Design and Analysis of a Spray Cooling System for a Heavy-Duty Fuel Cell Truck

Wagenblast, Max; Pollak, Markus; Trägner, Jakob; Heinke, Steffen; Tegethoff, Wilhelm; Köhler, Jürgen; Swoboda, Jan

doi:10.4271/2022-01-5054

Cited by 2 publications

(2 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Second there is a lack of fast charging stations, especially MW -Chargers [9], for trucks along the main transport routes resulting in longer stop times compared to conventionally powered vehicles. Third, electric trucks are still much more expensive than conventional trucks [10] and their diesel engines are already optimized on efficiency [2]. Several investigations found in the literature motivate the current study.…”

Section: Introductionmentioning

confidence: 91%

See 1 more Smart Citation

Innovative Thermal Management Operating Strategies for Battery-Electric Heavy-Duty Trucks

Hellmuth,

Steeb,

Pollak

et al. 2023

36th International Conference on Efficiency, Cost, Optimization, Simulation and Environmental Impact of Energy Systems (ECOS 20

View full text Add to dashboard Cite

Thermal management systems of electrified vehicles especially heavy-duty trucks face multiple competing goals such as minimum energy consumption, minimum battery degradation and highest passenger comfort. The design process of a suitable thermal management system addressing these goals requires a holistic approach including the various cross couplings occurring in real world operation. Therefore, a physics-based modular full-vehicle model is introduced. The model includes an electrified drive-train, passenger cabin and thermal management system. The mechanical and electrical drive-train components, including the battery, motor and power electronics are thermally connected with each other and the cabin using various cooling circuits. A reversible heat pump and several control units are used to adjust the specific thermal requirements leading to complex interconnections and cross couplings. We estimate the performance of a heavy-duty truck on typical long-distance trips including stops based on legal regulations used for fast charging and overnight charging. While charging overnight, conservation air conditioning of the cabin is performed as efficiently as possible. For this operation, we present different strategies for battery thermal conditioning. Operating strategies for the full vehicle, especially the thermal systems in a summer and a winter scenario are proposed. Simulations of a typical deployment scenario are performed to explore the effects of different operating and control strategies for thermal management. Our virtual deployment scenarios include easy to modify driving cycles, driving time regulations, charge stops and climatic boundary conditions. For evaluation purposes we present an energyflow-diagram for the full vehicle. Based on the simulation results we recommend thermal system operating strategies in a full-vehicle context for heavy-duty truck long distance trips and charging.

show abstract

Section: Introductionmentioning

confidence: 91%

“…Both, battery-electric or fuel-cell trucks show promise for flexible transport of goods [1]. Some recent investigations discuss opportunities and challenges for fuel-cell trucks [2,3]. An overview of current long-haul heavy-duty fuel-cell trucks is given by Pardhi et al [4].…”

Section: Introductionmentioning

confidence: 99%

Innovative Thermal Management Operating Strategies for Battery-Electric Heavy-Duty Trucks

Hellmuth,

Steeb,

Pollak

et al. 2023

36th International Conference on Efficiency, Cost, Optimization, Simulation and Environmental Impact of Energy Systems (ECOS 20

View full text Add to dashboard Cite

show abstract

Investigation of Different Cathode Path Topologies for Water Recovery in a Heavy-Duty Polymer Electrolyte Membrane Fuel Cell Vehicle

Petersen,

Wagenblast,

Pollak

et al. 2024

SAE Technical Paper Series

View full text Add to dashboard Cite

<div class="section abstract"><div class="htmlview paragraph">Heavy-duty vehicles equipped with polymer electrolyte membrane fuel cells (PEM-FC) are an environmentally friendly alternative to vehicles powered by internal combustion engines. A major challenge for heavy-duty fuel cell vehicles is the potential cooling deficit under high load conditions at high ambient temperatures. To solve this problem, a spray cooling system can be utilized, in which liquid water is sprayed on the main cooler at the front end of the vehicle. The evaporation of the sprayed liquid water results in an increased cooling power. In this paper, the recovery of liquid water within the cathode loop of a mobile PEM-FC system is presented and discussed. For this purpose, three different topologies of the cathode subsystem of the PEM-FC are investigated for recovering liquid water directly from the fuel cell exhaust gas. To obtain liquid water, vapor in the exhaust gas is cooled below the saturation temperature in an additional heat exchanger. Three possible positions of such a heat exchanger in the exhaust gas system are analyzed and discussed in this study. The first investigated position is at the outlet of the turbine and the other two are either upstream or downstream of the membrane humidifier. For the position upstream of the humidifier, a control and operating strategy is established. To investigate the water recovery of the three topologies, a simulation study is conducted using a validated physics-based model of the entire fuel cell system. The result of the study is a recommendation that the additional cooler should be placed upstream of the membrane humidifier.</div></div>

show abstract

Design and Analysis of a Spray Cooling System for a Heavy-Duty Fuel Cell Truck

Cited by 2 publications

References 28 publications

Innovative Thermal Management Operating Strategies for Battery-Electric Heavy-Duty Trucks

Innovative Thermal Management Operating Strategies for Battery-Electric Heavy-Duty Trucks

Investigation of Different Cathode Path Topologies for Water Recovery in a Heavy-Duty Polymer Electrolyte Membrane Fuel Cell Vehicle

Contact Info

Product

Resources

About