Volvo Trucks 2: Fuel Cell Model Integrated with Vehicle Cooling System and Battery

Overview

In a world increasingly affected by climate change and global warming, we are still dependent on fossil fuels for transportation; which is one of the main contributors to this global crisis. Finding alternative solutions to combustion engines will become a necessity to decrease the amount of greenhouse gas emissions. To reduce the dependence on fossil fuels, the electric vehicle market has grown and is constantly evolving. Nowadays, lithium-ion batteries are commonly used in these vehicles. Compared to lithium-ion batteries, fuel cells generate energy instead of storing it, are lighter in weight, and have better refueling time. These properties are especially advantageous for long running times. As a result, it becomes interesting to study this mechanism’s potential in heavy-duty vehicles.

Volvo Trucks (Hagerstown Location) along with many other names in the trucking industry are aggressively pursuing renewable sources of energy for their transportation vehicles. Based in Sweden, Volvo manufactures and distributes consumer and commercial grade vehicles around the world. By the year 2030, Volvo plans to end production of all internal combustion (gasoline and diesel) engines. To meet this rapidly approaching deadline, the company is interested in implementing alternate fuel sources in large commercial grade trucks. The fuel cell electric vehicle (FCEV) is a vehicle that uses fuel cell technology as its power source.

The goal of this project was to successfully create a software model that can predict the degradation of a fuel cell over its lifespan. There are many different parameters that can cause a decrease in the performance of a fuel cell. Some of the most prevalent modes of degradation include Ostwald Ripening in the catalyst layer and corrosion of the proton exchange membrane (PEM). Both these phenomenon will be explored.

Objectives

-Research known degradation modes of PEM fuel cells.

– Create a 1D model of a fuel cell to study degradation methods over time.

– Implement degradation research into the cell model.

Approach

The approach for this project involved the use of several software tools, including MATLAB, SolidWorks, and Simulink. MATLAB is a powerful programming language that is widely used for mathematical computations and data analysis. SolidWorks is a 3D CAD software that enabled us to create and manipulate virtual models of our design concepts, including complex assemblies and parts. It provided us with the necessary tools to simulate the behavior of our designs under different conditions and constraints. Finally, Simulink is a simulation and modeling tool that integrates with MATLAB and allowed us to model and simulate dynamic systems, including mechanical, electrical, and hydraulic systems. Use of these software tools allowed for a comprehensive approach to problem-solving and design optimization that yielded effective and efficient solutions.

Outcomes

The extensive research performed in this project resulted in three independent degradation models.

– A large-scale Simulink model provides a steady-state model to use as a baseline performance reference.

– A more specific catalyst layer model within MATLAB can predict the decay of the platinum catalyst material during cell operation.

– The SOLIDWORLS fuel cell model created was used for thermal analysis of the various cell layers.