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?