Hybrid polymer electrolyte membrane fuel cell–lithium‐ion battery powertrain testing platform – hybrid fuel cell electric vehicle emulator

• Published in: International journal of energy research Vol. 41; no. 11; pp. 1596 - 1611
• Main Authors: Bujlo, P., Xie, C. J., Shen, D., Ulleberg, O., Pasupathi, S., Pasciak, G., Pollet, B. G.
• Format: Journal Article
• Language: English
• Published: Bognor Regis Hindawi Limited 01.09.2017
• Subjects: Alternating current; Automobile industry; D C motors; Dynamic tests; Electric vehicles; Electrolytes; Fuel cells; Fuel technology; Fuels; hybrid fuel cell electric vehicle; hybrid powertrain system; Hybrid systems; Hybrid vehicles; Hydrogen storage; Lithium; Lithium-ion batteries; lithium‐ion battery; Low temperature; Modules; Performance tests; Polymers; proton exchange membrane fuel cell; Rechargeable batteries; Temperature; Temperature effects; Testing; Vehicles; Europe
• ISSN: 0363-907X; 1099-114X
• DOI: 10.1002/er.3736

Summary A testing and validation platform for hybrid fuel cell (FC)–lithium‐ion battery (LIB) powertrain systems is investigated. The hybrid FC electric vehicle emulator enables testing of hybrid system components and complete hybrid power modules up to 25 kW for application in electric light‐duty vehicles, light electric vehicles and so forth. A hybrid system comprising a 10‐kWel low‐temperature polymer electrolyte membrane FC stack and an 11.5‐kWh LIB pack is installed. The system supplies power to a 20‐kW permanent magnet synchronous motor and a 25‐kW alternating current asynchronous, electrically programmable dynamometer is used to simulate the vehicle load during testing at dynamic drive cycle. The steady‐state performance tests of the direct current (DC) motor, DC/DC converter, low‐temperature polymer electrolyte membrane FC stack and LIB are performed as well as dynamic tests of the complete hybrid system. The Economic Commission for Europe driving cycle is selected as a reference cycle to validate the investigated hybrid FC–LIB powertrain. An efficiency of 83% and 95% is measured for electric motor and DC/DC converter, respectively. An average stack efficiency of 50% is achieved. An average hydrogen consumption of 3.9 g * km−1 is reached during the Economic Commission for Europe driving cycle test. Copyright © 2017 John Wiley & Sons, Ltd. A platform for testing full‐scale hybrid fuel cell electric vehicle powertrain systems under simulated real conditions is developed and validated at the HySA Systems laboratory. The functionality of the testing setup allows to test hybrid fuel cell electric vehicle components like electric motor, DC/DC converter, lithium‐ion battery pack and fuel cell system as well as complete hybrid systems under real operating conditions. The setup is predicted for testing of powertrains suitable for application in a light‐duty vehicle or light electric vehicle type of electric vehicle.