Hybrid Fuel Cell Vehicles

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Hybrid Fuel Cell Vehicles

• Robert Thomas
• Mother McAuley Liberal Arts High School
• IIT Research Mentor Donald Chmielewski

This material is based upon work supported by the
National Science Foundation under grant No.
EEC-0502174. Any opinions, findings, and
conclusions or recommendations expressed in this
material are those of the author(s) and do not
necessarily reflect the views of the National
Science Foundation.
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Hybrid Fuel Cell/Battery Powered Vehicles Overview

• High School Chemistry/Physics/Physical Science
• Objectives
• Differentiate between hybrid electric and hybrid
  fuel cell
• Learn dynamics of automotive vehicle
• Use Problem Based Learning trade-off analysis of
• Vehicle forces
• Energy storage device weight, cost, energy output
• Hydrogen fuel cell/energy storage materials and
  utilization
• design a consumer accepted hybrid fuel cell
  vehicle to meet all government regulations

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Timeframes based on scenario

• Choice A Physics only
• 2 days research on problem, 1 day presentations
• Choice B Chemistry only
• 2 days research on problem, 1 day presentations
• Choice C Physics/Chemistry
• 2 days each research on problem
• 1 day coordination between physics and chemistry
  groups
• 1 day presentations
• Choice D Physical Science
• 2 days research on simplified physics or
  chemistry problem
• 1 day presentations

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Late High School Illinois Learning Standards

• 11.A.5a Formulate hypotheses referencing prior
  research and knowledge
• 11.A.5d Apply statistical methods to make
  predictions and to test the accuracy of results.
• 11.B.5a Identify a design problem that has
  practical applications and propose solutions.
• 12.D.5a Analyze factors that influence the
  relative motion of an object
• 12.C.5b Analyze the properties of materials

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Why solve this problem?

• Minimal pollution
• Minimize hazardous by-products
• Provide efficient refueling options
• Low health risk
• Minimize exposure to hazardous by-products
• Minimize toxicity of by-products
• Reduce use of fossil fuels
• Renewable fuels
• Higher efficiency

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Engineering and ethics

• ASME Fundamental Canon on safety
• Engineers shall hold paramount the safety, health
  and welfare of the public
• Asphalt Emulsion Manufacturers Association COE
• Be active in the advancement of the technology .
  so as to improve the environment through reduced
  hydrocarbon emissions pollution, and to aid in
  the conservation of fuel resources.
• Canon of Ethics for cost engineers
• Will be honest and impartial, and will serve
  employer, clients, and the public with devotion

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Ethics and you

• Statement on Integrity in Science
• 1) No plagiarism or unauthorized use of original
  material
• 2) fabrication of data or selective reporting of
  results
• 3) submission of the same paper or trivial
  variations thereof
• This applies to research we are doing as well as
  school work you are doing this fall!

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Historical Perspective

• 1970s lunar rover
• 1980s GM created the EV1
• Early 1990s Dodge and Ford prototypes
• Late 1990s Toyota and Honda Hybrids
• 2000s hybrid fuel cell/battery prototypes
• Fuel cell overview

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Background material

• Aerodynamic drag opposing vehicle movement
• Rolling resistance moment of inertia
• Gravity 9.8 m/s
• Normal force
• Motor Torque
• Acceleration S Forces / Mass
• Driving scenarios using city/urban driving

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Physics Example increase vehicle performance

• Reduce vehicle resistance by minimizing
• Frontal area width x height
• Aerodynamic Drag by vehicle body design
• Rolling resistance by wheel selection
• Minimize weight of
• Energy storage based on Lead acid, Nickel Metal
  Hydride, Li ion batteries, capacitor
• Fuel cell based on energy needed
• Properly matched transmission
• Matching motor torque to wheel radius

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Chemistry Example - Choosing a hydrogen fuel cell

• Fuel cell Energy output versus
• Number of cells and weight of each cell
• Hydrogen / air flow
• Fuel cell temperature
• Energy storage output versus weight
• Lead acid, nickel metal hydride, lithium ion
  batteries, capacitor
• Differences between energy and power

