Design and integration challenges for a fuel cell hybrid electric sprot utility vehicle

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Design and integration challenges for a fuel cell hybrid electric sprot utility vehicle

Gurski, S. / Nelson, D.J.

A series hybrid PEM fuel cell sport utility vehicle has been modeled, designed, and built by the Hybrid Electric Vehicle Team of Virginia Tech for the FutureTruck Challenge. The ZEburban vehicle meets most of the goals and requirements for the competition. An efficient electric drivetrain combined with vehicle accessories, low rolling resistance tires, and properly sized battery and fuel cell subsystems results in combined city/highway fuel economy of 24 mpg (gasoline equivalent) or 1.4X the fuel economy of the stock vehicle. The ZEburban meets or exceeds the performance of the stock vehicle in most areas, including towing. Due to limitations of compressed gas hydrogen storage, the range of the vehicle is limited to 120 km (75 mi). The overall single speed gearing of the electric motors limits the top speed to 130 kph (80 mph). The consumer options and safety features have been maintained, including stock vehicle interior and exterior. The lower greenhouse gas (GHG) emissions per unit energy of hydrogen fuel combined with lower energy consumption of the vehicle results in total GHG emissions of 135 gm/mile. This represents an 80 % reduction in GHG emissions, exceeding the FutureTruck goal of 67 % reduction. The ZEburban fuel cell vehicle is also locally zero emission with no evaporative emissions. A ground up redesign of this SUV could provide significant weight savings and allow packaging of fuel tanks to meet consumer requirements for range.