Powertrain Technology for Future Fuel Cell Vehicles

Frank Bryan, Prof. Andrew Forsyth

Contact: Frank.Bryan@manchester.ac.uk

DC-DC Converter
Introduction
As low temperature, portable fuel cell technology The fuel cell interface DC-DC
matures, opportunities are opening for the converter is a dual interleaved
development and manufacture of fuel cell powered boost converter with
electric vehicles. These new vehicle are cleaner, interphase transformer. This
quieter and have the potential for less fossil fuel
topology has high input and
dependence. The development of supercapacitors as a
complimentary technology also allows improved output voltage ripple extending
performance and increased operational life of these fuel cell and supercapitor life,
vehicles when operating as a peak power buffer whilst minimising weight.
compared with traditional battery based alternatives.

Energy Management
The energy level of the power buffer needs to be controlled to provide the best
mix of energy from fuel cell and supercapacitors. The strategy depends on:

Fuel cell operating efficiency

Ability to recapture regenerated energy

Reduction in fuel cell transients to extend fuel cell life

The Cushman Diabline, Traditional Electric Delivery Vehicle
Robustness to changing vehicle parameters

Fuel Cell and Supercapacitors

 Fuel Cell Allows vehicle to be
refuelled instead of recharged,
reducing down time

Output voltage variation

)

requires DC-DC converter and

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r
opo
se
dS
tr
ate
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ow
Ga
in R
a
te
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ite
d V
e
lo
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Refe
r
enc
e
g

3
00
power buffer for traction interface
rVolta

2
50
acito

2
00
ercap

1
50
Sup

0 1
00 2
00 300 4
00 5
00 6
00
Peak power buffer allows tim
e(
s)
d(W)

reduced rating of fuel cell 8

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0
man

6
00
0
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System requires supervisory

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4
00
0
ll Po

control to manage multiple 2

00
0
lCe

energy sources
ue

0
F

0 1
00 2
00 300 4
00 5
00 6
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tim
e(
s)

Simulated Fuel Cell Power Demand for Laden Diabline

Intellicon System Configuration
The ‘Intellicon’ system configuration uses a single DC-DC Conclusion
converter to interface the fuel cell. The supercapacitors are then
connected directly to the traction drive. The voltage of the traction
drive is then allowed to vary between set limits allowing energy The addition of a supercapacitor based peak power
into and out of the power buffer. buffer allows the potential for extended system life and
increased efficiency. The careful design of an energy
I fc I Iload
management strategy is required that will operate
under a variety of vehicle conditions and on unknown
dc
3 Ø SUPPLY

+ INTERLEAVED +
FUEL CELL
SYSTEM
Vfc
-
BOOST
CONVERTER
Vdc
-
I
sc
3Ø
INVERTER
DRIVE
MOTOR
operational driving cycles.
DC-DC
Regulation SUPER
CAPACITOR Speed, Temperature,
Control . Performance and
STACK
Regeneration
SYSTEM Control.
CONTROL SC Monitoring
FC Monitoring /Control UNIT

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