PowerPoint

Thursday, May 26, 2016 1
Proof of Concept of aProof of Concept of a
Fuel Cell-Battery HybridFuel Cell-Battery Hybrid
ScooterScooter
Ashok Zachariah

1. Background
2. Objective
3. Scope
4. Review of Literature
5. Methodology
6. Observations and Results
7. Conclusion
Topics of DiscussionTopics of Discussion

• Internal combustion engine (ICE) is a mature, and well proven technology
• ICEs deliver maximum power, torque, and horsepower at any condition
• Hydrocarbon fuels, predominantly Diesel and Gasoline, are used to power
ICEs
• Engines available, are the four-stroke and the two-stroke
• If not burned completely, and efficiently, hydrocarbon fuels tend to pollute
the environment and can cause long-term health problems
• Two-stroke engines, mostly found in Asia and Europe, pollute the
environment, when coupled with increasing global population densities,
changes in lifestyle
BackgroundBackground

• Partial solutions, such as variable cylinder management and advanced
particulate filters help increase fuel efficiency, and reduce the amount of
harmful emissions
• Engineers have also considered using direct hydrogen fuel cells for a host
of applications, including transportation
FUEL CELL
hydrogen oxygen
water
The Result….
Fuel Cell: An electrochemical energy device that converts the chemical
energy from the combination of hydrogen and oxygen.

A fuel cell-battery hybrid scooter

1. Gather components from local vendors and university facilities;
2. Define and understand the components’ electrical and mechanical
characteristics and parameters;
3. Integrate components, to meet the performance characteristics of the fuel
cell device;
4. Gather and record qualitative data of the components in battery, fuel cell,
and hybrid modes, the cost estimates; and
5. State the conclusions, and suggest future recommendations on how to
improve performance and manufacturability.
ObjectiveObjective
Build and demonstrate the proof of concept of a fuel cell-battery
hybrid scooter, at the Polytechnic Campus of Arizona State University.

ScopeScope
The project focused on building a fuel cell-battery hybrid scooter by:
•Using university-donated or purchased components
•Understanding the electrical parameters of the fuel cell device, donated by the
PTL (Photovoltaics Testing Laboratory) at the Polytechnic campus
•Meet the electrical requirements of the scooter and fuel cell device
•Purchasing and modifying components based on some of the design constraints
of the fuel cell device and scooter
•Determining the performance using an electrodynamometer
•Plotting the performance measures analytically, by measuring the current, voltage
and power of the sources in normal and hybrid modes

Requirements
•The scooter must be small in size, and light-weight;
approximately between 13.6 and 22.7 kg [30 and 50 lbs];
•The scooter and other components are easy to assemble, and disassemble;
•The scooter will be driven on relatively smooth surfaces. In other words,
the driving conditions experienced by the scooter are
pavement independent conditions;
•University departments have access to a PEMFC stack; and
The fuel cell device and other components came with the necessary
documentation to support their operation.
Limitations
•The testing was limited to the geographical location of the university and
department laboratories;
•The driving range for the scooter was approximately 0 to 24 km [0 to 15 mi];
•Only one fuel cell device and hydrogen storage canister were used for the project
•A limited time of ten months was allowed to demonstrate the proof of concept.

Review of LiteratureReview of Literature
Various companies and academic institutions performed extensive research on
fuel cell-battery hybrid scooters, to evaluate and optimize their performance. Others
Have performed studies on different types of scooters that appeal to customers,
from an Industrial Product Design point of view.
Comparison between Fuel Cells and Batteries (Jossen, 2005)
Fuel Cells Batteries
Energy Content Defined by storage unit Specific energy: 25 to
200 Wh/kg
Power Capability Defined by fuel cell stack Coupled with the battery
size
Self Discharge 0; if switched OFF Approximately 1 to 10%
per month
Startup Characteristic At room temperature,
50% of rated power
Immediate full power
Electrically
Rechargeable
Not possible Possible
Charge Time Very fast; refill or
exchange
15 minutes to 10 hrs.
System Technology Complex Simple
Cost Energy, power &
periphery are expensive
Much lower than fuel
cells
1) Jossen et. al

•Batteries are considered high-power density devices. Fuel Cells are considered
high-energy density power sources
•According to Jossen, et. al, “the most popular, low temperature fuel cell is the
proton-exchange membrane fuel cell (PEMFC)…” (3).
•A hybrid system will produce adequate power. If the power demand is not met, a battery
provides spike-power for those instances.
“A small battery with a high peak-power capability, is used for peak shaving”
(3). This is the main advantage of a hybrid system.
•PEMFCs do not discharge when the power is turned OFF, or when the hydrogen canister
is closed. Batteries tend to discharge automatically, even when the power is
disconnected (Jossen, 2005).
Despite these advantages, there are drawbacks as well.
•Fuel cells are still expensive, compared to their battery counterparts. Clean manufacturing
and precision are some of the factors in the high cost.
•PEMFC’s are more sensitive to high temperatures.

