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Modelling and Validation of a Fuel Cell Electric Bus

Jørgen Kristoffer Tuset

Thesis submitted for the degree of Master in Renewable Energy Systems

30 credits

Department of Technology Systems

The Faculty of Mathematics and Natural Sciences

UNIVERSITY OF OSLO

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Modelling and Validation of a Fuel Cell Electric Bus

Jørgen Kristoffer Tuset

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© 2021 Jørgen Kristoffer Tuset

Modelling and Validation of a Fuel Cell Electric Bus http://www.duo.uio.no/

Printed: Reprosentralen, University of Oslo

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Abstract

Alternative powertrains for city transit buses have rapidly increased in popularity as a way to reduce emissions from the transport sector.

Modelling can be used as a valuable tool to understand what parameters are affecting the efficiency of the powertrain. This thesis presents a fuel cell electric bus model based on the Van Hool A330 FC bus equipped with a Ballard FCvelocity®HD6 150 kW PEM fuel cell. This specific bus was chosen to create a point of reference as it was in service from 2013 to 2016 in the Oslo Metropolitan area, operated by Ruter as part of the European CHIC project. The main objective is to simulate the hydrogen consumption for the fuel cell electric bus given a specific driving cycle.

To realize the objective, a proton exchange membrane fuel cell model is presented. The fuel cell model responds to operating and physical parameters and outputs cell voltage, stack voltage, hydrogen consumption, current density, efficiency and power. The fuel cell model provided a good fit with experimental data available for the Ballard FCvelocity®HD6 150 kW allowing it to be integrated into the fuel cell electric bus model with confidence. The fuel cell electric bus model responds to changes in physical parameters and outputs the hydrogen consumption, system power demand, battery state of charge and fuel cell performance metrics.

Under an extended 7,73 hour Braunschweig driving cycle with 5 kW of auxiliary load the hydrogen consumption was 10,34 kgH2/100km.

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Acknowledgement

I would like to thank my main supervisor Øystein Ulleberg for giving me good ideas and guidance and and my co-supervisors Ragnhild Hancke and Sabrina Sartori for providing valuable feedback. I would also like to thank my family and friends who helped keeping me motivated during these bizarre times.

Jørgen Kristoffer Tuset

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Contents

1 Introduction 1

1.1 Problem Statement . . . 3

1.2 Structure of the Thesis . . . 4

2 Theory and Literature 5 2.1 Proton Exchange Membrane Fuel Cell Basic Chemistry . . . 5

2.2 PEMFC Model . . . 6

2.2.1 Theoretical Fuel Cell Potential . . . 6

2.2.2 Real cell voltage . . . 7

2.2.3 Ideal Cell Voltage . . . 8

2.2.4 Activation Polarization Losses . . . 9

2.2.5 Membrane Water Content . . . 11

2.2.6 Ohmic Losses . . . 12

2.2.7 Concentration Polarization . . . 13

2.2.8 Cell and Stack Performance . . . 14

2.2.9 Water Transport . . . 15

2.3 Bus Modelling - QSS Toolbox . . . 18

2.3.1 Driving Cycle . . . 19

2.3.2 Vehicle Forces . . . 20

2.3.3 Simple Transmission . . . 21

2.3.4 Electric Motor . . . 22

2.3.5 Battery . . . 22

3 Methodology 24 4 Experimental 26 4.1 Fuel Cell Modelling . . . 26

4.1.1 Assumptions . . . 26

4.1.2 Constants, Parameters and Inputs . . . 27

4.1.3 Fuel Cell Model Validation . . . 28

4.2 Ballard FCvelocity®HD6 150 kW Simulation . . . 32

4.2.1 Operating Parameters . . . 32

4.2.2 Simulation Results and Validation . . . 32

4.2.3 Exporting Simulation Results to the FCEB Model . . 36

4.3 FCEB Modelling . . . 36

4.3.1 Parameters and Sizing . . . 37

4.3.2 Auxiliary Load . . . 38

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4.3.3 Fuel Cell Compressor . . . 38

4.3.4 DC/DC Converter . . . 38

4.3.5 Simple Control System . . . 38

4.3.6 Simulation Results . . . 40

5 Discussion 44 5.1 Fuel Cell Model Evaluation . . . 44

5.1.1 Ballard FCvelocity®HD6 150 kW Evaluation . . . 46

5.2 FCEB Model Evaluation . . . 46

6 Conclusions and Future Work 49 References 51 A Appendix 58 A.1 Fuel Cell Base Model Parameters . . . 58

A.2 FCEB Simulink Model . . . 59

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List of Figures

2.1 Overview of the model structure and calculation order (Lazar et al., 2019) . . . 6 2.2 Voltage losses in the fuel cell with the resulting polarization

curve (Ariza et al., 2018) . . . 8 2.3 Estimated water flux thorugh the membrane at various

thicknesses at 70 C. For VVP: the relative humidity were 96% cathode and 38% anode. LVP: cathode were flooded (100% liquid volume fraction) and 38% RH anode. LLP: both anode and cathode were flooded. For all the tests, pressure

= 1 bar (Lazar et al., 2019). . . 16 2.4 Simplified model flow. . . 19 2.5 Braunschweig driving cycle, time-speed (Barlow et al., 2009). 20 2.6 Remy HVH410-150 DOM efficiency map (Remy, 2012). . . . 22 3.1 Overview of the workflow and thought process to answer

the problem statement. . . 24 4.1 Overview of the model structure and calculation order . . . 26 4.2 Testing the model against experimental data by SINTEF, 2019. 29 4.3 Voltage losses at 100 kPa. . . 30 4.4 Testing the model against experimental data by Wang et al.,

2003 withT=50, 70CandP=3atm. . . 31 4.5 Voltage losses at 70C. . . 32 4.6 Performance of the Ballard FCvelocity®HD6 150 kW simu-

lation, comparison against experimental data by Q. Li et al., 2014. . . 33 4.7 Efficiency and H2 consumption of the Ballard FCvelocity®-

HD6 150 kW simulation. . . 35 4.9 Cell voltage losses of the Ballard FCvelocity®HD6 150 kW. . 35 4.8 Polarization curve of the Ballard FCvelocity®HD6 150 kW. . 36 4.10 Power flow logic. . . 40 4.11 Charging logic determined by battery SOC. . . 41 4.12 System power demand duringBW short 5 kW cycle. Trian-

gles indicates where the total system power demand exceeds 265 kW. . . 42 4.13 Battery SOC % for the first two hours of theBW long 5 kW

cycle. . . 43

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4.14 Step current limitation during the BW short 5 kW cycle.