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Design Project

• Using data on tradeoffs, design an affordable
  car you want to drive to be
• Commercially viable
• Consumer accepted
• Virtually pollution and health hazard free
• Using the pieces provided, propose solution for
• Mechanically efficient vehicle
• Environmentally friendly power plant
• Performance for all driving conditions

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Day 1 Physics activity - aerodynamic drag and
rolling resistance

• Rolling resistance opposes vehicle movement
• Raise one end of cardboard platform ¼ inch
• 1 by 1, put 6 matchbox cars at top of ramp
• Put aside any cars that do not roll down ramp
• Drag altered by vehicle shape front vehicle
  area
• make wind tunnel with fan, cardboard boxes, duct
  tape
• Working in groups of 3/4, try remaining matchbox
  cars in wind tunnel and determine least
  aerodynamic drag by measuring least movement
• Compare to known drag coefficients

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Day 2 Physics activity

• Investigate background references on internet
• Impact of design and weight on performance
• Impact of drag and resistance on acceleration
• Tradeoffs to be considered
• Aerodynamic drag from Day 1
• Motor power versus weight
• Wheel radius
• Have groups of 3 / 4 students research hybrid
  vehicles and design vehicle to meet project
  requirements, using tradeoff data

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Day 1 Chemistry activity

• Introduce concept of battery ratings
• Amp hours
• Current rating
• Cost / kWh and cost / kg
• Working in groups of 3 or 4, students will use
  battery tester in series with ammeter while
  measuring battery voltage to determine battery
  ratings for different composition batteries
• Choose battery based on energy, weight and cost
• Compare to known battery ratings

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Day 2 Chemistry activity

• Investigate background references on internet
• Impact of design and weight on performance
• Impact of fuel cell output on acceleration
• Tradeoffs to be considered
• Energy storage versus weight
• Fuel cell output versus weight
• Have 3 or 4 students in group design fuel cell /
  battery combination to meet design project
  requirements, using research and tradeoff data
  provided PEM

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Matlab data
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Day 3 Combined activity

• Combine one Physics/Chemistry small group and put
  together ideas
• Can fuel cell / energy storage combination meet
  requirements?
• Will total mass alter performance?
• Will cost exceed target price?
• Is mileage acceptable?
• Do you still want to drive this car?
• Have students groups present design to include
• fuel cell / energy storage combination
• mechanical design
• How project requirements were met

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Materials

• Access to computer laboratory for research
• Windtunnel testing
• box fan, cardboard boxes, duct tape, matchbox
  cars, scale, meter stick
• Battery testing
• Kits available for 9 to test batteries, or you
  can use a 330 ohm resistor also need voltmeter,
  ammeter, wire jumpers
• The project CD contains
• Student activities
• Assessments
• Teacher notes with solutions
• Presentations

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Pre-test on understanding and misconceptions

• Commercially available hybrid technology
• Where can hydrogen be derived from
• Batteries currently used in hybrids
• How are batteries recharged
• Moving vehicle Force diagram
• Forms of energy and how to store
• Hybrid vehicle performance

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Assessment

• Lab assessment
• all materials listed
• Assumptions stated
• Detailed procedure
• Experiment design
• Expected outcome and results present
• Project assessment
• All tradeoffs considered
• Vehicle meets 0-60 mph criteria

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Post-test students on concepts learned

• Minimizing aerodynamic drag
• Effects of Road resistance
• Battery characteristics
• How Hydrogen fuel cells work
• Use of a wind tunnel
• Acceleration tradeoff analysis
• Electrical output
• Vectors on motor powered vehicle

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References

• Larmine, L., Dicks, A. (2003), Fuel Cell Systems
  Explained Second Edition, England John Wiley and
  Sons.
• Ehsani, M. et al. (2005), Modern Electric, Hybrid
  Electric, and Fuel Cell Vehicles, New York CRC
  Press.
• Akella, S., et al, (2001), Model-Based Systems
  Analysis of a Hybrid Fuel Cell Vehicle
  Configuration, Proceedings of the American
  Control Conference, 25 June 2001, 1777-1782.