Design and Test of Pios
Hydrogen Fuel Cell Motorcycle
Jörg Weigl*, Inayati*, Hamdani Saidi*
*Institute of Hydrogen Economy,
Universiti Teknologi Malaysia,
International Campus,
Kuala Lumpur,
Malaysia.
It start with a fuel cell toy…
my first fuel cell ride!
2000
Construction
toys with
PEM-fuel cell
and metal
hydride
hydrogen
storage.
2001
“H2-power Scooter”
Fuel Cell technology can
move a person!
Buy private FC-system
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Fuel Cell Vehicle History
2001
2002
“Pios solar cycle”
“Pios hydrogen cycle”
2003
“PIOS Hydrogen Tricycle”
2003
“PIOS Hydrogen Tricycle”
Pios Hydrogen Tricycle update
2007
PIOS Hydrogen Tricycle 2007
1000 km test drive Australia
Pios Fuel Cell Motorcycle
South African Solar Challenge
Renewable Category 4000km
Shell Eco Marathon 7-9. Mai 2009
Mai 2009
“Trisikal Suria* =*Sun Tricycle”
Euro Speedway Lausitz Germany
1100Km per Liter petrol equivalent
Pios Fuel Cell
Motorcycle
Sepang Malaysia
F1 circuit
Pios Fuel Cell Motorcycle,
equipt with DAQ on
dynamometer test bench
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Content:
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Fuel Cell Vehicle History
Project Status
Concept
Fuel Cell Drive Train and Components
Dynamometer tests
Manufacturing
Launching by Prime Minister
Endurance Test/Racing and Winning
Technical Results /Outlook
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Introduction
Objective:
Design, prototyping and testing
of a motorcycle with fuel cell
drive train.
…market study:
H2Motive concept
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Concept:
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Advantages of Fuel Cell
Technology
1. Significant higher energy efficiency of 50%
compared to 30% for an internal combustion
engine system.
2. No harmful emissions, only clear water, and
a silent operation.
3. Compared with a battery powered electric
vehicle, a Fuel Cell Vehicle provides longer
cruising range.
(about 350 kilometers for the Motorbike)
4. Fast refilling of the hydrogen compared to
charging of batteries.
5. High efficiency with partial load.
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Technology in the Motorbike:
Hydrogen Tanks
(Compressed).
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Technology:
Fuel cell test bench
Max. Speed
Range
Hill slope
84 Km/h
350km
30%
FC-system Power
Combined Motor Power
Buffer Battery(LiPo)
Ultra Capacitor
7kW
10kW
2.072kWh
28F 60V
Curb mass
Aerodynamic drag
Rolling Resistance
Frontal area
290kg
0.7
0.014
1.0m²
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Fuel Cell Drive Train:
Fuel Cell System
• Type:
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Polymer Electrolyte Fuel Cell system
(PEM-FC-system) with balance of plants (BoP).
Manufacturer:
Hydrogenics
Model:
HyPM 7
Maximum power output:
7KW
Voltage level:
75 to 50 Volt
Voltage and Current at peak power:
53 Volt 140Amper
System peak Efficiency:
51% electrical efficiency
System weight (inclusive BoP)
74 kg
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Electric Motor:
• Electric Motor with controller
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Type:Axial flux, brushless, permanent magnet, hub motor
Manufacturer:
New Generation Motors Corporation (NGM)
Model:
MSF 215/125
Maximum power output:
9kW Reality 4,5kW
Nominal voltage:
48 Volt
Operation voltage range:
40- 60 Volts
Max voltage:
75 Volt
Motor peak efficiency:
95%
Motor average efficiency
92%
Motor weight (with controller): 24 kg (29 kg)
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Electric Motor 2:
• Electric Motor 2 “Booster Motor”
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Type:
DC brushless, permanent magnet motor
Transmission:
Chain with one way bear ring 3,7:1
Manufacturer:
Lynch UK
Maximum power output:
5kW
Nominal voltage:
48 Volt
Operation voltage range:
40- 60 Volts
Max voltage:
60 Volt
Motor peak efficiency:
89%
Motor average efficiency
78%
Motor weight (with controller): 10 kg (14 kg)
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Battery:
• Battery
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Type:
Manufacturer:
Capacity:
Number of cells:
Nominal Voltage:
Max. Voltage:
Weight
Lithium Polymer Battery
Eagle Picher Kokam
40 Ah
14 cells in series;
51.8 Volt
58.8 Volt
15.5 kg)
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Ultra Capacitor:
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Manufacturer:
Capacity:
Number of cells:
Max. Voltage:
Weight
Maxwell
28 F
2x4 “six pack” in series
60 Volt
4.5 kg
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Data Acquisition system
Compact Rio:
Measurement and
control hardware
based on Field
Programmable Gate
Array (FPGA)
Software is NI Lab
View.