Positive indicates that the fuel cell could not step up to fully cover the power demand and the missing power is covered by the battery. Negative indicates the fuel cell operating at a higher power than what is demanded by the system. . . 43 5.1 Polarization curve comparison using a liquid water ratio of

0,47 versus 0,4. . . 45 5.2 Comparing the effect of platinum loading on electrodes. . . 45 5.3 Historical temperature in Oslo, sourced from www.yr.no . . 47 A.1 FCEB Simulink model . . . 60

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List of Tables

2.1 Ethalpies and entropies for fuel cell reactant and products at

25Cand 1 bar (EngineeringToolbox, 2017) . . . 7

2.2 Braunschweig driving cycle key parameters (Barlow et al., 2009). . . 20

4.1 Model inputs for the fuel cell model. . . 27

4.2 Model parameters and constants for the fuel cell model. . . . 28

4.3 Main model parameters for SINTEF, 2019. . . 29

4.4 Main model parameters for Wang et al., 2003. . . 31

4.5 Operating parameters for the Ballard FCvelocity®HD6 150 kW. . . 33

4.6 Nominal and maximum operating point for the Ballard FCvelocity®HD6 150 kW. . . 34

4.7 Bus sizing parameters and coefficients. . . 37

4.8 Partial and full braking regeneration conditions. . . 40

4.9 FCEB results for 6 different profiles. . . 41

4.10 Selected data points, reported consumption by Ruter’s FCEB. 41 4.11 Key points, reported consumption by Ruter’s FCEB. . . 42

A.1 Base parameters and constants for the fuel cell model. . . 59

A.2 Base inputs for the fuel cell model. . . 59

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List of Abbreviations and Nomenclature

Abbreviations

FCEB Fuel Cell Electric Bus

ICE Internal Combustion Engine MEA Membrane Electrode Assembly PEMFC Proton Exchange Membrane Fuel Cell SOC State of Charge

CHIC Clean Hydrogen in European Cities

Nomenclature

A Active fuel cell area,cm2 Af Vehicle cross section,m2 af Acceleration vector,m/s2 a Water activity

ai Catalyst-specific areacm2/mg C Molar concentration,mol/cm3

Cw Membrane water concentration,mol/cm3 cd Drag coefficient

Di Diffusion coefficient,cm2/s

Dλ Diffusion coefficient of water through membrane,cm2/s Ei Voltage, V

EW Membrane equivalent weight, g/mol f Membrane liquid volume water fraction F Faraday constant, 96845 C/mol

∆G Gibbs free energy J/mol

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∆Gi Activation energy, J/mol i Current density,A/cm2

i0 Exchange current density, A/cm2

i0,re f Reference exchange current density,A/cm2 iL Limiting current density,A/cm2

ji Water flow, mol/s

Kλ Hydraulic permebility of the membrane,cm2 Li Catalyst loading,mg/cm2

mf Total mass of vehicle, kg Ni Molar flux,mol/cm2s P Power, W

Pi Pressure at inlet, bar pi Partial pressure, bar Pre f Reference pressure, bar Q Heat flow, W

R Universal gas constant, 8, 3144Jmol1K1 si Liquid water volume fraction

Ti Temperature, K

Tre f Reference temperature, K vf Speed vector,m/s

Xi Molar fraction

αi Charge transfer coefficient δ Thickness, cm

ρ Density

η Efficiency

τ Electrode Tortuosity

γ Pressure dependency coefficient λ Membrane water content e Electrode porosity σ Conductivity, S/cm

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Chapter 1

Introduction

The European Union adpoted the 2030 Agenda for Sustainable Develop- ment in 2015 in which the EU has the objective of cutting 40% in greenhouse gas emissions, gain 32% renewable energy share and a 32,5% improvement in energy efficiency compared to 1990 levels. The transportation sector in the EU currently accounts for 30,8% of the total energy used with a re- newable energy share of 7,6% in 2017 (eurostat, 2019), where heavy duty trucks and buses are responsible for 6% of total EU CO2 emissions (Eu- ropean Commission, n.d.). Private sectors and governments are working hard to develop and implement alternative sources for energy generation to reduce the reliance on fossil fuels and subsequently limiting greenhouse gas emissions. In the transportation sector this has lead to exploring alter- native powertrains, such as battery electric vehicles, hybrid electric vehicles and fuel cell electric vehicles. In this work the focus is on fuel cell electric vehicles, specifically fuel cell electric buses (FCEB) which utilizes hydrogen fueled fuel cells and batteries in order to power the electric motor. Provid- ing a zero-emission alternative to traditional internal combustion engines (ICE).

In Europe this has led to pilot projects testing out the viability of fuel cell electric buses in cities. Three of these projects include Clean Hydrogen in European Cities (CHIC), Joint Initiative for Hydrogen Vehicles across Europe (JIVE) and JIVE 2. The CHIC project was active from 2010 to 2016, while JIVE and JIVE 2 started in 2017 and 2018 respectively and is active today (2021).

The CHIC project was one of the first large scale projects in Europe to deploy and test FCEB and hydrogen refueling stations in European cities.

The project spanned to 9 cities across Europe and one city in Canada. CHIC operated a total of 54 FCEB buses with a consumption ranging from 8 kg H2/100 km to 16 kgH2/100 km, with the average being 12,1 kgH2/100 km.

The average availability was recorded as 69% where the objective was 85%.

Comparing this to the availability of a diesel bus at 95% shows that FCEB at the time of the CHIC project were not reliable enough to fully replace a fleet of diesel buses (Ruter, 2017, Müller et al., 2017).

Combined the two JIVE projects has planned deployment of nearly 300 fuel cell buses in 22 cities, in addition to providing the necessary

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infrastructure, making it the largest deployment in Europe to date. The end goal is to show bus operators the commercial viability of fuel cell buses without subsidies. The main objectives of the JIVE projects are to achieve a maximum price of€650.000/€625.000 (JIVE/JIVE 2) for a standard 12 m bus, reach an availability of 90% and demonstrate how low cost renewable hydrogen can be obtained. The project has received funding from the Fuel Cells and Hydrogen Joint Undertaking (FCH JU) under the European Union Horizon 2020 framework (Stolzenburg et al., 2020).

