A r c h e t yp e2

Hydrogen Fuel Cell Vehicle

Final PresentationFall 2013 

Cole BoothKurtis CalkinsScott DavisBenjamin Johnson

Jeremy JohnsonJohn McGee

Alfredo SarachoAlysha Yinger

IntroductionFuel Cell Technology

OverviewHorizon H-1000XP

Fuel Cell SystemDrivetrainMotor

Motor analysisSteering System

Front axle Suspension

WheelBraking System

Analysis on Incline Analysis on Wheel

Frame Analysis Fabrication

Summary Path ForwardReferences Acknowledgements

OVERVIEW

Shell Eco-Marathon Americas Competition Prototype Fuel Cell Apr 24th – 27th 2014

Design Goals Total weight: 80 lb 1000+ mpg-e Competition compliant

INTRODUCTION

Battery Energy storage device

Energy is stored within battery itself

Ceases to produce energy when reactants are consumed (discharged)

Fuel Cell Energy conversion device

Fuel and oxidant are supplied continuously

Produces power as long as fuel is supplied

FUEL CELL TECHNOLOGY OVERVIEW

Energy Exchange Diagram (Proton Motor)

FUEL CELL TECHNOLOGY OVERVIEW

Unit Cell Forms the core of the fuel cell Converts chemical energy

contained in reactants into electrical energy

Consists of an electrolyte layer in contact with an anode and a cathode

Fuel Cell Stacking Unit cells are combined in a

cell stack to achieve the voltage and power output required for desired application

Stacking means connecting multiple unit cells in series via electrically inductive connections

Fuel Cell Diagram (site)

Developed for the Shell Eco-Marathon

12 V battery required for start up, self suffi cient afterwards

Weight Stack: 4.9 kg (10.8 lbs) Entire system: 6.8 kg (15

lbs) Peak Power: 1100 W Rated Current: 0-33 A @ 30

VDC Fuel (Reactants): Hydrogen

and ambient air (Oxygen)

HORIZON H-1000XP FUEL CELL SYSTEM

Horizon H1000-XP Fuel Cell Stack (Horizon)

HYDROGEN FLOW DIAGRAM

Key:

H2 Flow

ELECTRICAL FLOW DIAGRAM

Key:

Electrical Flow

5 . 6 2 : 1 S c a l e m o d e l

C ro s s - s e c t i o n a l a re a o f 0 . 0 1 2 8 m ²

Rey n o l d s n u m b e r ra n g e 1 0 1 , 0 0 0 -3 4 0 , 0 0 0

D ra g c o e f f i c i e n t o f 0 . 2 7 9

At 1 5 m p h , D ra g f o rc e = 2 . 3 5 N ( 0 . 5 l b f )

At 2 0 m p h , D ra g f o rc e = 4 . 3 N ( 0 . 9 7 l b f )

AERODYNAMICS

S A E S t a n d a r d J 2 2 6 3

E s t a b l i s h e s p r o c e d u r e f o r d e t e r m i n a t i o n o f v e h i c l e r o a d l o a d f o r c e f o r s p e e d s b e t w e e n 7 1 . 5 a n d 9 . 3 m p h ( 1 1 5 a n d 1 5 k m / h r ) .

F i n a l r e s u l t d e l i v e r s a m o d e l o f t h e r o a d l o a d f o r c e , a s a f u n c t i o n o f s p e e d , d u r i n g o p e r a t i o n .

• Powe r s u p p l i e d by f u e l - ce l l to e l e c t r i c mo to r

• Ch ai n d r ive wi t h f re e wh e e l h u b

• P l an e t ar y g e ar s e t f o r i n te r me d i a te g e ar re d u c t i o n

• F i n al d r ive wi t h b i ke s p ro cke t s

• G e a r rat i o o f 11. 07: 1

DRIVETRAIN

To accelerate the 90.7 kg (200 lb) vehicle at 0.14 m/s 2 a propulsion force at the rear wheel was calculated from Newton’s Second Law.

ΣFx:max=FPr op u l s i on-2F r es i s t , f-F r es i s t , r-Fd r ag

Propulsion force = 18.3 N (4.11 lb) Corresponding torque of wheel is 4.65 N-m (3.4 lb-ft) The acceleration of 0.14 m/s 2 allows the vehicle to accelerate to

required average velocity of 6.7 m/s (15 mph) in 48 seconds.

ACCELERATION ANALYSIS

Permanent magnet DC motor

200 W @ 48 VDC input

Torque: 0.420 N-m (.31 lb-ft)

Effi ciency: 88%

Max speed: 4620 rpm

Current Rating: 4.58 A

Weight: 1.1 kg (2.4 lb)

MOTOR

Clean and lubricated chain is 98% effi cient

Maximum tension occurs when accelerating from rest

83.07 N (18.67 lb) Under dynamic tension

Fatigue safety factors of; KV=1.2, KC=1.34,

KS=1.3

173.6 N (39.03 lb) Light weight bicycle chain (ANSI 41)

has max permissible working load of 1.2 kN (269.7 lb)

Vehicle application the chain has a safety factor of 6.9

CHAIN ANALYSIS

PLANETARY GEAR SET

Used for intermediate gear reduction

Gear ratio 5.0:1 Max bending

fatigue stress 587.88 psi

Max surface fatigue stress 104.2 ksi

Requires case

(surface) hardened

or fully hardened

steel for gears. Assembly weight of

1.1 lbs

Sun gear is keyed to motor shaft

Stationary ring gear

Planetary gears drive the sprocket

MOTOR MOUNT

Machined from quarter inch

6061 aluminum

Motor mounts at the face

Cradles motor to resist torque

on face and body

Weight of 0.62 lbs

Mounts to the body of the

vehicle

FEA on part

STEERING AND SUSPENSION

Steering Wheel:• Brakes• LCD display

U-JointSuspension System • Manitou Air Shock

Wheels• Low rolling resistance tires

Rack and Pinion

STEERING SYSTEM

Where:

