fuel cell based hybrid power system design for a passenger tram · 2016. 7. 4. · iii. hybrid...

Fuel Cell Based Hybrid Power System Design For A Passenger Tram

Prof. Dr. CHEN Weirong

Prof. Dr. LIU Zhixiang

Dr. ZHANG XuexiaNational Rail Transit Electrification and Automation Engineering Technique Research Centre

SOUTHWEST JIAOTONG UNIVERISTY

11th HYDRAIL, Birmingham, UK2016.07.04~05

ContentsContents

Why Fuel Cell Tram?I

Hybrid System Design for TramIII

System Layout of the TramIV

11th HYDRAIL, Birmingham, UK - 4 & 5 July, 2016

Previous Work: FC LocomotiveII

Operation of the FC Hybrid TramV

ContentsContents







I. Why Fuel Cell Trams?

Urban Rail Transportation

Traffic Jams

Air pollutions

The Twelfth Five Year Plan of China： Promote the construction of inner city rail transportation

network including subway, LRV and trams gradually; Focus on the development of heavy load, high speed and new

energy rail transportation technologies.


LRV and subway have transit privilege, tram just have transit priority;

Catenary of trams affect the development and scenery of modern city greatly

Catenary free trams are developing trend



Traction power system of trams is very expensive: Catenary tram: 20~30 million RMB/km; Energy storage tram: 30~40 million RMB/km; Third rail and Magnetic powering tram: 60~70

million RMB/km. Fuel cell powered trams do not need the ground traction

power system, will be cheaper!

MagneticThird railEnergy storage



Comparison of Fuel cell trams with traditional trams

Grid Transformer Catenary tram

Fuel cell tramReforming and refueling station

NG pipline



Technology Tram investment

Power system

investment

Tram gross

investment

Power system gross

investment

Infrastructure investment

Tram line gross

investment

Investment increase

Catenary ￥15 M/car ￥20 M/km ￥600 M ￥400 M ￥2’000 M ￥3’000 M 0%

Third rail ￥18 M/car ￥60 M/km ￥720 M ￥1’200 M ￥2’000 M ￥3’920 M 30.7%

Electromagnetic induction ￥20 M/car ￥60 M/km ￥800 M ￥1’200 M ￥2’000 M ￥4’000 M 33.3%

Energy saving ￥18 M/car ￥25 M/km ￥720 M ￥500 M ￥2’000 M ￥3’220 M 7.3%

Fuel cell ￥25 M/car ￥30 M * ￥1’000 M ￥30 M* ￥2’000 M ￥3’020 M 1.0%

Investment comparison of a 20km tram line with 40 trams in operation with different powering technologies

Construction cost is much lower than those catenary free trams, a little bit higher than catenary based trams,

Operation cost is a little bit higher than catenary based trams.



Fuel cell rail vehicles vs fuel cell buses and cars:Duty cycles of rail vehicles are far less flexible and better for fuel cell performance;Hydrogen delivery infrastructures for fixed rail transportation lines are less;Investment of rail transportation is huge enough to absorb high cost of fuel cell power systems; Passenger carrying capacity is much greater and operation cost is lower



ContentsContents







II. Previous Work: FC Locomotive

Factor Value

Fuel cell type PEMFCFuel cell power 150 kWH2 storage High pressurePressure 35 MPaH2 weight 23 kgLoco weight 45 tonsTransmission DC‐ACDimensions 13.5m×2.6m

×3.6mDesign speed 65 km/h

China’s first fuel cell locomotive -- “Blue Sky” developed by NEEC ran successfully on Jan 24, 2013.


II. Previous Work: FC Locomotive

Fuel cell system


System layout of the hydrail locomotive

Hydrogen vesselsFuel cell moduleLoco Converter Loco BrakeDriver cabinEngine cabin

III. China’s First Hydrail Locomotive

the Eighth International Hydrail Conference Ryerson University – Centre for Urban Energy, Toronto, Canada , 2013.06.11~12

ContentsContents







From 2013, under financial support of National Key S&T Developing Program from Ministry of Science & Technology (MOST), we started research work on developing a fuel cell hybrid power system for a 100% low floor tram;

Partner: Tangshan Railway Vehicle Co. Ltd (TRC); The novel tram is planned to be developed in 3 years.

III. Hybrid System Design for Trams



167. Passengers: 180.

1. Marshal: 2 cars, 100% low floor;2. Voltage: DC750V;3. Traction motors: 8×50kW;4. Axle weight: 40 tons;5. Range: 30km;6. Max speed: 60km/h;7. Passengers: 180.

1. Peak power: 500kW;2. Fuel cell voltage: 550~750V

Fuel cell power: 150kW;3. Supercapacitor voltage: 280~528V;

Supercapacitor current: 600A;Capacitance: 30F.

