi

stationKasumigaseki

station

Yokohama/Daikoku station

(JHFC Park)

Ariakestation

Tokyo Bay

Result of On-Road Fuel Economy Test（Bench fuel economy also indicated）

Latest demonstrated vehicles have improved fuel economy steadilyin both local road and highway.

※１ Latest demonstrated vehicles：FCHV-adv、X-TRAIL FCV（2005）、FCX ClarityVehicles not updated since initial demonstration are not included.※２ Initial demonstrated vehicles: FCHV (2002) , X-TRAIL FCV (2003) , FCX (2002) , A-Class F-Cell, HydroGen3, WagonR-FCV※３ Calculated average segmental fuel consumption on local roads and highways in the fuel consumption road test for *1 and *2 respectively, and showed the distribution※４ Since the table fuel consumption test by JC08 was started from 2007, only 2 models out of initial demonstrated vehicles *2 were tested. Fuel consumption is not shown due to insufficient data.※５ Gasoline equivalent fuel consumption（km/L）：Gasoline energy LHV amount 45.1MJ/kg, gasoline density 0.729kg/L,

hydrogen energy LHV amount 120MJ/kg（25℃ 1 atmospheric pressure) is used. 7

Bench(10･15)

0

50

100

150

Fuel

con

sum

ptio

n（km

/kg-

H2）

Bench*4

(JC08)On-road*3

(Highway)On-road* 3

(Local road)

Gas

olin

e eq

uiva

lent

fuel

con

sum

ptio

n（km

/L）※

5

50

40

30

20

10

0

108.7

159.2

71.4

117.8

141.0

111.7109.8

80.5

87.5

59.8

116.6

91.2

107.1

75.1

Latest demonstrated vehicles ※１Initial demonstrated vehicles ※２

Seasonal Influence of On-Road Fuel Economy

8

Fuel economy is lower in summer (August) and winter (February) compared to spring (May) and autumn (November).

To further improve the fuel economy of FCVs, there is a need for improvement of systems such as A/C and further improvement of efficiency of accessories.

Fuel

eco

nom

y

Latest demonstrated vehicles *1

Feb. A/C ON

May A/C OFF

Aug. A/C ON

Nov. A/C OFF

※１ Latest demonstrated vehicles ：FCHV-adv, X-TRAIL FCV（2005）, FCX Clarity Vehicles not updated since initial demonstration are not included.※２ To set general conditions, the air conditioner was turned ON in Feb. (winter) and August (summer), and OFF in May (spring) and November (autumn). The temperature set was not specified.

Third Party Fleet Test

Objective and Target• To clarify practical problems through third

party FCV operation.

Fleet Operational Area

9

ToyotaHino

Nissan

HondaDaimler

Vehicles for Third Party Fleet Test (Passenger cars)

10

ParticipatingManufacturer

Fleet Company Business Test Duration Model Used Vehicle Photo

Mercedes-Benz Japan DHL Japan Courier July 2006 to March

2009 F-Cell

Toyota Motor Corporation

YamatoTransportCo., Ltd

Courier April 2007 to December 2010

FCHV↓

FCHV-adv

Nissan Motor Company

KanagawaToshikoutsu

Limousine service

February 2007 to January 2011

X-TRAIL FCV（35MPa）

Honda Motor Company

NipponKonpoUnyu Soko

Business support

March 2007 to December 2009

FCX（'03MY)↓

FCX（'05MY)

Honda Motor Company

Teito Motor Transportation

Limousine service

June 2010 to December 2010 FCX Clarity

Vehicles for Third Party Fleet Test (Bus)

11

Participating Manufacturer

Fleet Company

Business Content Test Duration Models Used

Toyota Motor Corporation

Hino Motors

Chita NoriaiRoute Bus(Including Island Circulation Bus)

July 2006 to December 2009

One FCHV-BUS（‘05MY)

ANA Ground ServiceChubu

Ramp Bus(Passenger trafficbetween Aircraft atRamp and Airport Terminal)

From July 2006

Two FCHV-BUS（'05MY)

Results for Bus Fleet （To September 2010）・ Overall travel distance of all fleet buses

was 153,000km

Performance of Third Party Fleet (Travel distance)Results for Passenger Vehicle Fleet

(To September 2010)・ Overall travel distance of all fleet passenger

vehicles was 64,000km

Cum

ulat

ive

trav

el d

ista

nce

(km

)

Cum

ulat

ive

trav

el d

ista

nce

(km

)

Limousine service 1

Sales support car

Delivery car 1

Limousine service 2

Delivery car 2

Ramp bus 1Ramp bus 2Route bus

Passenger car fleet cumulative travel distance Bus fleet cumulative travel distance 12

Results for Bus Fleet (To September 2010）・ Overall hydrogen refueling amount for

all fleet buses was 13,341kg.

