calstart fuel cell bus review short v3

Consortia ReviewCALSTART NFCB Program Awards

National Fuel Cell Bus ProgramFTA Headquarters

Washington, DCApril 8, 2010

Lawrence Wnuk PhD, Senior DirectorCopyright CALSTART 2010

Clean Transportation Technologies and Solutions

http://www.fta.dot.gov/

Copyright CALSTART 2009

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Agenda Topics

1. Brief Program Descriptions2. Status of Program Tasks

– remaining items – tests to be performed

3. Achievements, Technical/Financial Hurdles– Technology readiness of components and

subsystems4. Lessons Learned, Best Practices in Partnering

– Integration, logistics, support, training, infrastructure,

5. Communications and Outreach– Media attention and Outreach for innovative vehicles, fuels

and technologies

6. Conclusions and Recommendations



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1. Brief Program Descriptions Multi-Path Strategy for H2 in Transit

System Developments

Components Development

40’ Bus

Direct Path Projects

Component Path

Evolutionary Path

FTA Performance Objectives• Bus Cost – <5x

– Comparable Size Transit Bus

• Durability – 4 to 6 Years/ 20,000 to 30,000 hours

• Fuel Efficiency – 2x Comparable Transit Bus

• FC Bus Performance = or > Commercial Transit Bus• 2010 HD Emissions Standards• Increase Public Acceptance for

FC Bus Technology• Foster Competitiveness in FC

Bus Technologies



4IAM

CALSTARTNational FC Bus Programs

BDC

AC Transit HyRoad SunLine AFCB (Pending)

BAE Systems BUS 2010

US Hybrid BDC, IAM

40’ Bus




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Direct Path Vehicle & Systems Development

• AC Transit - Accelerated Fuel Cell bus operations underway• UTC Power - Engineer next generation Fuel Cell

with a reliability increase 2 - 4 times• Transit Bus - 40’• Heavy Duty Fuel Cell Power Plant• Hybrid Design with Energy Storage • High Efficiency Drive Systems• FC Bus Targeted Electronic Designs• Weight Reduction in Advanced Bus

– Vehicle and Sub-systems

AC Transit HyRoad Program - Van Hool, UTC Power, ISE Corp



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AC Transit HyRoad Program- Accelerated Service Shows Results

• 3 Buses Continuing to Perform Accelerated In-Service Testing• FC Reliability/Durability Improvements on Fuel Cell

– Resulted in manufacturing process and design improvements• Battery Subsystem, Two Stage Mitigation Has Been Successful

• UTC – Warranty, 6000 hrs with incentives to reach 10,000 hr• Current FC Stack has reached 5000

in service hours, maintains performance with no replacements

• Reliability >90% UTC FC Stack demonstrated in MBRC - Fuel Cell

• Balance of Plant improvements are still necessary

• Other Bus Systems also need improvement for total MBRC

• Continuing accelerated tests still very important, adding more buses

• Fuel Efficiency – 1.7x



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Evolutionary Path Vehicle & Systems Development

Scalable Designs/Applications are the Focus• Variety of Buses and Lengths

– Shuttle, School and Transit– 20’, 30’, 40’ and 60’ Articulated

• Scalable Fuel Cell Power Plant Hybrids or APU Designs• Conventional Internal Combustion

Engine (ICE), Battery or H2 ICE• Scalable Drive Systems• Selected Subsystem Designs• Targeted Industry Software

BUS 2010 Program Team - BAE Systems - Hydrogenics - EMP - SFMTA - Orion - Diversified Services




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BUS 2010 Evolutionary Path -Enhancing a Successful HEV

Better fuel economy

Lower emissions

Reduced maintenance

Better reliability

Path to future

Propulsion Control Electronics

Hydrogenics Fuel Cells for APU and H2 Storage System

Electrified Accessories

Propulsion Cooling Package

Lithium-IonEnergy StorageSystem



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BUS 2010 – Completed Vehicle Integration of Major Sub-systems

Roof Mounted H2 Storage System

Partial APU Rack Assembly, Thermal Management Unit

2 Fuel Cells

Power Plant Assembly withPropulsion Cooling Package /Integrated Starter Generator



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American Fuel Cell Bus (AFCB)- Direct Path Program Re-aligned

Full Size Fuel Cell Bus Hybrid Drive System

Program Manager - SunLine Transit Agency Supplier Partners - BAE Systems, ElDorado, Ballard

• FTA NFCBP Development Award • New purpose design fuel cell bus

– North American chassis – Lightweight bus body/chassis

design for H2 fuel components– U.S. sourced drive components– Latest-generation U.S. sourced

fuel cell (12,000 hr warranty)– New power electronics and

advanced energy storage– Unique hi-efficiency accessory

electronics• Zero Emission Bus vehicle demo in a very hot desert climate• Side-by-Side Comparisons of a Van Hool UTC Bus and BAE

