Fuel Cell Hybrid Drive Train：燃料电池混合动力传动系统.docx

FuelCellHybridDriveTrainMasterThesisinEnergyEngineeringJanuary2021PatrykKinnSupervisors:JoachimLindstromAzraSelimovic1.arsBackstromExaminatior:RobertEklundAbstractThisthesispresentsafuelcellhybriddrivetrainstudyofa26tondistributiontruckregardingthefuelconsumption.TheinvestigationismadeusingamodelimplementedinSimulink.TheconceptvehicleisaVolvoFM9,wheretheconventionaldieselpowertrainisreplacedbyanelectricaldrivesystem.TheelectricalpropulsionmotorispoweredbyaprotonexchangemembranefuelcellassistedbyaLi-ionpoweroptimisedbattery.Thepowerratingsoftheinvestigatedfuelcellsarebetween150kWand350kWandtheinvestigatedbatterycapacitiesrangefrom4.5kWhto22.6kWh.Twodrivecycles,whereonerepresentsurbandistributionwithnoroadinclineandtheotherrepresentssuburbandistributionincludingroadinclineareused.Byimplementingthreedifferentpowercontrolstrategies,itisshownthatthefuelconsumptioncanbereducedbyupto56%comparedtotheconventionaldieselreferencevehicle.Theurbandistributiondrivecycleisfoundmoresuitableforthefuelcellvehicleapplication.A250kWfuelcelland13.6kWhbatteryconfigurationissuggestedfortheurbandistributiondrivecycle,reducingthefuelconsumptionby53%.Forthesuburbandistributiondrivecyclethesuggestedconfigurationconsistsofa350kWfuelcellanda17.8kWhbattery,reducingthefuelconsumptionby25%.AcknowledgementsThereareseveralpeoplethatIwouldliketomentionandthankexplicitlyfortheircontributionsduringthisthesiswork.Thesepeopleare: JoachimJindstromwhosupervisedmeandcontributedgreatlybyhisknowledgeandexperiencewithinthefieldofelectricmachines.Iamgratefulforhiswarm,experiencedandopenmindedguidanceduringtheentireworkingprocessandsupportduringthefinalisationofthereport. AzraSelimovic,foransweringthatveryphonecallduringhertimeabroadthatledtotheworkonthisthesisandforinitiatingthisproject.Iappreciateheradviceduringmywork. AndreasBoden,whotogetherwhitAzrainitiatedthisprojectandhandleditovertotheexperiencedguidanceofJoachim. PaulAdamswhocontributedwithexpertiseonissuesregardinghydrogenstorageandtheEnglishlanguage. JensGrootwhoprovidedthebatterymodelandpatientlyansweredallmyquestions. MikaelHolber,forcompanionshipandinterestingconversationsaboutfuelcelltechnology,martialartsandargentinetango. Theentiregroup6120forthewarmwelcomingIreceived,forcontinuouslyansweringmyquestionsandforgenerouslyprovidingabroadspectrumofexpertise.NomenclatureAA/FIwheelgSJ-IhHEVICEI-SAM1wheelioK1.HVdiesel1.HVh2IfactorMMH2MairmFrontAreaofthevehicleTafelequationconstantVehicleaccelerationFuelcellstackareaDragcoefficientRollingfrictionElectricalVehicleFaradayconstantFuelCellVehicleDragforceForceduetomomentofinertiaofthewheelsForceduetogravityForceduetorollingresistanceSumoftheexternalforcesTractionforceAccelerationofgravityGibbsfreeenergyTotalhydrogenconsumptionHybridElectricVehicleInternalCombustionEngineIntegratedStarterAlternatorMotorMomentofinertiaofthewheelsMomentofinertiaofthemotorCurrentdensityExchangecurrentdensitySpecificheatratio1.owerheatingvalueofdiesel1.owerheatingvalueofhydrogen1.engthfactorVehicleMassMolarmassofhydrogenMolarmassofairMasstransportconstantmMasstransportconstantnNumberofcellsCompressorinletpressureCompressoroutletpressureCompressorpowerPowerenteringthefuelcellPowerdeliveredbythefuelcellMotorpowerMaximummotorpowerWheelpowerAmbientpressurePartialpressuresofhydrogenPartialpressuresofwatervapourSaturationpressureofwaterP2RrrfSOCTTwheellllTm,naxTinTmodeKniaxVocVoOCVVbaseVmaxXgearS0CVohinactVmassTfc,system(icdciselo9h2PartialpressuresofoxygenGasconstantWheelradiusArea-specificresistanceStateofchargeTemperatureWheeltorqueMotortorqueMaximummotortorqueInlettemperatureMaximumoriginaloutputtorqueOpencircuitvoltageOpencircuitvoltageatstandardpressureandtemperatureVehiclespeedVehiclespeedcorrespondingtomotorbasespeedMaximumvehiclespeedGearratioDeltastareofchargeOhmicresistancelossesActivationlossesMasstransportationlossesFuelcellsystemefficiencyDC/DCconverterefficiencyIsentropicefficiencyElectricefficiencyTotalmechanicalderivelineefficiencyInclineangleMolarflowofhydrogenairPairPdieselCOm(OnunotorCOtiuixtWheeICOwheeI(0wleelMolarflowofairAirdensityDieseldensityMotorspeedMaximummotorspeedMaximumwheelspeedWheelspeedWheelaccelerationTableofcontentIntroduction1Thefuelcellvehicle1Prerequisites3Purposeandgoal3Conceptvehicle3Dataandperformancespecification4Drivecycles4Sizing5Performance7Drivecycle10Themodelandcomponents11Thedriver11Thefuelcellsystem11Thefueltank12Thefuelcell13Thecompressor16Theauxiliaryload17Theelectricmotor17Thefinalgear19Thevehiclebody19Thebattery20Thecontroller20Controlstrategy20Powerdemand21Simulations21Batteryandfuelcellsizes21DeltaSOCcorrection22Performanceandfuelconsumption22Results24Performance24Fuelconsumption33Discussion43Performance43Fuelconsumption43General45Conclusions46Futurework47References48IntroductionTheemissionandfuelconsumptionfavourableoperationoftheHybridElectricVehicles(HEVs)haveresultedintremendouspopularityincreaseofthesevehiclesduringthelasttwodecays1.Theelectricvehicleishowevernotanewconceptandthemanufacturingofsuchvehiclesstartedasearlyasbefore1900.FerdinandPorsche,sfirsthybridvehicleproducedin1899wasforinstancepropelledbyfourwheel-mountedelectricmotorswithaseriesdrivelinesolution1.Thelackofinsightinthefinitenatureandintheenvironmentalimpactofthefossilfuels,aswellasthefastdevelopmentoftheinternalcombustionengine(ICE)duringtheFirsWordWarandthelowfuelprices,pushedtheelectricvehiclesaside2.Sincethen,theICEvehicleshavedominatedtheroadsandhavenowprobablydonethatfarlongerthananyofthosedrivingthemtodaycanremember.Theinfrastructure,performancedemands,manufacturingprocessandmanyotheraspectshavebeeninfluencedandformedbythisdominance.Nowhowever,whentheenvironmentalimpactofthetrafficcausedpollutionisbecomingvisibleandthefossilfuelreserveofthisplanetfadesrapidly,newpossibilitiestodevelopedalternativepowertrainconceptsarise.Thisdevelopmentmayevenbeconsideredasnecessaryifthefreedomofusingfastandflexiblepersonalandgoodstransportsarenottobeabandonedmeanwhiletheplanetsenvironmentispreservedforthefuturegenerations.Asubstantialamountofresearchanddevelopmenttime,aswellasfinancialmeansisnowinvestedbythemanufacturersandpoliticalorgansinordertomeetthedemandsfromaconstantlymoreawarepublic.Eveniflargeadvancehasalreadybeenmade,therearestillmanyaspectstobeconsideredandproblemstobesolvedregardingtheHEVsbeforetheycanbefullycommercialized.Twosuchaspectsarethecostandperformanceofthesevehicles.Becauseeveniftheenvironmentalconcernhasbeenbroughttoattention,thecustomersmustbeabletoaffordtheproductandtheproductneedstofulfilitspurpose.Anotheraspectistheoriginofasubstitutionfuelanditsdistribution.Variousresearchanddevelopmentactivitieshaveresultedinavarietyofdifferenthybridsolutions,fromtheelectricmotorassistedbicyclestomoreadvancedpluginhybridcarsandthefuelcellvehicles(FCV).ThisthesesaimstocontributetoageneraleffortofHEVstudybyinvestigatingthefuelconsumptionofafuelcellbaseddrivelinesolutionfora26tonnedistributiontruck.ThefuelcellvehicleWhenthereareatleasttwoformsofenergystoredonboardavehiclethatcanbeusedforpropulsionandiftheenergyinatleastoneofthecasesiselectric,suchavehiclequalifiestobecalledaHEV.SincethisisthecasefortheFCV,wherethepropulsionenergycanbetakenfromthehydrogensuppliedtothefuelcellorfromtheelectricenergystoredinthebattery,thesevehiclescanberegardedasHEVs.ThedrivelineoftheHEVisusuallyoneofthreebasictypes.Onetypeistheseriesdrivelineimposingthatonlyoneenergyformisusedtopowerthepropulsion.Theothertwotypesaretheparallelandcomplexdrivelinesolutions2.Theparalleldrivelineimposethattwoenergyformscanbeusedatthesametimeandthecomplexdrivelineimposethatboththeseriesandparalleldrivelinesareimplementedandthatachoiceismadewhichsolutiontouseinacertainsituation.Allthesedrivelinesolutionshavetheirprosandconswhencomparedtooneanother.However,sincetheenergyusedtopowerthepropulsionmotoroftheFCViselectric,theseriesdrivelinesolutionisonlyonestudiedinthefollowingwork.SincetheFCVispropelledbyelectricenergy,thistypeofvehiclepossesthesamepotentialofemissionfavourabletransportationasthebatterysourcedelectricvehicle(EV).Thefuelcellhowever,givesthebenefitofextendedtravelleddistanceforthesameorevensmallerbatterysize.Thisreductioninbatterydependenceisdesirablesincethebattery,atpresent,canberegardedastheAchillesheelinallhybrids3duetoe.g.lowlifetimeandhighcost.Thefuelcelltechnologyhoweverintroducesotherchallengingaspects.Oneissueistheabsenceoffueldistributioninfrastructure,makingithardtocommercializethefuelcellvehicle.Todealwiththisproblemthereareseveraldemonstrationprojectsofhydrogenhighwaysaroundtheworldandongoingresearchonstoragepossibilities.Inasensethisissueispartiallyaddressedinthisthesis,wherethefuelconsumptionandstoragecapacityisinvestigated.Naturallyithastobekeptinmindthatforthisemissionfavourableconcepttobecomereality,thehydrogenneedstobeproducedanddistributedinequallyemissionfavourableway.Intheidealcasealsothemanufacturingprocess,serviceandtherecyclingprocessallneedtobeemissionfavourable.EveniftheseissuesareofgreatimportanceandstronglyrelatedtotheenvironmentalbenefitsoftheFCVandothertypesHEVs,theyarenotconsideredinthistextandleftforotherinspiredinvestigatorsandfuturestudies.PrerequisitesInthissectionthepurposeandthegoalofthethesesarepresented.Theconceptvehicle,theperformancerequirementsandthedrivecycleschosenarealsopresented.Thefirstsubsectiondealwhitthepurposeandgoalandisfollowedbyamotivationofthevehicleselection.Thefollowingsubsectionsintroducethevehicledata,theperformancerequirementsandthedrivecycleschosenforthefuelconsumptionsimulations.PurposeandgoalThepurposeofthisthesisistoconductaprestudyonahydrogenbasedfuelcellserieshybriddrivetrainforamedium-heavydistributiontruck.Thefocusofthestudyistosimulateandevaluatedifferentsystemlayoutsforthedrivetrainanddefineprosandconsforeachconceptdefinedregardingmainlythefueleconomy.Thebasiccasewillbeanequivalentconventionaldieseldrivenvehicle.Otherimportantpartsoftheworkaretodefineandscalethecomponentsofthesystemsuchashydrogenstorage,battery,electricmachineandfuelcell.Importantaspectsherearetodefinethepowerbalancebetweenthefuelcell,electricmachineandthebattery.Thegoalwiththisthesisistodeliveramodeltakingmostoftheimportantaspectsofthedrivetrainintoaccount.Themodellevelshouldbeaccurateenoughtodeliverreliableresultsforbasicvehicleanalysis.Theresultsarecomparedwiththoseofaconventionaldrivetrainaswellasstateoftheartdiesel-electricparallelhybriddrivetrain.ConceptvehicleThevehiclechosenforthisstudyistheVolvoFM9illustratedinFigure1.Thevehiclechoiceisprimarymotivatedbytwofactors.ThefirstfactoristhelargeamountofreferencematerialandvehicledataspecifiedinthereportontheI-SAMproject4.Thereferencematerialincludesfuelconsumptionoftheconventionalversionofthisvehicle.ThesecondfactormotivatingthechoiceofthevehicleisthepossibilityofusingtheVolvoFM9forcitydeliveryapplications