Advantages and Disadvantages of Fuel Cells (3)
Advantages Disadvantages
•Low-operating temperature allows a rapid
start-up
•Free of corrosive cell elements (Sulfur, etc)
•Capable of high current densities of over 2
kW/L and 2 W/cm2
•Pure Hydrogen can be used as the fuel
•Low operating temperature range allows
difficult thermal management at high current
densities
•Hydration of the electrolyte against flooding
•Sensitive to poisoning of Sulfur, Carbon
Monoxide, and Ammonia.
Size versus Features of a Fuel Cell and Battery (3)

Fuel Cell and Battery Schematic of a Basic Hybrid System (3)
•Fuel cells produce current and voltage outputs, higher or lower, compared to the load.
•Appropriate converter devices are required to either step up or step down the current and voltage to desirable
levels for the load.
•For normal and hybrid systems, Jossen states that “as the voltage range of a fuel cell is very high, a DC/DC
converter is necessary to deliver a more stable output voltage” (3).
•To optimize the performance between the fuel cell and battery, charge controllers, or energy management
devices, are not necessarily required, but are highly recommended.

The exact recommendations of were not followed, but only the principles and general setup of the hybrid system.
The orientation of the fuel cell device and battery are setup in parallel; this is such that both power sources will enter
the input of the DC/DC converter, and provide adequate range of power for the load.
At peak conditions, the battery will momentarily be used for spike-power.
Other modifications to the general electrical diagram were designed, based on the availability of other components,
and certain design constraints.
Jyh-Rong Chou, and Shih-Wen Hsiao conducted their prototyping and design work in Taiwan.
Chou and Hsiao (2005) state that currently, there are
over 11 million registered motorcycles with the highest motorcycle per capita density (2.1 people per motorcycle), in Taiwan.
Two-wheel motor vehicles which include motorcycles, motorbikes, motor scooters, mopeds, and motorized rickshaws
represent over 50% of the vehicle fleet in many Asian countries. (1).
List of Countries with Scooter Availability
2) Chou and Hsiao
Asian countries: The Philippines, Malaysia, South Korea, Indonesia, Thailand, Taiwan, Japan, India, and China.
European countries: Greece, Belgium, the Netherlands, the United Kingdom, Germany, France, Spain, and Italy.
Other countries: Australia, Columbia, Argentina, Brazil, and the United States.

Thursday, May 26, 2016 14List of Countries with Scooter Availability
According to Whitney Colella (2000) from Princeton University, gasoline scooters, especially in Asia, are a growing segment
because of three different reasons:
1) The average GDP per person is a little less than 10%, than of countries in Europe. Therefore, scooters are more affordable to
purchase than automobiles.
2) Population densities are increasing rapidly. Collela (2000) states , that “urban population densities are on the average; three
to five times more than that of European cities
3) Cities do not have an adequate-enough road infrastructure (2)
Hence scooters are an attractive alternative to maneuver and park due to its small size. But despite its popularity and affordability,
scooters have had a negative effect on public health.
3) Colella

Annual Scooter Sales from 1994 to 1999 (Tso, 2004)
Colella (2000) indicates that “two-stroke [gasoline engines] pollute more than conventional engines [4-stroke engines] because
they expel significant levels of unburned hydrocarbons during the dual intake and exhaust stroke, and they tend to misfire under
low load conditions” (2).
Inhaling excess gasses can lead to respiratory illnesses. “…Benzene; a hydrocarbon commonly found in exhaust gasses
has been strongly linked with a greater incidence in leukemia…” (2).
As a result of the excess pollution, it has lead government organizations to think of alternative methods of cleaner transportation,
and a new legislation to combat pollution.
“Zero emission scooter initiatives have begun in Taiwan, India, Indonesia, Bangladesh, and China” (2).
In Taiwan, there is an initiative to reduce pollution by allowing consumers to purchase non-polluting fuel cell scooters.