The core of a FCEB is the fuel cell. In automotive applications the most commonly used fuel cell technology is the proton exchange membrane fuel cell (PEMFC) usually operating at temperatures between 60Cand 80C. A PEMFC has a fuel energy efficiency (chemical to electrical) of around 45- 60% compared to an ICE with a fuel energy efficiency of 30% (X. Li, 2006), making a FCEB more energy effective.

Vehicle modelling is a valuable tool to create more efficient powertrains, but also to compare different powertrain technologies. A few recent publications related to FCEB modelling are presented. Kivekäs et al., 2018, compared the energy consumption of 5 different bus powertrain configurations using driving cycle variation and variation in passenger load by creating 3000 synthetic cycles on line 11 in Espoo, Finland. Yulianto et al., 2017, modelled a FCEB and a battery electric bus using Matlab Simulink, comparing the battery state of charge, energy consumption and difference in mass. Jinquan et al., 2021, investigated a real time energy management strategy using dynamic programming and model predictive control for a FCEB which considers intersection speed planning for better fuel economy and to reduce the overall strain on the fuel cell.

Proton Exchange Membrane Fuel Cell

Performance of a PEMFC is visualized by comparing the total voltage losses to its real cell voltage at a given current. The goal of efficient fuel cell design is keeping these voltage losses to a minimum. PEMFC models become an important tool in exploring PEMFC performance given various parameters. The recent trend in 3D modelling of PEMFC seems to focus on one specific part related to the PEMFC performance. Zhang et al., 2017, Developed a 3D multiphase PEMFC model investigating the gas and liquid flow in channels and porous electrodes. They found that adding baffles in the cathode channels reduced the concentration polarization by increasing the oxygen concentration and aiding in water removal from channels. Mohammedi et al., 2020, investigated the effect of different cross- section shape design in a PEMFC with a single straight channel and its impact on performance and mass transfer. Cai et al., 2021, did a similar study as Mohammedi et al., 2020, investigating how adding various shaped blockades to the channel impacted the mass transfer and flow. S. Li et al., 2020, developed a 2D numerical model exploring the effect of membrane thickness on overall cell performance. They found that a thinner membrane decreased the ohmic resistance increasing the cell voltage at a given current density.

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Multi-dimensional PEMFC models are useful to create understanding and explore individual behavior in parts of the fuel cell. However these models are usually very computationally intensive and takes a lot of time to simulate. Shekhar, 2013, Did a master thesis comparing the accuracy between 1D and 3D PEMFC models, concluding that 1D models are useful for testing various operational and physical parameters for practical applications, though the results are different from the 3D models. Some recent 1D models include:

• Abdin et al., 2016, developed a 1D PEMFC model using Matlab Simulink and based the model largely on physical parameters.

• Vetter and Schumacher, 2019, published a free open reference 1D two- phase PEMFC model written in Matlab.

• Lazar et al., 2019, presented an open-source dynamic 1D PEMFC model with a low computational load making it suitable for real time applications.

1.1 Problem Statement

The open tools existing today to model buses either have no option for fuel cell operation or the fuel cell model is lacking. At the same time the available data for the large fuel cells typically used in heavy duty vehicles do not provide enough information to integrate them into a FCEB model.

This thesis will provide the equations needed to fully simulate the Ballard FCvelocity®HD6 150 kW PEMFC intended for heavy duty vehicles while disclosing all parameters and simulated performance parameters. With the end result of creating a FCEB model which can calculate the hydrogen consumption and give insight to other performance results. This creates three questions which must be answered in order:

• How accurate is this fuel cell model compared to other models and experimental results?

• What is the performance of the simulated Ballard FCvelocity®HD6 150 kW (efficiency, power output, polarization curve), and how accurate is the simulation compared to experimental results?.

• What is the consumption of the simulated fuel cell electric bus (kg H2/100km) in contrast to real reported consumption?

Scope of Work

The following main limitations and simplifications have been made:

• Infrastructure required by the FCEB such as hydrogen refueling stations have not been considered.

• The FCEB is modeled without a hydrogen supply system and a detailed compressor.

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• Custom driving cycles have not been made.

Other assumptions related to specific modelling of the PEMFC and FCEB are presented in their respective chapters.

1.2 Structure of the Thesis

The governing equations required to model the PEMFC and FCEB are presented in chapter 2 where each sub-chapter covers a specific part. The approach used to tackle the problem and split it into smaller parts is presented in Chapter 3. Chapter 4 contains the validation and results of both the PEMFC and FCEB model. The results from chapter 4 and theory from chapter 2 are combined in chapter 5, where model results and the background theory are evaluated. At the end, the conclusion and ideas for future work are presented in chapter 6 .

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Chapter 2

Theory and Literature

2.1 Proton Exchange Membrane Fuel Cell Basic Chem- istry

A proton exchange membrane fuel cell (PEMFC) is an electrochemical device which converts chemical energy into DC electricity. The three main active components of a PEMFC are an oxidant electrode (cathode), a fuel electrode (anode) and a membrane between them. This composition is called the membrane electrode assembly (MEA). The PEMFC utilizes a polymer membrane which is impermeable to gases, but allows proton transport. Reactant gases are delivered to the electrodes causing the electrochemical reaction to occur at the surface of the catalyst between the electrolyte and membrane. At the anode, hydrogen splits into protons and electrons, where the electron travel through current collectors on to the outside circuit where useful work is performed on an external load before returning to the catalyst side of the membrane. The hydrogen proton goes through the polymer membrane. On the cathode side the hydrogen proton and electron react with the supplied oxygen producing water (Babir, 2013).

The half cell reactions are as follows (X. Li, 2006):

Anode:H2−→2H++2e Cathode: 1

2O2+2H++2e−→H2O (Eq. 2.1) Combining the two half cell reactions yields an expression for the overall cell reaction, where W is the electric energy output:

H2+1

2O2 −→ H2O +W+Waste Heat (Eq. 2.2) This only covers the MEA, while a full fuel cell system needs additional support components to function optimally which include (Babir, 2013):

• Continuous supply of reactant gases given at a set temperature and humidity.

• Cooling system to maintain operating temperature.

• DC/DC converter for a steady output voltage supplied to the system.