Hybrid Power System

GOAL

Study on key technologies of the fuel cell / supercapacitor hybrid power system and develop a 100% low floor tram modern tram with 2 cars.

Performance of Tram



1. Top design of fuel cell hybrid tram

Key

Issu

es o

f stu

dy

Development of fuel cell/supercapacitorhybrid 100% low floor tram

Study on key technologies of fuel cell/supercapacitor hybrid power system

2. Fuel cell integration and optimization

3. Hybrid power system development

1. System integration of fuel cell tram

2. Tram development and test operation11th HYDRAIL, Birmingham, UK - 4 & 5 July, 2016

Tasks Requirements:1. Weight: <1.5 tons;2. Volume：<2.8m×2.0m×0.6m;3. Waterproof, shockproof, EMC;4. Temperature: -25~40 ;5. Power system redundancy.

System layout sketch map of the fuel cell tram

1. Weight control;2. Layout optimization;3. Adaptability design.

IV. Fuel Cell Tram Developing Plan


750VDC Bus

FCS‐2550~750V 150kW

FC‐DC‐2

FCS‐1550~750V 150kW

FC‐DC‐1

LiB‐DC‐2

LiB‐DC‐1

LiB‐2500V 20Ah

LiB‐1500V 20Ah

SC‐DC‐2

SuperCap‐2528V 45F

SC‐DC‐1

SuperCap‐1528V 45F

VVVF-1

Motors

VVVF-2

Motors

BrakingResistor

Aux DC/AC

Aux Power

Energy Control Unit (ECU)

H2 Tanks

Vehicle Control Unit (VCU)

Fuel Cell Hybrid System



Tram performance calculation

Calculated speed and acceleration


Power output of the hybrid system

Total PowerPower of FCPower of LiBPower of SC


VelocityAcceleration

Fuel cell system integration


3D design of the fuel cell system Fuel cell system after integration


Fuel CellSystem in testing

Fuel cell system

Heat radiator

Fuel cell system integration



SuperCapSystem

BatterySystem

Battery and supercapacitor systems integration



Hydrogen tanks

Hydrogen tank system integration



DC/DC Converter for Fuel Cell

Fuel cell converter system



ContentsContents







Tram formation： -Mc+ T +Mc-Mc：Motor Car with driver cabin and installed bogies with motorsT：Trailer Car installed bogies without motors

Side view and top view of the tram

IV. System Layout of Trams


Traction Inverter

SuperCap System

Air ConditionerBraking Resistor

DC/DCConvertor

and Batteries

Mc Car

Top view of the Motor Car



T Car

Heat Radiator

Hydrogen Tank Module

DC/DC converter

for FC

FCS-1 Box

Top view of the Trailer Car


FCS-2 Box


Picture of the systems integrated



Picture of the hybrid tram



Items SpecificationsFuel cells PEMFC，150kW×2Batteries 396V，20AhSupercapacitors 528V，45FAcceleration 1.2m2/s （0~35km/h)Top Speed 70km/h

Ambient temperature -25 ～+42Altitude ≤1200mHumidity ≤90%H2 tank pressure 35MPaHydrogen storage 10kgRange between refuelings 40km

Specifications of the hybrid tram



ContentsContents







0 100 200 300 400 500

0

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200放

流电电

/A

时时/s

超容级电充放流电电1 堆电出流净净电1 堆电出流净净电2 力池动电充放流电电1

Power sharing between FCSs, LiB and SC

V. Operation of the FC Hybrid Tram

Current of SC-1Current of FC-1Current of FC-2Current of LiB-1

Cur

rent

(A)

Time (s)11th HYDRAIL, Birmingham, UK - 4 & 5 July, 2016

Power sharing between FCSs, LiBs and SCs


Current of FC-1Current of FC-2Current of LiB-1Current of LiB-2Current of SC-1Current of SC-2

Cur

rent

(A)

Time (s)


Two ECUs are installed inside the tram

ECUs




010203040506070

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Velocity

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(km

/h)

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FC current 电堆1总电流电堆2总电流

Cur

rent

(A)

Time (s)

-500

0

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120

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560

780

910

1112

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1516

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5354

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6162

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7172

7374

7576

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8384

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9394

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SuperCap Current超级电容1充放电电流超级电容2充放电电流

Cur

rent

(A)

Time (s)


Costumer taking a ride



Future work

Pilot running of the hybrid fuel cell tram in Tangshan;

Optimize multi fuel cell system power sharing strategy in real operation conditions;

System optimization;

Promote commercial operation tram lines in China.



Acknowledgement

Financial support from theNational Key Technology SupportProgram (2014BAG08B00) isheartily appreciated.


Thank you for your attention!

SOUTHWEST JIAOTONG UNIVERISTY

— 2016. 07. 04 —

fuel cell based hybrid power system design for a passenger tram · 2016. 7. 4. · iii. hybrid...

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