Electric hydrogen fuel cell hybrid bus.pptx

Winning presentation (zonal level) of Naan Mudhalvan Autodesk Fusion design challenge.
Presentation about a electric hydrogen fuel cell hybrid bus concept.
Designed using Autodesk Fusion.

1. “Naan Mudhalvan ” Autodesk Fusion 360 Design challenge Level 3 Student names:- Jebin Kamalesh . l Jerome Christo. S Mentor Name :- Prof. Parimala Murugaveni College/ Institute name:- Government College of technology, Coimbatore

2. Electric- Hydrogen fuel cell hybrid bus The scope of the project is to design a 40 seater electric bus augmented by Hydrogen fuel cell system. Introduction & scope of work

3. Research and analysis

4. Why Why analysis Problem Root cause Solution Range anxiety Low energy density of batteries, No alternate way to reach destination at the right time in case of empty battery. Charging time Low charging rate of batteries Expensiveness, Safety concerns Inherent qualities of batteries Use Hydrogen fuel cell as an auxiliary power source to charge the batteries while running. Hydrogen has higher energy density than batteries (35 kWh/kg vs 0.1-0.27 kWh/kg) Filling a hydrogen tank will consume less time than recharging a battery.

5. To design an electric bus capable of being charged by hydrogen fuel cells. Range > 600 km Structural solar panels to power electronics and lights. Design Objectives

6. Design Process Problem definition Conceptualisation of solution Rough sketch Market analysis Refinement of concept Design individual components Sub assembly Final assembly Rendering

7. Three power sources: Fuel cell, solar & battery Novelty of Design :

8. Three phase supply wires Coolant in To vehicle control unit 400 V 3 phase AC induction motor with integrated gear box and motor control unit. Regenerative braking feature 100 kW MOTOR

9. Brake disc with anti corrosion coating Brake caliper with galvanized backing plate for friction pads *EVs have regenerative braking feature which results in less frequent usage of traditional brakes. This makes them prone to corrosion. To prevent this, several protection measures are adopted.

10. Battery management and power distribution system Battery modules Motor Fuel cells Hydrogen storage cylinders

11. Proton exchange membrane Fuel cells (2) (PEMFC)

12. Outer case Aluminium coolant tube Flexible coolant channel Cell Battery module

13. Fuel cell Water out Hydrogen + oxygen in Electricity output to battery

14. Low and optimal positioning of centre of gravity results in high stability.

15. Unconventional lightweight seat design gives more legroom and comfort.

16. Standard wheel rim design for easy production maintenance and replacement. Avoided generative design to minimise cost.

17. Generatively designed wheel optimised for easy manufacturing can be used in high end models. No sharp edges  no stress concentration, easy and safe maintenance.

18. Roof mounted hydrogen storage vessels to avoid impact on floor height. Has no impact on fuel refill. Filament wound light weight vessels can be used in high end vehicles.

19. Structural monocrystalline solar panels act as roof and power the battery without any impact on vehicle’s weight.

20. Battery pack energy estimation: Cell dimensions: 42.5 mm diameter ,110 mm height
Current capacity: 19 Ah Voltage rating: 3.99 V Configuration: 33 series* 3 parallel
33*3.99 =131.67V (Voltage adds up in series connection)
3*19 =57 Ah (Current capacity adds up in parallel connection)
3 modules in series  131.67*3 = 395V
29 modules in parallel  29*57 = 1653 Ah
Total energy available= 1653*395= 652 kWh

21. Fuel cell energy estimation Cylinder dimensions: 1500 mm length , 380 mm dia meter Volume of hydrogen stored: 170 l at 200 bar pressure 12 cylinders  2040 l at 200 bar At 0.5 kWh/ l, total energy available = 1020 kWh Assuming the efficiency of fuel cell to be ^65%, Energy available= 663 kWh

22. Range approximation: Total energy available= 652+663= 1315 kWh
Assuming ^1.8 kWh/km,
Range=1315/1.8 = 730 km. (> current average of 500 km) ^all assumptions are made in reference to currently available products of similar dimensions and specifications.

23. Dimensions : Height: 4.6 m Width 2.5 m Length 9 m Range : 730 km (approximate) Seating layout : 39+1(Driver) Hydrogen storage capacity: 34.2 kg / 2040l at 200 bar pressure Weight (With cargo): 30 tonnes 12 Hydrogen storage vessels each of 170 l capacity Charging time: 4.5 hours (150 kWh charging) < 2 hours (350 kWh fast charging) Battery life: 7 years (min) Specifications:

24. Cost estimation: Product Cost Fuel cells (2) INR 7 lakhs Hydrogen storage vessels (12) INR 3.6 lakhs Chassis, motors, wheels and suspension INR 19 lakhs Seats and covers (40) INR 1.2 lakhs Battery pack (8613 cells, 87 modules) INR 97.5 lakhs Others (lights, electronics, mirrors ...) INR 9 lakhs TOTAL INR 1.37 crores [ Based on existing components of similar specifications.]

25. Autodesk Software Usage (Technology), Specific Software workflow Design of individual components (motor, wheel, seats, battery pack, brakes...)
Creation of body and integration of individual components with body
Application of physical materials to each component.
Analysis
Minor modifications based on analysis results and peer review
Rendering

26. Presence of hydrogen fuel cell system allows the driver to drive confidently even with low charge as the hydrogen tanks can be refilled within several minutes. Low operating cost as compared to traditional gasoline powered vehicles. Reduced maintenance requirements as compared to traditional cars due to the absence of complex mechanical systems. Impact/ User Experience

27. Hi Res. Images