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2.2 PEMFC Model

The PEMFC model used in this project is an open-source one dimensional model developed by Lazar et al., 2019 with additions related to partial pressure and concentration. The model is written in MATLAB and runs inside Simulink. It is built upon simplified equations in order to reduce the computational demand, meaning the PEMFC model can be integrated into a vehicle model. Based on the variable inputs and the set physical parameters the model outputs cell voltage, stack voltage, power, efficiency and hydrogen consumption. Figure 2.1 shows the basic model structure.

Figure 2.1: Overview of the model structure and calculation order (Lazar et al., 2019)

The next chapter will explain the mathematical equations forming the model.

2.2.1 Theoretical Fuel Cell Potential

The theoretical maximum amount of electrical energy is given by Gibbs free energy, ∆G. Gibbs free energy is given by the change in enthalpy of the system while subtracting the product of temperature and change in entropy. For a system at constant temperature and pressure this can be written as (Doan et al., 2020):

∆G=∆HT∆S (Eq. 2.3)

As mentioned, for an electrochemical cell the maximum amount of work done or received is correlated to Gibbs free energy:

Wel =G (Eq. 2.4)

The relationship between and electrochemical cell and gibbs energy can further be written as:

Wel =G=−nFEcell (Eq. 2.5)

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Where:

n = is the number of electrons per molecule (for H2 = 2 electrons per molecule .

F = the faraday constant of 96,485 C/mol.

Re-arranging Eq. 2.5 gives the theoretical fuel cell potential (Norby, 2020):

Ecell = −G

nF (Eq. 2.6)

To calculate ∆G for fuel cell reaction Eq. 2.3 is used together with an enthalpy and entropy table:

∆Hf @ 25C(kJ/mol) ∆sf@ 25C(kJ/mol)

HydrogenH2 0 0,1307

Oxygen,O2 0 0,2052

H2O(l) -285,8 0,070

Table 2.1: Ethalpies and entropies for fuel cell reactant and products at 25C and 1 bar (EngineeringToolbox, 2017)

Applying the fuel cell reactants and products gives the following equation (Khotseng, 2019):

∆G(l) = (Hf)H2O(l)−T−(sf)H2O(l)−(sf)H21/2(sf)O2=−237.1kJ/mol (Eq. 2.7) Inputting ∆G, n and F into Eq. 2.6 calculates the theoretical fuel cell potential:

Ecell = −∆G

nF = 237100J mol

1

2∗96485C mol1 =1, 23V (Eq. 2.8) The theoretical fuel cell potential at 25Cand 1 bar is 1,23V.

2.2.2 Real cell voltage

The estimated real cell voltage Ecell is based on subtracting the various voltage losses happening inside the cell from the ideal cell voltage ET,p. These losses are summarized as activation polarization lossesEact,i, ohmic lossesEohmand concentration polarization lossesEcon(Babir, 2013). As seen in the equation below.

Ecell = ET,p−Eact,i−Eohm−Econ (Eq. 2.9) Figure 2.2 shows how the losses inside the fuel cell affects the resulting polarization curve. A polarization curve shows the voltage output for a given current density (current per unit area of the surface). The calculations behind the losses are explained in the next sub chapters.

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Figure 2.2: Voltage losses in the fuel cell with the resulting polarization curve (Ariza et al., 2018)

2.2.3 Ideal Cell Voltage

The theoretical fuel cell voltage changes with both temperature and partial pressure. Substituting Eq. 2.3 into Eq. 2.6 yields an expression on the effect of temperature (Babir, 2013):

ET =− ∆H

nF − T∆S n f

(Eq. 2.10) Where∆His the change in enthalpy while∆Sis the change in entropy.

The effect of partial pressure can be expressed using the Nernst equation. The Nernst equation relates how the electrochemical potential changes with the partial pressure and is derived from Gibbs free energy. It is written as (Lower, 2021):

E=ERT

nFlnQ (Eq. 2.11)

Where Q is the reaction quotient. The partial pressure of the reactants are given as a function of the saturation pressure of water, reactant pressure and temperature. Where the saturation pressure of water (atm) is calculated by (Springer et al., 1991):

log PH2O =−2, 1794+0, 02953∗Tc−9, 1837∗105∗Tc2+1, 4454∗107∗Tc3 Tc =Temperature in Celsius.

(Eq. 2.12)

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The partial pressure of hydrogen and oxygen are given by Spiegel, 2008:

pH2 =0, 5∗ PH2

exp(1, 653∗i/Tan1,334)−PH2O pO2 = PO2

exp(4, 192∗i/Tcat1,334)−PH2O

(Eq. 2.13)

When considering a fuel cell reaction using hydrogen and oxygen, the Nernst equation becomes (Babir, 2013):

EP = E0+ RT nF ln

pH2p0,5O

2

pH2O

(Eq. 2.14) Combining Eq. 2.10 and Eq. 2.14 yields an expression for the ideal cell voltageET,P:

ET,P =− ∆H

nF − T∆S n f

+ RT

nF ln

pH2p0,5O

2

pH2O

(Eq. 2.15) The changes brought by enthalpy∆Hand entropy∆Swith temperature can be neglected as the error is very small below 100 C (Babir, 2013), Eq.

2.15 can then be written as :

ET,P =1, 482−0, 000845T+0, 0000431T ln

pH2p0,5O

2

(Eq. 2.16) 2.2.4 Activation Polarization Losses

Activation polarization is the activation overpotential required for the cell to overcome the activation energy needed to get the reaction started.

This is the voltage difference from the equilibrium potential of the cell (Menictas et al., 2014). Activation overpotentials result from the resistance to electrochemical reaction kinetics in the anode and cathode, meaning the speed in which the reaction can occur. In the case of fuel cells the oxygen reaction need higher overpotentials, giving that oxygen reaction is a lot slower compared to the hydrogen oxidation (Babir, 2013).

