The document summarizes an extended range fuel cell utility vehicle demonstration project sponsored by the Defense Logistics Agency and Crane Naval Base. The project goals were to build and deliver hydrogen fuel cell utility vehicles to Warner Robbins Air Force Base within 8 months for a 12-month evaluation. The project team, led by the Center for Transportation and the Environment, designed and built two retrofitted hydrogen fuel cell utility vehicles that demonstrated a range of over 300 miles during testing.

1. Extended Range Fuel Cell Utility Vehicle: Design, Build, and DemonstrationClay HearnApril 27, 2011

2. IntroductionProgram GoalsTeam MembersModel Based DesignVehicle Build

3. Program GoalsProgram sponsored through Defense Logistics Agency (DLA) and Crane to provide extended range hydrogen fuel cell vehicles for use at Warner Robbins AFB in GeorgiaHydrogen refueling infrastructure on baseCurrently using hydrogen fuel cell fork liftsNumerous all-electric utility vehicles and NEVs Maximize on-board hydrogen storage without sacrificing vehicle performanceBuild and deliver units in 8 months to Warner Robbins AFB for 12 month evaluation

4. Project Team MembersCenter for Transportation and the EnvironmentProject managementVehicle Modeling (PSAT)Vehicle DesignFinal IntegrationVehicle Support and AnalysisFuel cell system and integration supportGas Technology InstituteHydrogen storage developmentBase vehicle supplier and support

5. Energy Storage Options

6. Vehicle ConfigurationsLi-Ion batteries double range of vehicle over stock lead-acid batteriesRange of hydrogen vehicle driven by onboard stored hydrogen~ 10X higher specific energy storage with 350 bar hydrogen fuel cell over advanced Li-ion batteriesAnalysis to right assumes 2 kg on-board hydrogen storagePlug-in options increase range by 25% – 50% over fuel cell alone, but also increase vehicle mass up to 250 kgFuel cell dominant hybrids increase range 25% – 27% over fuel cell alone

7. Hydrogen Storage OptionsGravimetric capacityAffects overall vehicle mass Limits additional cargo bed capacityReduces vehicle economyVolumetric capacityLimits storage volumePoses integration issues

8. Evaluating Hydrogen StorageIncreasing on-board H2Increasing on-board H2

9. Vehicle Integration8-month build schedule to retrofit two vehiclesSupervisory control and data recordingNI CompactRIOLabview softwareCAN communication between fuel cell and boost converter“Rolling Benchtop” testing

10. Final Integration and TestingCompleted October 2010Vehicle Range Testing309 mile range demonstrated87.8 mi/kg average5 days to complete!Vehicles include 120V 1.5 kW inverter for on-site power12 month demonstration at DDWG began November 2010

11. Questions?