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Fuel-Cell Hybrid Vehicle System Component Development

PROJECTS
Funding
European
European Union
Duration
-
Status
Complete with results
Geo-spatial type
Other
Total project cost
€22 130 545
EU Contribution
€11 197 201
Project website
Project Acronym
HYSYS
STRIA Roadmaps
Transport electrification (ELT)
Vehicle design and manufacturing (VDM)
Transport mode
Road icon
Transport policies
Safety/Security,
Societal/Economic issues
Transport sectors
Passenger transport,
Freight transport

Overview

Call for proposal
FP6-2004-HYDROGEN-1
Link to CORDIS
Background & Policy context

Fuel-cell drive-trains for road transport applications are seen as the most promising technology for sustainable mobility, especially when fuelled with hydrogen. Until now, intensive research and development has led to significant improvements of fuel-cell (FC) technology. However, market introduction of fuel-cell vehicles (FCV) has not yet been achieved due to several reasons. One very important point is the availability of reliable series components which can be mass-produced at a low cost.

This is a prerequisite for competitive fuel-cell vehicles. On the other hand, hybridisation of cars with internal combustion engines (ICE) is also a viable option for future transport. Hybrid (ICE) electric vehicles (HEV) could help to bridge the gap until hydrogen FCVs are available on the general market. FCVs and HEVs both need low cost e-drive components.

Thus there is a need to achieve synergy between these two technologies in order to use scale effects for the cost reduction of e-drive components. With this background, the project aims at the development of low-cost components for FCV hybrids and ICE hybrids in Europe. Automotive industries, suppliers, universities and research institutes are cooperating in a common effort to make the necessary steps forward.

Objectives

Project goals were:

  • Improvement of fuel cell system components for market readiness
  • Improvement of electric drive train components (Synergies FC and ICE-hybrids) 
    for market readiness
  • Optimisation of system architecture for low energy consumption, 
    high performance, high durability and reliability
  • Optimisation of energy management
  • Development of low cost components for mass production
  • Validation of component and system performance on FC Vehicles

Project targets were:

  • Low cost automotive electrical turbochargers for air supply 
    with high efficiency and high dynamics
  • Low cost humidifiers with high packaging density
  • Low cost hydrogen sensors for automotive use
  • Effective low cost hydrogen supply line
  • High efficient, high power density drive train
  • Low cost high power Li-Ion batteries
  • Enhanced FC-drive train efficiency
Methodology

The project was structured in technical subprojects directed to three different areas of research:

Research on Standardisation and Requirements
In the sub-project 2000, all research aimed at requirements and standardisation, identification of common components and modular design, interfaces, simulation, Safety Aspects, identification of synergies with ICE-Hybrid and comparison of e-storage technologies is comprised.This sub-project has a strong link with the other sub-projects where the detailed component and system specifications are elaborated.

Research on System Components: 
Aimed at the development of innovative system components such as air supply, humidification, H2- sensors, hydrogen supply line, e-motors and batteris. This is the main focus of the project HySYS. Based on input and exchange with SP2000, the detailed system specifications are elaborated in these research activities.

Research on System level:
All system related research and the work to integrate the improved components in a base fuel cell system and the validator vehicles is done in the SP5000. Energy management and system control strategies and necessary software work is also done in SP5000. As with the system components, the detailed FC-system-specifications and vehicle specification are elaborated in this SP as well.

Funding

Parent Programmes
Institution Type
Public institution
Institution Name
European Commission
Type of funding
Public (EU)

Results

On September 21-22, 2010, the HySYS Final Event took place in Stuttgart-Möhringen, hosted by the Daimler AG.

The EU-funded Project HySYS contributed to the research of low-cost components for fuel cell (FC-) systems and electric drive systems which can be used in future fuel cell electric vehicles and other electric vehicles.

The Consortium presented the results and achievements of the project. Experts, including the European Commission, the Fuel Cell & Hydrogen JTI and industry representatives from e.g. Honda joined the event.

On a technical exhibition the main achievements of HySYS, such as an electrical turbo charger for the air supply of the fuel cell system, H2-Sensor, hydrogen metering device, humidification systems for air and hydrogen supply, a new approach for the hydrogen line, innovative high efficient e-motors, high efficient power electronics with increased cooling temperature, electric drive inverters and DC/DC converters and a lithium-ion battery system were shown. During the final event a vehicle demonstration of a Daimler Sprinter van with fuel cell electric drive train and a Fiat Panda with fuel cell electric drive train was organised to show the successful integration of the hardware- and software components that have been developed during the five years of the project.