The activation overpotentialEact,i can be estimated based on the Butler- Volmer equation. The Butler-Volmer equation describes the relationship between electrode potential and current density (Dickinson and Wain, 2020).

i=i0

exp

αRdF(E−Er) RT

−exp

αOxF(E−Er) RT

(Eq. 2.17) Butler-Volmer equation (Babir, 2013)

Where:

• i= electrode current density, A/m2

• i0= exchange current density, A/m2

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• E= Electrode potential, V

• Er= Equilibrium potential, V

• T= Temperature, K

αRd = Charge transfer coefficient, reduction

αOx= Charge transfer coefficient, oxidation

• F= Faraday constant

• R= Universal gas constant

Assuming that αRd = αOx, Eq. 2.17 can be inverted yielding the activation potential: (Marangio et al., 2009):

Eact,i = RTi

αiFarcsinh i

2i0,i

(Eq. 2.18) This equation can be applied to both the anode and cathode:

Eact,an = RTan

αannFarcsinh i

2i0,an

(Eq. 2.19)

Eact,cat = RTcat

αcatnFarcsinh i

2i0,cat

(Eq. 2.20) In order to use the equations above the exchange current density i0

is needed. The exchange current density in electrochemical reactions is similar to the reaction rate constant found in chemical reactions which quantifies the speed of the reaction. By utilising a reference exchange current density (value at 25Cand 1.0125 bar) the exchange current density for any temperature and pressure can be calculated by (Babir, 2013):

i0 =ire f,i0 aiLi Pr

Pre f γ

exp

Gi RTi

1− Ti

Tre f

(Eq. 2.21) Where:

• ire f,i0 = reference exchange current density per unit catalyst area.

Anode = 1∗103Acm2, cathode = 1∗109Acm2

• ai= catalyst specific area,cm2mg1

• Li= catalyst loading,mg cm2

• Pr= reactant partial pressure, bar

• pre f = reference pressure, 1,025 bar

γ= pressure dependency coefficient, 0,5

• ∆Gi = activation energy,kJ mol1

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• R= universal gas constant, 8,314J mol1K1

• T= temperature, K

• Tre f = reference temperature, 298, 15K(25C)

A high exchange current density means the surface of the electrode is more active, this results in lowering the energy barrier needed by the charge in moving from electrolyte to catalyst surface, and vice versa (Babir, 2013).

Song et al., 2007 showed that the activation energy∆Gi varies under real operating conditions, but for simplicity reasons constant values are chosen.

2.2.5 Membrane Water Content

The water content λ inside a Nafion-membrane is estimated by using a function of water activity a. This polynomial equation was fitted by Springer et al., 1991 based on their experimental results.

λ=0, 043+17, 81a−39, 85a2+35, 0a3 f or0<a≤1 (Eq. 2.22) λ=14+1, 4(a−1) f or1<a ≤3 (Eq. 2.23) Distribution of water in the membrane is assumed to be uniform (Lazar et al., 2019). The water activityais given by (Jiao and Li, 2011):

a=RH+2s (Eq. 2.24)

WhereRHis the relative humidity andsthe liquid water volume fraction in the pore regions of the membrane. In this model it is assumed that liquid water only exists in the catalyst layer of the fuel cell. In order to account for nonhomogenenous water distribution inside the channels a logarithmic average is used forRHands(Lazar et al., 2019).

The equation for estimating the maximum amount of non-frozen water membrane water during a cold start at subzero temperatures is given by Jiao and Li, 2009 and is based on the experimental results by Thompson et al., 2006.

λsat =





=4, 837 i f T <223, 15K

= [−1, 304+0, 01479T−3, 594∗105T2]1 i f 223, 15K≤T <Tf rost

>λn f i f T ≥Tf rost

(Eq. 2.25) Saturated membrane water contentλsat, (Jiao and Li, 2009)

The non-frozen water concentration Cw in the membrane is estimated by using a proportional correlation between the membrane density ρmem, polymer equivalent weightEWand the water contentλ(Babir, 2013).

Cw= ρm

EWλ (Eq. 2.26)

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2.2.6 Ohmic Losses

The ohmic resistance inside the fuel cell occurs due to the resistance of electron flow through the various fuel cell components such as electrolyte, electrodes, current collectors and their physical contact points. Using Ohm’s law to describe the losses gives:

Eohm =iRi (Eq. 2.27)

wherei=current density andRi= the total resistance of the cell. The total losses can be summarized as (Abdin et al., 2016):

Ri =Rel+Rpl+Rmem (Eq. 2.28) Where the contributing resistances are:

• Rel= electrodes.

• Rpl= bipolar plates.

• Rmem= membrane.

According to Babir, 2013, the electronic resistance contribution is so small it is negligible. Through experimental results Laurencelle et al., 2001, showed that the ohmic overpotential is mostly related to the membrane humidity and cell temperature. Thus in this model only the ionic loss caused by the membrane resistance is considered. The ohmic overpotential is then calculated based on Ohm’s law (Abdin et al., 2016):

Eohm = δmemi

σmem (Eq. 2.29)

where σmem is the membrane conductivity and δmem is the membrane thickness (when wet). The membrane thickness is assumed to be constant.

(Lazar et al., 2019).

The membrane conductivityσmem is given by fitting experimental data by Weber and Newman, 2004:

σmem =1, 16max{0,f −0, 06}1,5exp

15000 R

1 Tre f1

T

, (Eq. 2.30) Tre f =353, 15K(80C), f = λVW

λVW+Vm, (Eq. 2.31) Vm = EW

ρmem, VW = 18, 01528

ρW(T) (Eq. 2.32) Where f represent the water volume fraction of the membrane. Calculated byVm, the membrane equivalent weightEWdivided by membrane density ρmem, and VW the molar volume of liquid water divided by the water densityρW(T)(Vetter and Schumacher, 2019). The density of waterρW(T) at 1 bar can be estimated by (Lazar et al., 2019).:

ρW(T) =999.972−7∗103(T−4)2∗103 (Eq. 2.33) Calculated inkg m3

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2.2.7 Concentration Polarization

Concentration polarization occurs when the fuel and oxidant is rapidly consumed at the electrodes and concentration gradients (when the con- centration is higher in one area than the other) are formed. The Nernst equation relates how the electrochemical potential changes with the partial pressure or concentrations. This is also known as nonstandard conditions.

∆V= RT nF ln

CB

CS

(Eq. 2.34) Nernst equation

Where:

CB = bulk concentration of reactant, mol cm3

CS= concentration of reactant at the surface of the catalyst, mol cm3 (Babir, 2013).

By utilzing Fick’s law of one dimensional diffusion and Faraday’s law of electrolysis this relationship is obtained (Babir, 2013):

i= n f ∗Di∗(CB−CS)

δe (Eq. 2.35)

WhereDiis the diffusion coefficient.

The current density at the point where the reactant is consumed at the same pace as it is reaching the surface of the catalyst is known as limiting current density. At this current density the surface concentration of reactants equals 0 and the fuel cell is unable to produce a higher current. By using the previous equation Eq. 2.35 and CS = 0, i = iL, the limiting current density becomes:

iL = nFDiCB

δe (Eq. 2.36)

The bulk concentrationCb is estimated by the ideal gas law and mole fractions of reactant in the gas mixture. Mole fractions are calculated by (X.