Driver Interface
Tough book touch
screen laptop.
Locked and position
adjustable
Dynamometer Schema:
Drive test of Motors
Dynamic response test Hybrid system
Tough book touch
screen laptop.
Locked and position
adjustable
The manufacturing :
Standard frame bevor modifications
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The manufacturing:
Custom made frame with fuel cell system on board
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The manufacturing:
Carbonfieber and fiberglass
body work
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The Launching by the
Prime Minister of Malaysia:
fuel cell motorbike,
with Abdullah
Badawi, 17.9.2008
Putra jaya, Malaysia
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The News:
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Racing and Winning:
Participating in:
South African
Solar Challenge 2008
Technology Class*
4000 km endurance race
through South Africa.
28. Sept. to 8 Oct. 2008
* for
environmentally
friendly vehicles
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…hydrogen refilling:
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…finish line in Pretoria:
The winning team, H2Motive with Etianne Zind, Hairul Izmail, Prof. Hamdani Saidi, Dr. Kamarul, Kristofer Arbeus, Jörg Weigl,
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Technical Results
Efficiency:
Consumption 0.510 kg H2 per 100Km
(0.510kg x 33kW/kg =16,83kwh per 100km
equals 1,91 l Petrol per 100km
(Comparable Motorbike with 380kg total mass at 75km/h
~4l petrol 100km
~54% less consumption)
Further test
Full Drive Cycle tests with Drive train
Variations.
•Hybridized with Ultra capacitor
•Hybridized with Battery
• Dual hybridized with Capacitor and Battery
(new for fuel cell drive train in Motorcycles)
• Direct FC-drive with DC-DC converter
The future of Pios Fuel Cell Motorcycle:
„To win the puplic support for the
environment“
&
“To lead the way for green technology!“
A future FC motorbike would have a
simplified fuel cell with air cooling and
would be lighter.
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April 2010
Fuel Cell Cycle with Pios Power Pack
Base Vehicle
Gocycle - foldable electric assisted bicycle
Motor. Speed
31 Km/h (limited to 25 km/h as Pedelec in EU)
Range on Battery
10/20 km (motor only /with easy pedal assistance)
Range with Pios Power Pack 120/240km (motor only /with easy pedal assistance)
Weight Base Vehicle
17kg (with battery 3kg)
Weight converted with Pios Power Pack
23kg
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April 2010
Pios Power Pack
Pios Power Pack
System
Continues System Power
Power Peak from Hybrid system
System Voltage
Voltage Adjustments
Energy Storage
Material
Hydrogen Stored
Useful Energy
Weight
Energy Density by Weight
Hydrogen Filling System
PEM air-cooled fuel cell system
500 Watt
4.4 kW 3 min
22.2 V nominal (18-25.4 V)
optional DC/DC converter 30 to 60 V
optional DC/AC inverter 230 V 50 Hz
Compressed Hydrogen Cylinder
( 6.8 l @ 350bar)
Carbon fiber with Aluminum liner
2.94 m³ or 0.265 kg H2
4.3 kWh
9.3kg (H2 vessel 3.9kg, FC-system 3.2 kg,
H2 piping 1kg, Enclosure 1,kg,
Data Acquisition System 0.2kg)
216 Wh/kg
Standard 350 bar Hydrogen WEH TN 01 / 39
TK 15
Thank you …!
Thank You….
Dankeschön …!