Post on 04-Jan-2016
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
Current Activity
Car Dismantled Simulations New manual transmission AC motor Control system Battery source
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
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
Block diagram of the system
Hydrogen Storage
Off Board Battery Charger
FAN FAN
Fuel In
BOOST CONVERTER
AIR COMPRESSOR
FUEL CELL
AIR COMP INV
DC/DC BUCK CONVERTER
BATTERY PACK
ELECTRICITY IN
Air In
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
Proton Exchange Membrane Fuel Cell (PEMFC)
AC Electric Motor
Solectria AC55
Specifications
Peak Torque 240 Nm
Max Current 250A rms
Continuous Torque 55 Nm
Continuous Power 34 KW
Peak Efficiency 93%
Peak Electrical power 78 KW
Nominal Speed 2.5K rpm
Max Speed 8K rpm
Weight 234 lbs
*All Reading taken at 312 VDC
AC Electric Motor
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 $$$$
3 – Phase AC Motor InverterSpecifications
DMOC445 DMOC445LC
Dimensions 450mm x 252x 242450mm x 252 x
200
Min. Nominal 120VDC 120VDC
Battery Voltage
Max. Nominal 336VDC 336VDC
Battery Voltage
Min. Operational 100VDC 100VDC
Voltage
Max. Operational 400VDC 400VDC
Voltage
Unit Efficiency 96-98% 96-98%
Min./Max. -40°C to 75°C -40°C to 70°C
Operating Temps.
Max. Motor 280A rms 280A rms
Current
Peak Power 78kW @ 312V 78kW @ 312V
Continuous Power 38kW @ 312V 46kW @ 312V
Max. Voltage “On 450VDC 450VDC
Charge”
DMOC445 & DMOC445LC
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
Fundamental Voltage Source Inverter
Z Z Z
S1 S2 S3
S1' S2' S3'
Phase A Phase B Phase C
Neutral
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
Time Schedule
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
Questions / Comments?