Li, 2006, Musio et al., 2011):.

XH2O = PH2O P XH2 =1−XH2O

XO2 = 1−XH2O 1+ (79/21)

(Eq. 2.37)

The total concentration in the mixture is given by the ideal gas law:

C= P

RT (Eq. 2.38)

And the bulk concentration becomes:

CBi =Xi∗C (Eq. 2.39)

WhereidenotesH2orO2from Eq. 2.37.

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By combining the three equations Eq. 2.34, Eq. 2.35 and Eq. 2.36 the following equation is obtained which relates the voltage losses in the fuel cell due to concentration polarization (Babir, 2013):

Econ= RT nFln

iL

iL−i

(Eq. 2.40) Eq. 2.40 can underestimate the real concentration polarization losses and a gain factor K is added to better approximate the behaviour of the polarization curve. The gain factor makes the curve more aggressive and decreases earlier than with just the equation alone (Musio et al., 2011).

To calculate the diffusion coefficient D found in Eq. 2.36, Vetter and Schumacher, 2019, utilized the Chapman-Enskog formula in addition to a saturation correction(1−s)(Rosén et al., 2012).

Di = e

τ(1−s)3Di,re f T

Tre f

1,5Pre f Pi , Tre f =353, 15K; Pre f =1, 01325bar

(Eq. 2.41) In the model it is required to add an external reference value for the diffusion coefficient Di,re f. This reference value is then adjusted per Eq.

2.41 using electrode porositye, tortuosityτ, temperatureT, pressurePand the ratio of liquid water volumes. The liquid water volumes has a value between 0 and 1 where 1 serves as a fully flooded channel. (Lazar et al., 2019). For the reference diffusion coefficientDi,re f the following values are used (Vetter and Schumacher, 2019):

• DH2,re f =1, 24cm2/s(hydrogen in water vapor)

• DO2,re f =0, 28cm2/s(oxygen in air)

• DH2O,re f =1, 24cm2/s(Water vapor in hydrogen, anode side)

• DH2O,re f =0, 36cm2/s(water vapor in air, cathode side) 2.2.8 Cell and Stack Performance

Fuel cell efficiency is the ratio between work produced (electricity) and fuel (hydrogen) consumed. The electrical efficiency in this model ηelectric is based on the lower heating value of hydrogenELHV. Using Eq. 2.6 and

∆HLV H =242kJmol1, the theoretical voltage is calculated in Eq. 2.42. The heat flowQis calculated by using the power delivered by the fuel cell and the efficiency and is given in Eq. 2.44. It is assumed that the product water evaporates and leave the stack(Babir, 2013).

ELHV = −∆G

nF = 242kJmol

1

2∗96485 =1, 254V (Eq. 2.42) ηelectric = Ecell

ELHV (Eq. 2.43)

Qstack =

Pstack ηelectric

−Pstack (Eq. 2.44)

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Fuel cell stack heat flow.

2.2.9 Water Transport

The transport of water jw from anode to cathode is split into three parts:

osmotic josmo, diffusive flow jdi f f and hydraulic permeation jhyd. The equation for the cathode has jgen, which is the water produced on the cathode side as a result of the electrochemical reaction. Whenjwis positive the water concentration increases (Lazar et al., 2019).

jw,anode = jdi f f +jhyd−josmo (Eq. 2.45) jw,cathode= jgen+josmo+jhyd−jdi f f (Eq. 2.46) The rate in which water is produced on the cathode side (mol1cm2) is (Babir, 2013):

jgen = i

2F (Eq. 2.47)

Three assumptions are made to reduce the water transport complexity (Lazar et al., 2019).

• Only water transport through the membrane is considered. Other water transport mechanisms (both liquid and vapour) related to the porous catalyst layer and gas diffusion layers are ignored.

• Liquid water is only present when the gas mixture has been saturated.

• The two water phases, liquid and vapour, are not utilized directly.

Using experimental data from Adachi et al., 2010, Lazar et al., 2019 used a curve fitting tool in order to adjust the equations for the diffusive and hydraulic flow. The three cases show permeation of water flux through Nafion membranes at various thicknesses based on water phase and differential pressure at 70 C. The three cases are: vapor-vapor (VVP), liquid-vapor (LVP) and liquid-liquid permeation (LLP) and is displayed in figure 2.3.

The next part will show the different equations which make up the sub- parts of jw. In addition, the experimental data is used later to adjust the equations used for calculating diffusive and hydraulic flow.

Osmosis

Osmosis is movement of water through the membrane. In the case of fuel cells, water is dragged from the anode to the cathode. This is also known as electroosmotic drag. The water transport due to this effect can be written as (Babir, 2013):

josmo =nosmoI

F (in mols1cm2) (Eq. 2.48) Wherenosmo is the electroosmotic drag coefficient which is defined as the number of water molecules per proton. According to Babir, 2013 this

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Figure 2.3: Estimated water flux thorugh the membrane at various thicknesses at 70 C. For VVP: the relative humidity were 96% cathode and 38% anode. LVP: cathode were flooded (100% liquid volume fraction) and 38% RH anode. LLP: both anode and cathode were flooded. For all the tests, pressure = 1 bar (Lazar et al., 2019).

coefficient has varied greatly in published papers over the years due to different methods of measurement and data fitting. In this model an equation from Dutta et al., 2001 is used for estimating the electroosmotic drag coefficient, which is reliant on the (average) water content in the membraneλ.

nosmo =0, 0029λ2+0, 05λ−3, 4∗1019 (Eq. 2.49) Diffusion

The effect of water generation and electroosmotic drag on the cathode side often results in flooding on the cathode side and drying out the anode side.

However back diffusion creates a counter flow which helps against drying the membrane on the anode side (Ji and Wei, 2009). The flow of water from this process can be estimated by integrating Fick’s law through the membrane (Abdin et al., 2016):

jdi f f = ADλCw

δmem (Eq. 2.50)

Where: A= the cell area, Dλ = the average diffusive coefficient of water,

∆Cw = the difference in water concentration between the anode and cathode, and δmem = membrane thickness. In this equation δmem is set as a constant with a value of 201µm. This equation is used as a reference in order to calculate the diffusion for the VVP and LVP scenarios.