“The introduction of zero-emission PEM scooters could significantly reduce pollution in Asian cities.
If PEM scooters replaced 20% of the two-stroke market, this would reduce emissions of carbon monoxide, hydrocarbons,
and particulate matter by 6%, 11%, and 12% respectively” (2).
Colella’s analysis, in some aspects, is similar to the objectives of this project.
He illustrated the result of his calculations. They calculations were not shown explicitly but the qualitative results were shown
at the end.
Some tips on how to preserve the fuel cell stack, and how to handle it during operation, were also given.
The parameters, such as envelope of performance, driving characteristics, and analysis of the battery and fuel cell stack,
are more broad and long-term, compared to the scope of this project.
The objective for this project was to use conventional manufacturing and data gathering techniques, prove the proof of concept,
and to demonstrate it.

MethodologyMethodology
1. Obtain Components
Vapor Electric Scooter (5)
•24 V; 7 Ah sealed lead-acid battery
•Belt Driven Transmission
•3000 RPM motor with up to 13 mph speed
•Maximum loading weight limit: 90kg [200 lb]
•110V AC SLA charger/adapter included
•Unit Weight: 16 kg [35 lbs]
•Cost: $179.99
a. Upright position b. Folded position

1. Obtain Components
H-Power PS 250 fuel cell stack
•Proton Exchange Membrane Fuel
Cell (PEMFC) stack
•Weight: 20 kg [22.5 lbs]
•Low Temperature, low pressure, low
power system
•Rated power: 250 W
•Fully regulated with internal
components
•Accepts only hydrogen as the fuel
•Cost: $5,600.00
Ovonics hydrogen storage
metal hydride canister
•9 cm O.D., 40 cm length [3.5” O.D.,
155/8” length]
•Weight: 7 kg [15 lbs]
•Storage Capacity: Up to 85 grams,
940 std. liters [depending on operating
conditions]
•Cost: $1000.00
+

2. Evaluate Condition of Components
a. Purchase and replace worn-out ball bearings
b. Purchase new ignition switch and key
c. Purchase new set of 24V; 7 Ah batteries from BatteriesPlus in Mesa, Arizona
d. Purchase speedometer from Toys R’ Us in Chander, Arizona
a. Ball bearings b. Ignition switch
c. Two, 12V; 7 Ah SLA batteries
d. Speedometer

3. Obtain Data Parameters
To efficiently test the electrical and mechanical performance of the
scooter, the PEMFC stack, and battery, is to simulate the scooter
using an Electrodynamometer with a Variac
+
Electrodynamometer: A device that electrically, measures the amount of torque generated by a
motor, by using a variable AC power source. It consists of two rotating mechanisms concentric
within each other; a Squirrel-cage, and a Stator (Rotor). As electrical power entered, the squirrel
cage spins freely in one rotational direction. The stator also spins freely in the same direction, but is
restricted by a helical spring along the cylindrical axis.
Variac: A variable transformer that magnifies an incoming AC voltage. The purpose of the Variac is to
apply a consistent electrical load to the electrodynamometer in the form of a mechanical brake.

3. Obtain Data Parameters
The parameters obtained from the electrodynamometer test are:
•Current (A),
•Voltage (V), and
•Torque (N.m)
The parameter calculated from the data are
• Power (W)
Assume: The torque and power data observed, are pavement independent.
In other words, the rough effects of the road and surface are neglected,
We assume the scooter will be driven on a relatively smooth surface.

3. Testing of Fuel Cell and Motor
Unite Motor Manufacturing, Inc.
Model: MY1016
Voltage: 24V DC
Rated Current: 10.5A
Rated Speed: 2500 rpm
The Curves of Current and Power Vs Voltage Unit 004
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
0 5 10 15 20 25
Current (A)
Voltage(V)
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
Power(W)
Volt Vs Current
power
31.38V
334.52W
21A

4. Purchase Additional Components
Component Weight
Scooter 18.14 kg [40 lbs]
Fuel Cell Stack 9.98 kg [22 lbs]
Hydrogen MH Storage Cylinder 11.33 kg [25 lbs]
DC/DC converters & Mounting Kits 0.240 kg [0.53lbs]
Typical Rider 90.72 kg [200 lbs]
TOTAL 118.31 kg [260.82 lbs]
Parameter Value
Input Voltage [based on the PEMFC stack] 18 to 40V DC
Input Current 0 to 15A
Output Voltage 24V DC
Output Current 0 to 6.26A
Output Power >200W

