Plug-In Hybrid Electric Vehicle Concept with Fuel Cell Range Extender for Urban Delivery Transport-Powertrain Concept

Abstract:

The electrification of vehicle fleets for urban delivery transport is becoming increasingly important due to ever stricter legislation and the high social pressure on companies. In this paper， a converted 3.5 t light-duty vehicle with a maximum gross weight of 7.5 t is introduced. The vehicle has a serial hybrid electric powertrain with a maximum electric traction power of 150 kW and a 60 kW fuel cell range extender. The vehicle uses a 46 kW·h battery with a 400 V mean voltage level， resulting in a full electric range of 120 km. The electric drive is realized with an induction motor and a lithium-manganese-iron-phosphate （LMFP）-battery as well as a 2-speed gearbox. The fuel cell system has a fuel tank with a 95 L volume and 700 bar pressure level， which enables an overall vehicle range of 400 km. A proton-exchange membrane （PEM）， for direct hydrogen application， with a rated power of 1.0 W / cm2 is used. The PEM is integrated in a 60 kW fuel cell system for on-board energy generation on the vehicle. For the air-path the fuel cell system has an electrically assisted turbocharger to use the enthalpy of the exhaust air. The humidification of the intake air is realized with a water injector that uses water from dehumidification of the exhaust air. The hydrogen path is realized with an ejector circuit and a purge-valve for nitrogen disposal. In this paper， the design and control of the fuel cell system is introduced. Finally， the most important effects during the operation of the fuel cell system are presented.