The diffusion coefficientDλ used in Eq. 2.50 is estimated by Vetter and Schumacher, 2019 who refitted the measurement data done by Mittelsteadt

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and Staser, 2011. The resulting equation is dependent on water contentλ and membrane temperatureTmem.

Dλ = 3, 842λ

3−32, 03λ2−67, 74λ λ3−2, 115λ2−33, 013λ3+103, 37

∗106exp

20∗20000 R

1

Tre f1 Tmem

, Tre f =353, 15K

(Eq. 2.51)

The next three equations use the correction for VVP and LVP as mentioned earlier and is based on the data points from figure 2.3. When there is a mixture of gaseous and liquid phases a linear scaling based on jdi f f,vvpandjdi f f,lvpis applied (Lazar et al., 2019).

jdi f f,vvp =0, 9178∗jdi f f(σ|0, 0201)(−947, 5δ2mem−6, 198δmem+1, 508) (Eq. 2.52) jdi f f,lvp=3, 592∗jdi f f(σ|0, 0201)(−687δ2mem−21, 73δmem+1, 714)

(Eq. 2.53) jmix =jdi f f,vvp+ (jdi f f,lvp−jdi f f,vvp)∗ |(sanode−scathode)| (Eq. 2.54) Where VVP-correction is used in when there is no liquid water and LVP if one side is flooded with liquid water.sin Eq. 2.54 refers to the liquid water volume fraction.

Hydraulic Permeation

Hydraulic permeation occurs when there is a pressure difference between the anode and the cathode. With this pressure difference water can be pushed through the membrane (Babir, 2013). This effect is only considered when liquid water is present in both anode and cathode. The water flux related to hydraulic permeation is given by (Jiao and Li, 2011):

jhyd= ACwKλ

µwδmemP∗ 105 (Eq. 2.55) jhyd is linearly correlated with the pressure gradient ∆P, which is the pressure difference between both sides of the membrane. ∆P is affected by the cell area A, water concentration in the membrane Cw, hydraulic permeability Kλ, dynamic viscosity of waterµw and membrane thickness δmem.

The dynamic viscocity of water µw is estimated by a function of temperature and constants (Likhachev, 2003):

µw=µ0exp

aµp+ Eµ−bµp R(T−θµ−cµp)

(Eq. 2.56) Likhachev, 2003 utilized tabulated values from experimental data contain- ing the viscosity of water at various temperatures and pressures. The con- stants found which fit the formula are:

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µ0=2, 4055∗105 Pa·s(Pascal-second and reference value)

• aµ =4, 42∗104bar1

• Eµ =4, 753kJ mol1

• bµ=9, 565∗104kJ(mol bar)1

θµ=139, 7K

• cµ =1, 24∗102K bar1

The pressurePof Eq. 2.56 is ignored as the pressure levels a typical PEM fuel cell operate at is low enough that p only has a minor impact on the water visocityµw(Lazar et al., 2019).

Jiao and Li, 2011 suggests the following relationship between hydraulic permeability Kλ and membrane water content λ, using a constant value Kw =2, 86∗1020:

Kλ =Kwλ (Eq. 2.57)

From the experimental data by Adachi et al., 2010, the correlation between hydraulic flow of water and the membrane thickness appears to be nonlinear. Thus to better estimate the hydraulic flow an adjustment function is applied. This function takes the membrane thickness into account and is at a reference pressure difference of 0,025 bar (Lazar et al., 2019):

Kλ,LLP













=0, 1158Kλ

5, 749∗103 δmemexp[−1, 326] forδmem≥0, 005cm

=0, 1158Kλ

2, 518∗104 δmemexp[−1, 872] forδmem<0, 0056cm

(Eq. 2.58)

At last the hydraulic flow is corrected for the pressure difference between anode and cathode, where jhyd,re f is jhyd from Eq. 2.55 after applying the correction from Eq. 2.58, Lazar et al., 2019:

jhyd,LLP = jhyd,re f(32, 41δp+0, 06016) (Eq. 2.59)

2.3 Bus Modelling - QSS Toolbox

The QSS Toolbox is a vehicle simulation library designed for Matlab Simulink. It is developed by ETH Zürich Insitute for Dynamic Systems and Control. The model built by the QSS Toolbox is simulated in a quasistatic approach, meaning the model is built "backwards". Instead of calculating the vehicle speed from forces, the model calculates acceleration from the velocity given by a driving cycle and determines the forces acting on the vehicle in each time step (1s) (Guzzella and Sciarretta, 2013).

The inputs for the system are speedvand accelerationa, supplied by a driving cycle. The forces acting on the wheels are calculated in each time

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step. For each time step the vehicle is assumed to run at a constant speed and acceleration. The forces acting on the wheels are used as input for the transmission gear which outputs the required torque and revolutions per minute (rpm) to the motor. The motor in turn calculates the energy required to move the vehicle at the current speed and acceleration and feeds the energy requirement to the control system which distributes the load to the fuel cell and battery. The control system is not a part of the QSS library. Figure 2.4 display a simplified model flow. The next sub-chapters will explain the relevant modelling blocks and their equations as described in the included QSS manual (Guzzella and Amstutz, 2005) or by examining the calculation flow within Simulink.

Figure 2.4: Simplified model flow.

2.3.1 Driving Cycle

The driving cycle provides input to the system and is sourced from a normalized test drive or test cycle. A driving cycle is defined by at least two vectors: A time vector and a vehicle speed vector. The acceleration vector is calculated from the supplied speed vector using:

af(k∗h) = vf(k∗h+h)−vf(k∗h

h ,k=1, . . .kmax−1, af(kmax) =0 (Eq. 2.60) Where k is the current time of the simulation, h is the size of time-step, and vf the vehicle speed. The driving cycle used in this model is the Braunschweig cycle, measured in the Lower Saxony German town of Braunschweig. This driving cycle is frequently used to model city buses.

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The cycle is characterized by "stop and go" driving with a low amount of cruising at a steady speed. The key parameters are listed in table 2.2 and the time-speed graph in figure 2.5.

Figure 2.5: Braunschweig driving cycle, time-speed (Barlow et al., 2009).

Parameter Value

Duration 1740s

Max speed 58, 2km/h

Average total speed 22, 6km/h Average driving speed 27, 03km/h

Distance 10, 9km

Idle time 16, 55%

Stops per km 2, 39

Table 2.2: Braunschweig driving cycle key parameters (Barlow et al., 2009).

