HyLite Project - Development of a Fuel Cell Powered Hybrid Vehicle

Kurzfassung

The HyLite Project is a joint project of 10 supplier companies and the German Aerospace Center (DLR) to develop a fuel cell powered vehicle, wich shall serve as a "technology carrier". The majority of companies develops advanced components for the fuel cell system comprising essential components of air supply subsytem (e.g. advanced air compressor), heat and water management, hydrogen supply system and the control system. Some companies support DLR in the system integration. The basic vehicle for the integration of the PEM fuel cell system is a battery car, wich was produced by a German manufacturer in a small scale production of nearly 150 vehicles. One objective of the project was to replace the battery pack of that base vehicle by an electrical power generation system with a fuel cell system. As basis for the development of the power supply system the battery vehicle has been characterized in a condensed measuring campaign. The paper reports about the results of the vehicle characterization, e.g. driving resistance parameters, performance curves and as well as NEDC characteristics. Based on the findings of the vehicle characterization it was decided to apply a hybrid fuel cell system, whereby the power distribution between battery and fuel cell system is realized by means of a bidirectional DC/DC converter. Further, the paper describes the layout of the fuel cell power unit and gives details about components - especially the fuel cell system. The vehicle management unit, wich handles the overall vehicle control, and the energy managment unit, wich controls fuel cell system and battery, are explained in detail. Furthermore the packing concept of the vehicle and the hydrogen safety concept are described. Recently, the integration of the system in the vehicle has been completed. The successful initial start up and first operation sequence of the vehicle on a test bench followed directly afterward.