System - Ballard Design

√√

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American Fuel Cell Bus (AFCB) – Direct Path Program

• New purpose design fuel cell bus– North American chassis – Lightweight bus body/chassis

design for H2 fuel components– U.S. sourced drive components– Latest-generation U.S. sourced

fuel cell – New power electronics and

advanced energy storage– Unique hi-efficiency accessory

electronics• Zero Emission Bus vehicle demo

in a very hot climate



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US Hybrid Efficient, Low-cost, Compact, Bi-directional DC-DC(BDC) Converter

• $60/kW in low production

• 150-300VDC / 300-600VDC Input Voltage Range

• 400A Input Current

• Output– Vin < Vout < 900 VDC– Power 60 kW to 200 kW

New Design

Component Path ProjectReplaces functions now custom designed for fuel cell and electric drive buses



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Component Path - BDC Plug-n-Play Electronics for Multiple Applications

• Programmable, plug-and-play, with diagnostics

• User reconfigurable via RS232 interface

• Tailored unit performance, speeds, simplifies integration

• User performs Configuration Management



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In-Service Trials Demonstrate BDC Power Converter

• Smoothes Fuel Cell Transients Improving FC Durability• Fast Response Captures More Regen Energy• Low Standby Power & High- Efficiency Reduces System Cooling Requirements • Features Together Improve Vehicle Fuel Economy

Fuel Cell

Battery

Drive System

BDC

High-frequency, Multi-phase DC-DC Power Conversion – Why Important

BDC fast dynamic response & current/voltage mode agility optimizes energy flow between fuel cell, energy storage and drive system



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Component Path Program - US Hybrid Integrated Auxiliary Module (IAM)

• Low cost, $55/hp for motor drives and $15/A for DC-DC

• Single Unit eases vehicle integration, increases reliability

• 94% Rated Efficiency, for Motor Drives and DC-DC Converter

• Motor Control– Speed, torque and Sensor-less– Hydraulic and/or Air System

Pressure Regulation– CAN Command or Analog

• Configuration User ManagedMotor Drive 1

10 hpMotor Drive 2

10 hpDC-DC Converter

200A12/24 VDC

Aux Battery

HydraulicSystem

AirSystemInput: 250-450, 500-700 VDC

Cooling: Liquid WEG < 60°C



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IAM High-frequency Switched Power Stages- accepts wide input dynamic voltage range

• Simplifies vehicle integration of auxiliary motors– Single enclosure

• Lowers cost and increases reliability by eliminating some– high voltage wiring – high voltage connectors – separate water-cooled enclosures

• IAM price < 1/3 for comparable functionality today– Even in low quantity production

• Enhances vehicle fuel economy – Vehicle CAN control allows

efficient operation and control of the auxiliary loads

US HybridIAM Characteristics

DC-DC 200A , 28.7 VDC Line regulation (±10% Input)

1 % Output

Load regulation (10- 90%)

1 % Output

Turn-on rise time

Soft-start, 300 ms typical

Storage Temperature -40°C to +85°C

Dimensions 43 x 33 x 13 cm



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2. Status of Program Tasks

Milestones and Schedule

Go

BAE Bus 2010 Test ReportDelivery

Q2Q1 Q3 Q42008

Q2Q1 Q3 Q4Q4 Q2Q1 Q3 Q4 Q2Q1 Q32007 2009 2010 2011

US Hybrid

IAM

BCDTest Reports

FinalReports

AC Transit HyRoad FC & Drive H/W Upgrade Test Report

BAESunLine AFCB Delivery

SunLine

Program Complete

Program Complete



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AC Transit Fuel Economy ~ 1.7 x Diesel

GTT

BOP H/W & S/W + CSAs Upgrades to retain performance



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AC Transit HyRoad Program- Rotable Fuel Cell Essential

• Operations with More Buses Needs Rotable FCMilestones Date

TIP Certification for NFCB Grant November 2007

Accelerated Operations (3 Buses) 2008

Accelerated Operations (3 Buses) 2009

Accelerated Operations (3 Buses) Early 2010

Prototype Bus April 2010April 20102nd and 3rd Buses April/May 2010

4th and 5th Buses June 2010

6th, 7th, and 8th Buses July/August 2010

9th Buses September 2010

10th and 11th Buses October 2010

12th Bus November 2010

• Rotable fuel cell will reduce any FC downtime

• RFC will speed continued FC performance growth



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BUS 2010 - In Platform Testing, On-Track for Fleet Testing in June

• On-Time, Within Budget

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Program planning and initiation activities

Program review meeting

System Level Requirements

Fuel Cell APU Requirements

Initial Hardware Build

LRU and Integration

LRU Testing

SIL Integration

Fuel Cell SIL Integration

Vehicle IntegrationSystemIntegration

Start Platform Testing

Start Fleet Testing Fleet Test (90day) Result Report

Fleet Test (180 day) Result Report Final Report

CompletedEngineering Tasks

System Development(In Progress)