Performance of Third Party Fleet(Hydrogen refueling amount)

Results for Passenger Vehicle Fleet(To September 2010)・Overall hydrogen refueling amount for all fleet passenger vehicles was 858kg.

Passenger vehicle fleet cumulative hydrogen refueling amount

Bus fleet cumulative hydrogen refueling amount

Cum

ulat

ive

hydr

ogen

refu

elin

g am

ount

(kg)

Limousine service 1

Sales support car

Delivery car 1

Limousine service 2

Delivery car 2

Ramp bus 1Ramp bus 2Route bus

Cum

ulat

ive

hydr

ogen

refu

elin

g am

ount

(kg)

13

Number of subjects: 31 in FY 2009(Average results for sale support cars,

limousine service, delivery cars)

Third Party Fleet Driver Questionnaire Data

Bus Fleet・Performance was well received・Certain dissatisfaction about hydrogen

refueling time.

14

Passenger Vehicle DriverNumber of subjects: 36 in FY 2009

(Average results for route buses and ramp buses)

Bus Driver

Passenger Vehicle Fleet ・Well received with comments “easy drive,

good acceleration, and quiet”.・Certain dissatisfaction about refueling

time and work time before and after refueling.

Driving range

Hydrogen safetyHydrogen safety

Refueling procedure and time

Refueling procedure and time

Feeling of self-refueling

Response to throttle

pedal

Feeling of self-refueling

Response to throttle

pedal

Running noise

Running noise

Very goodVery good

BadBad

Very Bad

No opinion

Very Bad

No opinion

Good Good

Driving range

Noiselessness

Hydrogen safety

Smooth start/stopNasty smell

Vibration during stopping

Very good

Bad

Very Bad

No opinion

Good

FC Bus Passenger Questionnaire Data *1

FC Bus Passengers・20% of passengers replied that there were “slightly apprehensive” or “felt insecure” about hydrogen.・ Favorable impression with smooth start/stop, no vibration during stopping, noiselessnesness.- Comments indicated need for more FC buses.

Bus Passengers

15

Subjects : 174 passengers in FY 2009(Average of 117 passengers of route buses, and 57 passengers of ramp buses)

*1 : Result of JHFC ‘s first questionnaire for bus passengers

Evaluation of Driving Range

Comparison of Distance between refuelingsaccording to refueling pressure

Improvement of satisfaction of driving range of latest fleet lease generation, and 70MPa refueling vehicles.

Distance between refuelings also increased by 70MPa refueling, etc.

16

Freq

uenc

y

35MParefueling

70MParefueling

Distance between refuelings (km)

Comparison of results of questionnaire on driving range

Very good

Good

No opinion

bad

Very badFleet/Lease

Initial generation

Fleet/Lease Latest

generation

Fleet/LeaseUse of 70MPa

refueling

Summary of Third Party Fleet Drive Results (1) General◇Passenger cars; 5 purposes, Buses; 2 purposes, Approx. 4-year performance; Mileage of

approx. 220000 km, Hydrogen consumption; Approx. 14000 kg.(2) Vehicle technology◇Well received by drivers saying “easy to drive”, “good acceleration”, “quiet”.◇Initially there was considerable dissatisfaction with driving range, however driving range

increased with improved fuel economy and 70MPa refueling, which improved satisfaction. →70MPa refueling efforts are being made for both FCVs and hydrogen infrastructures,

which are expected to resolve existing problems.◇Driving range of FC route buses is slightly inadequate compared to diesel route buses.

→Automobile manufacturers have the same views, and are currently considering measures such as use of 70MPa tank pressure.

(3) Refueling technology◇Certain dissatisfaction with refueling time and work time before and after refueling.

→Pre-cooling and communication refueling efforts are being made for refueling time problems, and the reduction of work time before and after refueling is also being reviewed. （WG3）

◇Buses require considerable on-board hydrogen load, resulting in the certain dissatisfaction with the hydrogen refueling time.→There is a need to deploy passenger car refueling technologies to buses.