Partners

Lead Organisation
Organisation
Daimler Ag
Address
Wilhelm-Runge-Str. 11, ULM, Germany
Organisation website
Partner Organisations
Organisation
Magna Steyr Engineering Ag & Co Kg
Address
Liebenauer Hauptstraße 317, 8041 Graz, Austria
EU Contribution
€0
Organisation
Selin Sistemi Spa
Address
Via Chiaravagna, 28, GENOVA, Italy
Organisation website
EU Contribution
€0
Organisation
Saft
Address
Rue Sadi Carnot 12, 93170 Bagnolet, France
Organisation website
EU Contribution
€0
Organisation
Avl List Gmbh
Address
Hans-List-Platz, 8020 Graz, Austria
Organisation website
EU Contribution
€0
Organisation
Robert Bosch Gmbh
Address
Robert-Bosch-Platz1, 10 60 50 STUTTGART, Germany
Organisation website
EU Contribution
€0
Organisation
Centro Ricerche Fiat Societa' Consortile Per Azioni
Address
Strada Torino, 50, ORBASSANO (TO), Italy
EU Contribution
€0
Organisation
Fuma-Tech Gesellschaft Für Funktionelle Membranen Und Anlagentechnologie Mbh
Address
Am Grubenstollen 11, 1327 ST. INGBERT, Germany
Organisation website
EU Contribution
€0
Organisation
Rivoira S.p.a.
Address
Via Durini, 7, MILANO, Italy
Organisation website
EU Contribution
€0
Organisation
Netherlands Organisation For Applied Scientific Research
Address
Stieltjesweg 1, 155 DELFT, Netherlands
Organisation website
EU Contribution
€0
Organisation
Conti Temic Microelectronic Gmbh
Address
Sieboldstrasse 19, 90411 NUERRNBERG, Germany
EU Contribution
€0
Organisation
Fischer Ag Praezisionsspindeln
Address
Maria Waser Strasse 30, HERZOGENBUCHSEE, Switzerland
Organisation website
EU Contribution
€0
Organisation
Nucellsys Gmbh
Address
Neue Strasse 95, KIRCHHEIM/TECK-NABERN, Germany
Organisation website
EU Contribution
€0
Organisation
Eldor Corporation S.p.a. Con Socio Unico
Address
Via Plinio 18, ORSENIGO (CO), Italy
Organisation website
EU Contribution
€0
Organisation
Ecole Polytechnique Fédérale De Lausanne
Address
Batiment Ce 3316 Station 1, 1015 LAUSANNE, Switzerland
Organisation website
EU Contribution
€0
Organisation
Rheinisch-Westfaelische Technische Hochschule Aachen
Address
Templergraben, 52062 Aachen, Germany
Organisation website
EU Contribution
€0
Organisation
Microchemical Systems Sa
Address
Rue de Porcena 15, 191 CORCELLES, Switzerland
Organisation website
EU Contribution
€0
Organisation
Peugeot Citroen Automobiles S.a.
Address
Route de Gizy, 78140 VELIZY-VILLACOUBLAY, France
Organisation website
EU Contribution
€0
Organisation
Volvo Bus Corporation
Address
Fästningsvägen 1, 40508 Gothenburg, Sweden
EU Contribution
€0
Organisation
Volkswagen
Address
Berliner Ring 2, 1894 WOLFSBURG, Germany
Organisation website
EU Contribution
€0
Organisation
University Of Maribor
Address
Slomškov Trg 15, SIN/A2000 Maribor, Slovenia
EU Contribution
€0
Organisation
Université Montpellier 2
Address
Place E. Bataillon, 34095 MONTPELLIER, France
Organisation website
EU Contribution
€0
Organisation
Regienov
Address
Quai Alphonse le Gallo 13/15, 92100 BOULOGNE-BILLANCOURT, France
Organisation website
EU Contribution
€0
Organisation
Fachhochschule Esslingen, Hochschule Für Technik
Address
Kanalstr. 33, ESSLINGEN, Germany
Organisation website
EU Contribution
€0
Organisation
Italian National Agency For New Technologies, Energy And Sustainable Economic Development (Enea)
Address
Via Aguillarese, 301, S. MARIA DI GALERIA (ROMA), Italy
Organisation website
EU Contribution
€0
Organisation
Agencia Estatal Consejo Superior Deinvestigaciones Cientificas
Address
CALLE SERRANO 117, 28006 MADRID, Spain
Organisation website
EU Contribution
€0
Organisation
Fischer Fortuna Gmbh
Address
Gaußstraße 2, LEINFELDEN-ECHTERDINGEN, Germany
EU Contribution
€0
Organisation
Thien Edrives Gmbh
Address
Millennium Park 11, 6890 Lustenau, Austria
EU Contribution
€0

Technologies

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