5. Testing (General Layout)

5. Testing (Detailed Layout)

6. General Layout
24 V SLA Battery
Wagon
Metal Hydride
CanisterFuel Cell
DC/DC
Converters
Fuel Cell
Activate Switch

Observations and ResultsObservations and Results

Battery in
Sleep mode

Power from Battery = 0 W;
Current = 0

Hydrogen Consumption
(x)(I) / (n)(F)
X = Number of Cells in Series
I = Current (A)
n = Number of ions [n=2 for Hydrogen]
F = Faraday’s Constant [96,500 C/mole]
•Calculate hydrogen consumption for 10 A in one hour.
(40 cells)(10 A) / (2)(96,500 C/mole) = 0.002073 moles/sec
To convert to grams per Ah:
1 mol H = 2.02g, therefore (0.00273 moles/sec)(2.02 g/mol)(3600sec) = 15.072 g/Ah
Storage Capacity of metal hydride hydrogen canister: Up to 85 g
Therefore, (85 g)/(15.072 g/Ah) = 5.6 hours

•Calculate the Higher Heating Value (HHV) Efficiency of the stack
HHV = (Vcell/1.48)*100%
Vcell = Voltage per cell
STACK
Number of Cells = 40
Power = 250 W
Current = 10 A (Assumed to be 100% efficient)
Total Voltage = 25 V
Vcell = Total Voltage/Number of Cells = (25 V/40 cells) = 0.6 V/cell
Therefore HHV Efficiency of stack is HHV = (0.6 V/1.48)*100% = 40.54

ConclusionConclusion
• Concept of Fuel Cell-Battery Hybrid scooter was proven and
demonstrated
• Current and Speed increased proportionally as Torque is increased
• Resulting power from Fuel Cell dominated power from Battery
• Load tends to favor power source with a higher source potential
• Because of a reduction in size, a compact data-logger can be
implemented to log data in real-time
• Fuel Cell-Battery Hybrid scooter served the purpose of function and
utility.
• Future Recommendations
• Optimize and reduce the size and power rating of the stack (e.g. use
50 W, instead of 250 W)
• Reduce the size and replace certain components
• Perform same experiment with a smaller stack in real-time with a
data-logger

ReferencesReferences
. Chou, Jyh-Rong, & Hsiao, Shih-Wen (2005). “Product design and prototype making for an electric scooter”.
epartment of Product Design, Fortune Institute of Technology, Kaohsiung 831, Taiwan, ROC. Department of Industrial
esign, National Cheng Kung University, Taiwan 701, Taiwan, ROC. Materials & Design. Volume 26, pp. 439 – 442.
une 2005.
. Collela, Whitney G. (2000). “Market prospects, design features, and performance of a fuel cell-powered scooter”.
Mechanical and Aerospace Engineering, Princeton University, Princeton, New Jersey, U.S.A. Journal of Power Sources.
olume 86, pp. 255 – 260. November, 2000.
. Jossen, Andreas; Garche, Juergen; Doering, Harry; Goetz, Markus; Knaupp, Werner; & Joerissen, Ludwig (2005).
Hybrid systems with lead-acid battery and proton-exchange membrane fuel cell”. Zentrum für Sonnenenergie-und
Wasserstoff-Forschung, Division 3: Electrochemical Energy Storage and Energy Conversion, Helmholtzstrasse 8, 89081
lm, Germany. Journal of Power Sources, Volume 144, pp. 395 – 401. January 2005.
. Tso, Chunto, & Chang, Shih-Yun (2003). “A viable niche market-fuel cell scooters in Taiwan”. Research Division I,
aiwan Institute of Economic Research (TIER) 7FI, 16-8, Tehui St., Taipei, Taiwan, ROC. International Journal of Hydrogen
nergy, Volume 28, pp. 757 – 759. September 2003.
. World Wide Web: http://rocvision.com/ss/scottyscooters.htm. Scotty’s Electric Scooters Transportation Vapor. April, 2006.

Questions…?Questions…?

PowerPoint

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (20)

Similar to PowerPoint

Similar to PowerPoint (20)

PowerPoint