1. Conversion from Internal Combustion to Fuel Cell Vehicle Group Members: Rob Pliml, Lee Walker, Andrew Massey, John Regenauer, Mark Mutton, Chad Mammen, Zac Maslowski, Patrick Montalto, Magda Nocko, Erik Hansen, Rick Kozmer Website: www.niusd2k5.info

2. Current Activity Car Dismantled Simulations New manual transmission AC motor Control system Battery source

3. Why Fuel Cells? According to the EPA, 60% of carbon monoxide in our atmosphere comes from automobiles. Two byproducts of fuel cells  Water  Energy  No Polution

4. How Does a Fuel Cell Work? Two inputs Hydrogen and Oxygen H2 enters anode and O2 enters cathode Protons and electron split Byproducts Water and Energy

5. Block diagram of the system

6. Proton Exchange Membrane Fuel Cell (PEMFC) P = V*I I = P/V = 68 kW / Range(450-250V) 151 A < I < 272 A Max input current of the motor is 250A

7. Proton Exchange Membrane Fuel Cell (PEMFC)

8. AC Electric Motor Solectria AC55 Specifications Peak Torque240 Nm Max Current250A rms Continuous Torque55 Nm Continuous Power34 KW Peak Efficiency93% Peak Electrical power78 KW Nominal Speed2.5K rpm Max Speed8K rpm Weight234 lbs *All Reading taken at 312 VDC

9. AC Electric Motor

10. Why Gel Cell Batteries? Very Fast Recharge Long Cycle Life Do not exhibit “Use it or Lose it” effect like NiCd No negative effects wiring in series like NiMH Li-ION $$$$

11. 3 – Phase AC Motor Inverter Specifications DMOC445DMOC445LC Dimensions 450mm x 252x 242 450mm x 252 x 200 Min. Nominal120VDC Battery Voltage Max. Nominal336VDC Battery Voltage Min. Operational 100VDC Voltage Max. Operational 400VDC Voltage Unit Efficiency96-98% Min./Max. -40°C to 75°C -40°C to 70°C Operating Temps. Max. Motor280A rms Current Peak Power78kW @ 312V Continuous Power38kW @ 312V46kW @ 312V Max. Voltage “On450VDC Charge” DMOC445 & DMOC445LC

12. From DC to AC DC to AC Inverter  Constant output voltage  Variable frequency and current output  Output wave form dependant on switching frequency and switching order  Interfaced with control system  Three Phase AC output

13. Fundamental Voltage Source Inverter

14. Transmission of Power Fixed ratio single speed transmission Using manual transmission in second gear  Motor to wheel speed ratio of 7.817:1  Maximum motor speed of 8000 rpm allows for a maximum speed of 77 mph Flexible coupling

15. Time Schedule

16. Acknowledgements Mechanical Engineers: Chad Mammen, Zac Maslowski, Patrick Montalto, Magda Nocko, Erik Hansen, Rick Kozmer Project Advisors: Dr. Anima Bose, Dr. Brianno Coller, Dr. Simon Song, Dr. Donald Zinger Dr. Romesh Kumar – Argonne Nat’l Lab Dr. Promod Vohra, Dr. Clifford Mirman – Northern Illinois University

17. Questions / Comments?