Outer turning angle Inner turning angleL = Wheel base

R = Turning Radius

t = track width

SUSPENSION

Purposes of a Suspension System:

1. Reduce the effect of shock forces

2. Keep the tires in contact with

the road (reduce scrubbing)

3. Obtain Responsive handling

4. Support vehicle weight

5. Control the vehicle’s direction of

travel

Upper Arm

Lower A-Arm

Manitou Air Shock Axle

Knuckle

Body Mount

ANALYSIS

FEA ran on spindle during cornering. Lateral Force 437NNormal Force 359NMaterial: Aluminum 6061-T6

ANALYSIS

FEA analysis on Upper Arm and Lower A-Arm:

Upper Arm:Normal Force 359 N

Lower A-Arm:Normal Force 359 N Lateral Force 437N

Material: Aluminum 6061-T6

WHEELS

Rear wheel will utilize a chain driven freehub for increased efficiency over 2013’s hub motor design

20 in. rims have been selected to be compatible with Michelin low rolling resistance tires supplied by Shell Eco-Marathon for added efficiency

Front hubs will feature solid 15 mm through axles for added strength in order to withstand cantilever forces

Rear hub will feature solid 12 mm through axle

Design Parameters Front and rear systems

must be independently controlled by one controller each

Front and rear systems must be capable of immobilizing the vehicle independently from each other when placed on a 20% incline

Lightweight Inexpensive Hydraulic disc brakes are

recommended for stopping power

BRAKING SYSTEM

Shimano XT Hydraulic Mountain Bike Disc Brakes

Custom designed caliper mount Aluminum 6061 T6

Lightweight Strong

Material removed at strategic locations to reduce weight

Attach to spindle via carriage through bolts Easy vertical adjustment

BRAKE CALIPER MOUNTING

h-adaptive FEAFrictional force required to stop vehicle from 20 mph in 30 feet

Local yielding at corner of caliper – mount interface

Local yielding does not cause failure of assembly

CALIPER MOUNT ASSEMBLY STRESS ANALYSIS

BRAKING ANALYSIS ON INCLINE

Incline Safety Requirements Front and rear

independent actuation

Track Performance Stopping distance @ 25 mph ≤ 30 ft

Required static braking torque for competition:

78 N-m (57.5 lb-ft) 156 N-m (115.0 lb-ft)

Stopping distance (with reaction time):

16.8 m (55 ft)

BRAKING ANALYSIS FOR WHEEL

Considerations weight performance manufacturing

FRAME DESIGN

Carbon Fiber Monocoque Body

polymer honeycomb 37x increase in stiffness 9.2x increase in flexural strength 1.06x increase in weight

embedded inserts provides strong and precise

mounting

FABRICATION

Monocoque multiple female mold

CNC milled insulating foam PVA sealant sanding

hand lay-up j ig for location-dependent

inserts joining pieces

Rear Arms milled aluminum 6061-T6 takes advantage of motor

mounting lightweight

Windshield Lexan heat lamp

draping

FRAME ANALYSIS

Material Weight FOS

Displacement Stress

Al 6061-T6

0.53 kg (1.17 lb)

2.84

2.18 mm (0.008 in.)

96.9 MPa (14.1 ksi)

Al 7075-T6

0.55 kg (1.21 lb)

5.21

2.09 mm (0.008 in.)

96.9 MPa (14.1 ksi)

Finite element analysison rear arms

Analysis

550 NFinite element analysis on front wheel

mount

Practice lay-up on small-scale mold Fabricate full mold and body Purchase raw material and components Begin EdgeCam work for machined parts

PATH FORWARD

1. EG&G Technical Services, Inc. (2004, November). Fuel Cell Handbook (Seventh Edition). Morgantown, West Virginia, USA.

2. Fuel Cells: Working Principle . (n.d.). Retrieved September 11, 2013, from Fuel Cell Technology: http://www.fuelcelltechnology.info/

3. Horizon. (2013). Retrieved October 4, 2013, from Horizon Fuel Cell Technologies: http://www.horizonfuelcell .com

4. Shell Global. (n.d.). Shell Eco-Marathon . Retrieved September 11, 2013, from http://www.shell .com/global/environment-society/ecomarathon.html

5. Proton Motor . Cutting-Edge in Fuel Cell Technology . 2012: http://www.proton-motor.de

6. Shenzen Unite Industries Co. (2011). BLDC Motor BM1412ZXF 1000W . From

http://www.cn-dcmotors.com/en/ProductShow.asp?id=1927. Tsubakimoto Chain Co. (2006). The Complete Guide to Chain . from jkjhttp://chain-guide.com/toc.html8. Wong, J.Y. Theory of Ground Vehicles (Fourth Edition). 2008. John Wiley & kkSons, INC. Hoboken, NJ.

REFERENCES

Bellco Credit UnionMerrick & Co.H2 Eco-Challenger Team Joseph Cullen, MSRonald Rorrer, PhDDouglas GallagherChris Yakacki, PhDMark HadenFriends and Family

ACKNOWLEDGEMENTS

QUESTIONS

DID WE DO THIS RIGHT?

QUESTIONS