Fuel Cells and Advanced Technologies 29 © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458 Advanced Automotive.

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FUEL CELLS AND ADVANCED TECHNOLOGIES

FIGURE 41-1 Ford Motor Company has produced a number of demonstration fuel-cell vehicles based on the Ford Focus.

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Fuel Cells and Advanced Technologies 29 © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ Advanced Automotive Electricity and Electronics James D. Halderman

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.1 Ford Motor Company has produced a number of demonstration fuel-cell vehicles based on the Ford Focus.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.2 Hydrogen does not exist by itself in nature. Energy must be expended to separate it from other, more complex materials.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.3 The Mercedes-Benz B-Class fuel-cell car was introduced in 2005.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.4 The Toyota FCHV is based on the Highlander platform and uses much of Toyota’s Hybrid Synergy Drive (HSD) technology in its design.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHART 29.1 Fuel-cell types and their temperature operating range.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.5 The polymer electrolyte membrane only allows H 1 ions (protons) to pass through it. This means that electrons must follow the external circuit and pass through the load to perform work.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.6 A fuel-cell stack is made up of hundreds of individual cells connected in series.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.7 A direct methanol fuel cell uses a methanol/ water solution for fuel instead of hydrogen gas.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.8 A direct methanol fuel cell can be refueled similar to a gasoline-powered vehicle.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 29.9 Powertrain layout in a Honda FCX fuel-cell vehicle. Note the use of a humidifier behind the fuel-cell stack to maintain moisture levels in the membrane electrode assemblies.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The Honda FCX uses one large radiator for cooling the fuel cell, and two smaller ones on either side for cooling drive train components.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Space is limited at the front of the Toyota FCHV engine compartment, so an auxiliary heat exchanger is located under the vehicle to help cool the fuel-cell stack.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The secondary battery in a fuel-cell hybrid vehicle is made up of many individual cells connected in series, much like a fuel-cell stack.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The Honda ultracapacitor module and construction of the individual cells.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An ultracapacitor can be used in place of a high-voltage battery in a hybrid electric vehicle. This example is from the Honda FCX fuel-cell hybrid vehicle.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Drive motors in fuel-cell hybrid vehicles often use stator assemblies similar to ones found in Toyota hybrid electric vehicles. The rotor turns inside the stator and has permanent magnets on its outer circumference.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The General Motors “Skateboard” concept uses a fuel-cell propulsion system with wheel motors at all four corners.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The electric drive motor and transaxle assembly from a Toyota FCHV. Note the three orange cables, indicating that this motor is powered by high-voltage three-phase alternating current.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The power control unit (PCU) on a Honda FCX fuel-cell hybrid vehicle is located under the hood.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Toyota’s FCHV uses a power control unit that directs electrical energy flow between the fuel cell, battery, and drive motor.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE This GM fuel-cell vehicle uses compressed hydrogen in three high-pressure storage tanks.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The Toyota FCHV uses high-pressure storage tanks that are rated at 350 bar. This is the equivalent of 5,000 pounds per square inch.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The high-pressure fitting used to refuel a fuel-cell hybrid vehicle.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Note that high-pressure hydrogen storage tanks must be replaced in 2020.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE GM’s Hydrogen3 has a range of 249 miles when using liquid hydrogen.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Refueling a vehicle with liquid hydrogen.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Carbon deposits, such as these, are created by incomplete combustion of a hydrocarbon fuel.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Both diesel and conventional gasoline engines create exhaust emissions due to high peak temperatures created in the combustion chamber. The lower combustion temperatures during HCCI operation result in high efficiency with reduced emissions.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A typical electric vehicle charging station on the campus of a college in southern California.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A cutaway view of a Nissan Leaf electric vehicle showing the two charging connectors. Both of these connectors are located in the center of the vehicle in the front making plugging in the cable easy to access.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The SAE J1772 plug is used on most electric and plug-in hybrid electric vehicles and is designed to work with Level 1(110–120 volt) and Level 2 (220–240 volt) charging.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE (a) The motor in a compact electric drag car. This 8-inch-diameter motor is controlled by an electronic controller that limits the voltage to 170 volts to prevent commutator flash-over yet provides up to 2,000 amperes. This results in an amazing 340,000 watts or 455 Hp. (b) The batteries used for the compact drag car include twenty 12-volt absorbed glass mat (AGM) batteries connected in series to provide 240 volts.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Wind power capacity by area. (Courtesy of U.S. Department of Energy)

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A typical wind generator that is used to generate electricity.

29 Fuel Cells and Advanced Technologies Advanced Automotive Electricity and Electronics James D. Halderman © 2013 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The Hoover Dam in Nevada/Arizona is used to create electricity for use in the southwest United States.