,whichwastheinitialproposalofthetheses.Duringtheliteraturestudyintheinitialpartoftheprojectitwashoweverdiscoveredthatasimilarinvestigationhasalreadybeenperformedforalightdistributiontruck5.Beingnearlytwiceasheavyasthevehiclealreadyinvestigated(FL6),theVolvoFM9waschoseninordertocontributetotheresultsoftheexistinginvestigation.Figure1:TheVolvoFM6.DataandperformancespecificationThephysicaldataofthevehiclearesummarizedinTable1.Table1:TheVolvoFM9dataWeight(loaded)26tonRollingfriction,Cr0.005N/NFrontarea,A9.7m2Dragcoefficient,Cd0.65Wheelradius,r0.492mAuxiliaryload4.4kWThefollowingperformancerequirementshavebeenchosenforthestudy:1.Cruisingability:Thevehicleshallbeabletocruiseat100km/hatlevelground.2.Gradeability:Thevehicleshallbeabletocruiseat40km/hattheinclineof8.7%(5o).3.Acceleration:Thevehicleshallbeabletoperformmaximalaccelerationfromstandstillto100km/hatlevelground.Thevehicleshallbeabletoperformmaximalaccelerationfromstandstillto50km/hattheinclineof8.7%(5°).Aswillbeshownlateron,thegradeabilityrequirementisdemanding.ForcomparisonitcanbestatedthatthehighwayE6,whenpassingtheHaIlandsaseninSwedeninthesoutherndirection,hastheinclineof6%(3.43o).DrivecyclesTwodifferentdrivecycleshavebeenselectedforthestudy.Thesort3drivecycleandthesx365drivecycle.Thesort3drivecycleisasyntheticcyclewithacompletelyflatroadtopologyduringtheentireduration.Itconsistsofanaccelerationsection,aconstantvelocitysection,adecelerationsectionandastandstillsectionrepeatedforthreedifferentconstantvelocities.Theconstantvelocitiesare30km/h,50km/hand60km/h.Duringonesimulationthisdrivecycleisdrivententimes.Thesort3drivecycleisconsideredsuitableforcitydistribution4.Thesx365drivecyclecorrespondtoanactualroadintheneighbourhoodofHallerdtestgroundinSweden,itishillyandcontainsfewstops.Thesx365drivecycleisconsideredsuitableforsuburbandistribution4.DatasummeryforbothdrivecyclesispresentedinTable2.Thereferencespeedofthesort3cycleisshowninFigure2andthecorrespondingspeedofthesx365cycleisillustratedinFigure3,wheretheroadtopologyhasbeenincluded.ThefuelconsumptionofthereferencetruckandtheI-SAMtruckaregiveninTable3.Table2:DriVeCyCledaiaSUmmary4.sx365sort3Durations2150200Distancem356601450Stoptime(%7%20%Averagespeedkmhl6026AveragespeedexcludedstopsknVh6549Maximalspeed(krnh9060RoutetopologyyesnoTable3:Fuelconsumptionofthereferencevehicle4.DrivecycleReferencetruckI-SAMtrucksort35.681/10km4.661/10kmsx3654.291/10km4.08(1/10kmFigure3:Speedandheightprofileofthesx365drivecycleApartfromthefactthatfuelconsumptionofthereferencevehicleforthesetwodrivecyclesisdocumented,thechoiceofsort3cycleismotivatedbythecitydeliverysuitabilitywhilethechoiceofsx365cycleismotivatedbythehillyroadtopologyandsuburbandrivingrepresentation.SizingTheinformationaboutthedrivecyclesincludesvelocityandaccelerationrequirementsaswellastheslopeofthedrivewayduringtheentirecycle.Thisinformation,andtheperformancerequirementinformationstatedintheprevioussection,combinedwiththevehicledataandNewton,ssecondlowofmotioncanbeusedforanestimationoftheelectricmotorrequirementandthegearratio.TractionforceThefirststepinthissizingprocessisthecomputationofthetractionforcethatisrequiredatthewheelsforpropulsionofthevehicle.AspostulatedbyNewtoninhissecondlowofmotion,themotionofthevehiclewilldependontheresultingforcefromallexternalforcesactingonthevehicle.TheseexternalforcesarethetractionforceFtr,therollingresistanceforceFrOM,thedragforceFdandthegravitationalforceFlllgx7.Whenthevehicleisacceleratingtherearealsoadditionalforcesduetothemomentofinertia.Onesuchforce,theforceFhvheelcorrespondingtothemomentofinertiaofthewheels,isincludedinthefo