(4) Hydrogen◇It has been found that 30% of drivers feel insecure about hydrogen.

→Review of continuation of education and details (education program according to driver needs).

17

Cold Region Startability Test （2008 Hokkaido）

Demonstration tests on startability below freezing point were conducted in Hokkaido in the coldest month of February.

The cars were confirmed to start and run without any problems in the minimum temperature of about -10 degrees Celsius. 18

Out

side

tem

pera

ture

(deg

. C)

February 4 February 5 February 6

← -10.8℃ ← -9.6℃

Engine off (14h) Engine off (8h)

1,100km Long-Distance Test Drive

19

Completed 1,137km with two refuelｌings. Average fuel economy of three cars was 118.4km/kg, with the best fuel economy amongst

the three cars being 132km/kg.At the on-board hydrogen load of 6kg, driving range was 792km.

OsakaNagoya Tokyo

Kita-kyushu

Kyushu University

Nikko

1st Refueling2nd Refueling

Nikko

Tokyo

NagoyaOsaka

Kita-kyushu

Kyushu University

2nd Refueling

2nd Refueling

1stRefueling

2

1．Demonstration Test Results(1) Mileage/efficiency demonstration：Bench fuel economy, on-road fuel economy(2)General test：①Third party fleet test

②Hokkaido cold region startability test③1,100km long distance test drive

2．Clarification of FCV Positioning (Characteristic and Compartmentalization)

3．Progress of FCV Technology・ Progress of Solutions for Technical Problems

4. Summary of JHFC2 WG2 Activities

Contents

20

FCV Characteristics (2010）

21

Item Fuel cell vehicle(FCV)

Electric vehicle(BEV)

Plug-in hybrid vehicle(PHEV)

Hybrid vehicle(HEV)

Internal combustion

engine vehicle(ICE-Gasoline)

CO2 emission *1Based on JHFC2 Well to Wheel analysis review

results

★★★★★Zero emissions on the road

and use ofCCS, recyclable energy are

important

★★★★★Zero emissions on the

road and use ofCCS, recyclable energy

are important

★★★★ ★★★ ★

Energy diversity★★★★★

(Fossil, nuclear energy, hydraulic energy, etc.）

★★★★★(Fossil, nuclear energy, hydraulic energy, etc.）

★★（Mainly petroleum）

★（Petroleum）

★（Petroleum）

Driving range ★★★★★（ＪＣ08 mode：～760km）

★★（ＪＣ08 mode：～200km）

★★★★★(EV＋HＥV)

★★★★★ ★★★★★

Durability（Reduced performance）

★★★★（FC stack）

★★★★（Battery）

★★★★（Battery）

★★★★★ ★★★★★

Cold districtperformance

★★★★★ ★★★★ ★★★★★ ★★★★★ ★★★★★

Vehicle costs

★★

★★★Technical projections atstarts of dissemination

★★★ ★★★ ★★★★ ★★★★★

Infrastructure availability

★（Several ten locations）

★★★Projections at start ofdissemination

★★★★（100/200V：More than

2200 locations, Rapid：More than 200

locations）

★★★★（100/200V：More than 2200

locations）★★★★★

（Gasoline about 40000 locations）

★★★★★（Gasoline about 40000 locations）

★★★★★（Gasoline about 40000 locations）

Gasoline refuelling/recharging

Refueling time

★★★★★（Hydrogen refueling：

3mins）

★（Normal recharge：8 hrs.）

★★★（Rapid recharge：20～

30mins）

★（Normal recharge：4 hours）

★★★★★（Gasoline refuelling：2～3

mins）

★★★★★（Gasoline

refuelling：2～3 mins）

★★★★★（Gasoline

refuelling：2～3 mins）

★ → ★★★★★（Poor） （Good） .Reduced CO2 emissions and energy diversity most expected in FCV and BEV

※1 Indicates all CO2emissions (Well to Wheel ) including that other than vehicles .

22

Segmentation of FCV and BEV (2010 version)

Vehicle size

Driving range

Large

Small

FCV can replace existing internal combustion engine vehicles in terms of vehicle size and driving range.

Compact and short-distance BEVs and FCVs can be spread, coexisting together.