2.3.2 Vehicle Forces

The vehicle forces are calculated on the basis of the average speed from the current and previous time-step and acceleration. The forces acting on the vehicle are split into three parts and subsequently added together to get the torque acting on the wheels (Guzzella and Amstutz, 2005).

Rolling resistance:

Froll =mf ∗g∗mu (Eq. 2.61) Aerodynamic:

Faero = 1

2∗ρ∗cd∗Af ∗v2 (Eq. 2.62)

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Inertia (resistance to acceleration):

Finertia=mf ∗(1+mt2mf)∗a

h (Eq. 2.63)

Where:

• mf = Total mass of vehicle (kg).

• mu= Rolling friction coefficient.

ρ= Air density.

• cd= Drag coefficient.

• mt2mf = Rotating mass (%).

• Af = Vehicle cross section or frontal area (m2)

The added resistance from climbing or gradients are not considered as this value is not included in the driving cycle. The speed and acceleration of the wheels are dependent on the wheel radius:

ωwheel =v∗rwheel1 (Eq. 2.64)

wheel = a∗rwheel1 (Eq. 2.65)

2.3.3 Simple Transmission

The simple transmission assumes that kinematic relationships are ideal and there are no inertia effects by backlashes, which is loss of motion caused by the gaps in gear teeth. The relationship between torque or rotational speed is fixed to the gear ratio and is given by:

ωtrans =ωwheel∗gear_ratio (Eq. 2.66) aωtrans =aωwheel∗gear_ratio (Eq. 2.67)

Ttrans+=

PGT0

ωwheel +Twheel

gear_ratio∗eGT (Eq. 2.68) Ttrans =

PGT0

ωwheel ∗eGT+Twheel

gear_ratio∗eGT1 (Eq. 2.69) Where:

ωtrans= Speed of the fly wheel, rad/s.

• aωtrans= acceleration of the fly wheel, rad/s2.

• Ttrans= torque on the fly wheel, Nm.

• PGT0= Idling losses (friction), W.

• eGT= efficiency of gearbox.

Ttrans+andTtrans−denotes if the torque flow goes from engine to wheel (+) or wheel to engine (-).

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2.3.4 Electric Motor

The electric motor requires the torque and rotational values outputted by the transmission. The output of the electric motor is the required electric power demanded by the transmission in the time-step. The motor efficiency is given based on a lookup table which relates the required torque and rotational speed to a given efficiency. The lookup table consists of two quadrants, the first quadrant is active when the vehicle is accelerating:

TEM >0 andωEM > 0. The second quadrant is active during deceleration:

TEM < 0 and ωEM > 0. The power required by the electric motor is expressed as (Guzzella and Amstutz, 2005):

PEM = ωEM∗TEM1

ηEM(ωEM, TEM) (Eq. 2.70) TEM = (aωtransθEM) +Tgear, ωEM =ωtrans (Eq. 2.71) WhereθEM = motor rotational inertia (kg∗m2). The efficiency map can be seen in figure 2.6 and is referenced to create the lookup table used in the model. It is assumed that the motor has the same effectiveness in both quadrants.

Figure 2.6: Remy HVH410-150 DOM efficiency map (Remy, 2012).

2.3.5 Battery

The input to the battery model block is electric power (W). Given a positive input the battery discharges and when the input is negative it charges. The output is the current state of charge (SOC). SOC is the current charge of the battery, relative to its maximum capacity. The power is integrated after calculating it from the known power and voltage of the battery, from which the actual battery charge is calculated. This leads to an implicit equation as the voltage is dependent on the battery charge and from the current either

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charging or discharging the battery. From the QSS Toolbox manual the equations for the charging mode are given as (Guzzella and Amstutz, 2005):

q(k∗h) = Q(k∗h)

Q0 , Q(k∗h) =Q(0) +

k

i(k∗h)∗h (Eq. 2.72) WhereQ0is the nominal capacity, andQ(0)the initial charge of the battery.

c(k∗h) = i(k∗h)

i0 , i0 = Q0

1h (Eq. 2.73)

Wherei0is the current where the battery is fully charged in one hour. C rate is the rate in which the battery is charged or discharged in 1 hour based on its nominal capacity.

Two weightsu1Landu0Lare calculated and depend on the C rate:

u1L(c(k∗h)) =CL4∗c(k∗h) +CL3 (Eq. 2.74) u0L(c(k∗h)) =CL2∗c(k∗h) +CL1 (Eq. 2.75) CL4 is the internal resistance, CL3 the varying battery voltage, CL2 the internal resistance causing the initial voltage drop, and CL1 the nominal battery voltage. These 4 variable descriptions are not explicitly stated in the QSS manual (Guzzella and Amstutz, 2005), but deducted based on similar equations in the Vehicle Propulsion Systems book (Guzzella and Sciarretta, 2013).

Using the two weightsU1LandU0Lthe battery load is calculated by:

uBL(k∗h) =uL1(c(k∗h))∗q(k∗h) +u0L(c(k∗h)) (Eq. 2.76) When the battery is discharging the equations are similar, except for the negative C rate in Eq. 2.74 and Eq. 2.75.

By using the the equations for voltage Eq. 2.74 and Eq. 2.75, in addition to the power Eq. 2.76, makes it possible to calculate the voltage as a function of power only. During charging the following equation is obtained:

uBE(k∗h) = 1 2

cL3∗q(k∗h) +cL1+

q

(cL3∗q(k∗h) +cL1)2+4∗(cL4∗q(k∗h) +CL2)∗

PBL∗(k∗h)/i0)

(Eq. 2.77) The battery power can then be written as:

PBE(k∗h) =uBE(k∗h)∗uBE(k∗h)−uEi(k∗h)

REi(k∗h) (Eq. 2.78) In discharge mode the coefficients in Eq. 2.74 - Eq. 2.77 changes from cLn to cEn. The internal resistance constants, cL2,cE2 and cL4,cE4 may change from charge to discharge. While the voltage constants have to be cL1 =cE1andcL3 =cE3, as proven with physical considerations (Guzzella and Sciarretta, 2013).

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Chapter 3

Methodology

To answer the questions set out in the problem statement, a systematic approach has been used. The fuel cell model and the FCEB model are set up individually before being combined at the end to produce the final result.

An overview of the workflow is displayed in figure 3.1 and the steps are discussed below.

Figure 3.1: Overview of the workflow and thought process to answer the problem statement.

Referanser

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