FLEET TESTING0 Project Mobilization and Contract Development (09-07)

2008 2009 2010 2011



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3. Achievements, Technical/Financial Hurdles Achievement Highlights to Date

• Two Component Programs Completed– Electronics Price Point Close DOE 2015 Goals– Contributes to Vehicle Efficiency and Fuel

Economy

• Fuel Cell Performance– Reliability (Availability) Above 95%– Durability has Increased to 8,000 hrs,

Continuing to Grow

• Public Acceptance Very Positive



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US Hybrid BDC, IAM- Getting Hardware on the Road

Proterra Bus• Application - Fuel Cell Series Hybrid• Technology

– Bi-directional dc-dc– DC-DC Converter – Power Converter Module

• Benefits – Handling and Performance– Fuel Saving

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UTC PureMotion 120®•Application - Fuel Cell•Technology - Integrated Motor Drive



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AC Transit Line 18 – On-Road Challenge for Fuel Cell & Propulsion System

2.5 mile grade at approximately 5%

Albany

Berkeley

Oakland

UC Campus



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• 5,000 Pounds Lighter• OEM Integration• Energy Storage (Li-ion)• Lower profile

• Enhanced Electronics and Fuel Cell

– Performance– Reliability– Durability

AC Transit HyRoad – Doubled FC Durability, On a Path to a 5x Increase



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AC Transit HyRoadPassenger Survey – 429 Passengers

• ACT’s Fuel Cell Program – 84% Positive

• Program’s Effect on Opinion of Local Government – 70% Improved

• Importance of Considering Alternative Fuels – 90% Yes

• Support Expanded Fuel Cell Bus Program at AC Transit – 81% Yes



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BUS 2010: Advanced E-Accessories & Power Management; Broad Product Suite

• Seamless Operation of Fuel Cell APU with Energy Storage and Propulsion System across operating duty cycle

• Optimized Power Management– Maximize Total Fuel Economy across driving cycle– Minimize Diesel Fuel Consumption– Minimize total Emissions including engine off time

• Improved model / performance prediction of compound system

• Validated model predicts regimes where hybrid, compound hybrid/fuel cell and full fuel cell-hybrid work best

• Evaluate/demonstrate benefits of electrified accessories

• Gauge Reliability of the Technology• Enhance Public awareness and acceptance



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Achievements vs. Performance Objectives

FTA Performance Objectives

• Bus Cost – <5x – Comparable Size Transit Bus

• Durability – 4 to 6 Years/ 20,000 to 30,000 hours

• Fuel Efficiency – 2x Comparable Transit Bus

CALSTART Team Achievements

• BUS 2010, US Hybrid BDC, IAM– Bus alone < $2M

• UTC – 4 + yrs/8,000 hrs w/10,000 hr incentives

• Fuel Efficiency – 1.7x Diesel AC Transit FC Bus

40’ BusGoal -Facilitate ViableFCB Technologies

Metrics Examples of How We’re Doing

Program Objectives



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Achievements vs. Objectives (2)

FTA Goals and Objectives

• FC Bus Performance = or > Commercial Transit Bus• 2010 HD Emissions Standards• Increase Public Acceptance

for FC Bus Technology• Foster Competitiveness in FC

Bus Technologies

CALSTART Team Achievements

• Acceleration, gradeability, range, top speed (close)

• Verifying for Criteria Pollutants• AC Transit Public Survey,

SunLine Public Events• Encouraged Entry of Integrator

Team & Buy America Compliant FC Manufacturer

Metrics Examples of How We’re Doing



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4. Lessons Learned, Technology Readiness Lessons Learned

• Support Essential– Technical (People to Diagnose/Change Parts)– Logistics (Spare Parts)

• Integration– Teamwork and Coordination

• Over-all Poised for the Next Step– Beyond Demo Stage– On-Road Pilot Production Fleets (10’s of Buses)

Needed– Supplier Focus on Production Configurations to

further Reduce Cost and Increase Durability/Reliability

– Both Fuel Cell and Electronics Need More On-Road Testing



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Outreach – Internet Based

CALSTART website with NFCBP pages & documents



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Conference OutreachZero-emission, LC Bus Workshop



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6. Conclusions and RecommendationsNext Steps, Life after NFCBP

Observations• Fuel Cell Performance

– Reliability and Availability shown solid growth– Durability Increased, Continues to Grow, 20,000 Soon– Needs More On-Road Testing

• Public Acceptance Very Positive

Over-all Poised for the Next Step– Beyond Demo Stage– On-Road Pilot Production Fleets (10’s of Buses) Needed– Supplier Focus on Production Configurations to further

Reduce Cost and Increase Durability/Reliability– Logistics and Support Essential with Larger Numbers of

FC Buses in fleets



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