Short Long

1．Demonstration Test Results(1) Mileage/efficiency demonstration：Bench fuel economy, on-road fuel economy(2) General test：①Third party fleet test

②Hokkaido cold region startability test③1,100km long distance test drive

2．Clarification of FCV Positioning (Characteristic and Compartmentalization)

3．Progress of FCV Technology・ Progress of Solutions for Technical Problems

4. Summary of JHFC2 WG2 Activities

Contents

23

Progress of Solutions for Technical Problems –Summary (2010 version)

24※ Estimated from demonstration test results, presentation materials, hearings, etc.FCV development situation (Top runner)

FCV performance has significantly improved in the nine years of Phase 1 and Phase 2 of the JHFC Project. Projections of level of practical application in 2015 are starting to become visible.

-25℃

100 million

yen

Driving range（Practical level 500km）

Durability（15 years）

Low temperatureperformance

（Started at -30℃）

Hydrogen refueling time (5kg / 3 minutes)

(Common infrastructure area)

Vehicle efficiency （60%）

Vehicle price（Several million yen）

Practical level 300km

10 years3kg/3 mins

0℃

10 million

yen

5 years

50％

Progress of Solutions for Technical Problems - Driving range

Driving range has increased with improved fuel economy and high pressure hydrogen storage.

25

35MPa充填仕様70MPa充填仕様

Transition in FCV Driving Range(Source: Values disclosed for 10・15 mode by manufacturers）

Year of Presentation

Driv

ing

rang

e (k

m)

Toyota

Honda

Nissan

70MPa refueling spec. 35 MPa refueling spec.

Progress of Solutions for Technical Problems - Low-temperature performance

0℃

Low temperature

High temperature

1999 2003 2006

0℃

-20℃ -30℃

80℃95℃ 95℃

Honda / FC stack operation temperature(source: FC EXPO2009 data）

Toyota / FCHV subzero starting(source: SPring-8 Green energy meeting)

FCV can be started at stack operation temperature of -30℃.

26

Star

ting

time(

sec)

FC water temperature at start (deg. C.)

Progress of Solutions for Technical Problems - Durability

Power degradation of the FC stack after travelingequivalent to 500000 km is no more than approximately 30%(6% for 100000 km).

Toyota / FCHV-adv Fuel cell stack power maintenance ratio(source: September 2009 JSAE Kanto branch lecture meeting)

27

FC S

tack

Pow

er (%

)

Travel distance (km)

Approx. 30min. per cycle

Durability evaluation pattern

Progress of Solutions for Technical Problems -Costs

Daimler / Power train cost (Source：FC-expo 2010 data)

Costs are being reduced steadily for commercialization.

Toyota / FC system cost(Sourse: 2010 Toyota Motor Corporation press conference of ecological technology)

28

1．Demonstration Test Results(1) Mileage/efficiency demonstration：Bench fuel economy, on-road fuel economy(2) General test：①Third party fleet test

②Hokkaido cold region startability test③1,100km long distance test drive

2．Clarification of FCV Positioning(Characteristic and Compartmentalization)

3．Progress of FCV Technology・ Progress of Solutions for Technical Problems

4. Summary of JHFC2 WG2 Activities

Contents

29

(1) Demonstration（JHFC1,JHFC2）◇Total number of passenger vehicles; 135, Driving range; 1070000 km, Hydrogen refueling; 20000kg◇ Total number of buses; 13, Driving range; 320000 km, Hydrogen refueling; 29000 kg

(2) Bench fuel economy tests, on-road fuel economy tests◇Confirmed achievement of NEDO targets for bench fuel economy (Vehicle efficiency 60%，Japanese 10･15 mode).◇Confirmed improvement of fuel economy for on-road fuel economy. Also confirmed sharp reduction of fuel economy by A/C load.

→ Need for improvement of systems such as A/C, and further improvement of efficiency of accessories.

(3) Fleet test drives◇ Well received by drivers saying “easy to drive”, “good acceleration”, “quiet”.◇70MPa refueling vehicles have long driving range and high satisfaction.

→70 MPa refueling efforts are being made for both FCV and infrastructures, which are expected to resolve existing problems.◇Certain dissatisfaction for hydrogen refueling time of buses.

→Need to deploy passenger car refueling technologies to buses.(4) Review of technical problems

◇ Projections of level of practical application in 2015 are starting to become visible for tasks (vehicle price and durability) as well.

Summary of JHFC2 WG2 Activities

30