This report documents a portion of the results of the project entitled "Direct-Hydrogen-Fueled Proton-Exchange-Membrane Fuel Cell System for Transportation Applications" performed by Ford Motor Company, under contract DE-AC02-94CE50389. The project objective was to design, fabricate, and test a 50-kW direct hydrogen fueled proton exchange membrane (PEM) fuel cell system including onboard hydrogen storage, efficient lightweight fuel cell, gas management system, and complete system controls that can be economically mass produced and comply with all safety, environmental, and consumer requirements for vehicle applications for the 21 st century. Specifically, this report presents conceptual designs for a batteryaugmented fuel cell-powered vehicle based on three different vehicle classes, namely, small car, mid-size car, and full-size van.Dr. Djong-Gie Oei, project manager at Ford, prepared the report with contributions from Ford staff, namely, James Adams, Alan Kinnelly, Georgianna Purnell, Ron Sims, Mark Sulek, and David Wernette. Brian James, Franklin Lomax, George Baum, C. E. (Sandy) Thomas, and Ira Kuhn, all from Directed Technologies, Inc., also contributed to the report. AbstractIn partial fulfillment of the U.S. Department of Energy Contract No. DE-AC02-94CE50389, "Direct Hydrogen-Fueled Proton-Exchange-Membrane (PEM) Fuel Cell System for Transportation Applications", this conceptual vehicle design report addresses the design and packaging of battery augmented fuel cell powertrain vehicles. This report supplements the "Conceptual Vehicle Design Report -Pure Fuel Cell Powertrain Vehicle" and includes a cost study of the fuel cell power system. The three classes of vehicles considered in this design and packaging exercise are the same vehicle classes that were studied in the previous report: the Aspire, representing the small vehicle class; the A N (Aluminum Intensive Vehicle) Sable, representing the mid-size vehicle; and the E-150 Econoline, representing the van-size class. A preliminary PEM fuel cell power system manufacturing cost study is also presented.As in the case of the previous report concerning the "Pure Fuel Cell Powertrain Vehicle", the same assumptions are made for the fuel cell power system. These assumptions are fuel cell system power densities of 0.33 kWkg and 0.33 kW/l, platinum catalyst loading of less than or equal to 0.25 mg/crn2 total, and hydrogen tanks containing compressed gaseous hydrogen under 340 atm (5000 psia) pressure. The batteries considered for power augmentation of the fuel cell vehicle are based on the Ford Hybrid Electric Vehicle (HEV) program. These are state-of-the-art high power lead acid batteries with power densities ranging from 0.8 kW/kg to 2 kW/kg.The results reported here show that battery augmentation provides the fuel cell vehicle with a power source to meet instant high power demand for acceleration and start-up. Trade-offs between battery weight, volume and cost and fuel cell weight, volume and cost are carefully considered and discussed. Based on the assumpt...
This report documents a portion of the results of the project entitled "Direct-Hydrogen-Fueled Proton-Exchange-Membrane Fuel Cell System for Transportation Applications" performed by Ford Motor Company, under contract DE-AC02-94CE50389. The project objective was to design, fabricate, and test a 50-kW direct hydrogen fueled proton exchange membrane (PEM) fuel cell system including onboard hydrogen storage, efficient lightweight fuel cell, gas management system, and complete system controls that can be economically mass produced and comply with all safety, environmental, and consumer requirements for vehicle applications for the 21 st century. Specifically, this report presents conceptual designs for a pure (no power augmentation) fuel cell-powered vehicle based on three different vehicle classes, namely, small car, midsize car, and full-size van.Dr. Djong-Gie Oei, project manager at Ford, prepared the report with contributions from Ford staff, namely,
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