Regan Brown
Electric vehicles have gained a lot of traction in recent years, and for good reason: they're a more environmentally friendly alternative to traditional fossil fuel-powered cars. But within the category of electric vehicles, there are a few different types of powertrains. One of these is the hydrogen fuel cell, which uses hydrogen and oxygen to produce electricity and power the vehicle. While hydrogen fuel cell cars are still far less common than their battery-powered counterparts, several major automakers have invested in the technology, including GM, Honda, Hyundai, Toyota, and Volvo.
| Characteristics | Values |
|---|---|
| Companies that make electric car fuel cells | GM, Honda, Hyundai, Toyota, Volvo, Nikola, and more |
| Fuel cell vehicles | Cars, buses, boats, trucks, trains, forklifts, and more |
| Fuel cell vehicle types | Hydrogen fuel cell vehicles, fuel cell hybrid electric vehicles |
| Fuel cell vehicle advantages | Zero-emissions, longer range, fast fueling times, higher energy efficiency, reduced emissions |
| Fuel cell vehicle disadvantages | Less efficient than electric cars, expensive, limited fueling infrastructure |
| Fuel cell vehicle applications | Space applications, indoor applications, backup power use |
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What You'll Learn
Hydrogen fuel cell vehicles
The first 700 Bar (10000 PSI) hydrogen tanks were demonstrated in 2001, reducing the size of the fuel tanks that could be used in vehicles and extending their range. Honda established the world's first fuel cell vehicle dealer network in 2008, and was the only company able to lease hydrogen fuel cell vehicles to private customers. Since then, other car companies have offered hydrogen-powered cars for sale, including the Honda Clarity Fuel Cell, the Hyundai Nexo SUV, and the Toyota Mirai. However, Honda has now ended production of the Clarity, and Hyundai has sold only about 1600 Nexo SUVs in six years.
The process by which hydrogen fuel cells generate electricity is as follows:
- Hydrogen from the fuel tank combines with oxygen from the outside air in the fuel cell stack.
- An electrochemical reaction, aided by a catalyst, causes the hydrogen molecules to break apart into protons and electrons.
- The protons travel through the membrane to the cathode, while the electrons are forced to travel through an external circuit to provide power to the electric motor.
- The electrons then recombine with the protons on the cathode side, where they combine with oxygen molecules to form water.
- The electricity powers the vehicle's electric motor, turning the wheels.
The amount of energy stored onboard an HFCV is determined by the size of the hydrogen fuel tank. HFCVs can be refuelled in about five minutes and have a driving range of over 300 miles. However, critics argue that hydrogen cars are less efficient than electric cars, and that the production and transportation of hydrogen create pollutants.
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Fuel cell stacks
A fuel cell stack is a core component of a fuel cell power system. It is an assembly of individual membrane electrodes (each consisting of a membrane electrode assembly (MEA) and two flow-field plates) that use hydrogen and oxygen to produce electricity through a "cold combustion" process. This process involves catalytically splitting hydrogen into electrons and protons, with the protons diffusing through a polymer membrane towards the cathode while the electrons flow from the anode to the cathode via an electrical circuit, generating an electric current. The protons, electrons, and oxygen from the air ultimately react to form water, electricity, and heat as the only products of the reaction.
The power output of a fuel cell stack depends on its size, with the number of cells in the stack influencing the voltage and the surface area of the cells affecting the current. A typical fuel cell stack may consist of hundreds of fuel cells, with each cell producing less than 1V, which is insufficient for most applications. The fuel cell stack's performance can be enhanced by increasing the pressure of the reactant gases, which is achieved through the use of an air compressor. Additionally, fuel cell systems may include a humidifier for the inlet air, as the polymer electrolyte membrane functions optimally when moist.
To address these challenges, companies like Bosch have entered into collaborations with fuel cell stack manufacturers like PowerCell Sweden AB to advance and produce improved stacks. These advancements aim to make fuel cell technology more viable for various applications, including electric vehicles, where the fuel cell stack's power can be complemented by a battery system for improved performance and energy storage.
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Fuel filler
The fuel filler flap is an important access point for refuelling, and issues with it can cause inconvenience and even lead to costly repairs. For example, in the case of the 2003 Tundra, the spring-loaded flap in the fuel filler neck was reported to be missing, raising concerns about potential damage and the need for replacement.
In another instance, a user reported an issue with their Ampera's fuel filler flap, which stopped locking properly. This problem was attributed to a potential fault with the plastic pin, which, if broken, could result in an expensive repair. The user community provided a temporary solution, suggesting a method to manually open the flap using the fob instead of the door button to avoid putting pressure on the pin.
While fuel filler flaps are essential for refuelling, the design and placement of the flap can vary among vehicle models. Some vehicles may have a spring-loaded flap, while others might utilise a different mechanism for refuelling. It is important for car owners to familiarise themselves with the specific design of their vehicle's fuel filler flap and follow the recommended procedures for refuelling to ensure safety and maintain the integrity of the fuel system.
Overall, the fuel filler, or fuel filler flap, plays a crucial role in the refuelling process of electric cars with fuel cells, allowing for the safe and efficient transfer of hydrogen fuel into the vehicle's tank. Proper maintenance and understanding of this component are essential to ensure the vehicle's optimal performance and longevity.
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Hydrogen fuel tank
In contrast, cryogenic liquid hydrogen tanks store hydrogen in its liquid state at extremely low temperatures, typically below -253 degrees Celsius. While this type of tank has seen limited use in vehicles like BMW's "Hydrogen 7 automobile", it faces the challenge of boil-off, where the liquid hydrogen evaporates over time if the vehicle remains stationary for extended periods.
Safety is a critical consideration for hydrogen fuel tanks, and manufacturers have developed innovative solutions to address this concern. For example, Toyota's Mirai model features multi-patented, carbon-fiber-wrapped, polymer-lined hydrogen tanks with a three-layer structure that can absorb five times the crash energy of steel. Additionally, these tanks are equipped with an automatic shut-off mechanism for the hydrogen output valve, preventing the flow of hydrogen to potentially damaged systems outside the tank.
While hydrogen fuel cell technology has faced criticisms related to efficiency and the polluting nature of current hydrogen production methods, it offers advantages such as longer ranges and faster fueling times compared to traditional electric vehicles. Hydrogen fuel cells are also finding applications beyond cars, with their use expanding to buses, boats, submarines, and material handling vehicles.
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Power electronics controller
The power electronics controller (also known as the fuel cell control unit or FCCU) is a crucial component in electric vehicles equipped with fuel cells. It acts as the central control unit, managing the flow of electrical energy delivered by the fuel cell and the traction battery. This unit controls the speed and torque of the electric traction motor, ensuring optimal performance.
The FCCU plays a vital role in the overall operation of the fuel cell system and its individual subsystems. It regulates the hydrogen supply, air system, thermal and water management systems, and the storage system. The unit's closed-loop control algorithms and self-learning software functions enable it to adapt to different requirements and optimize the vehicle's performance.
One of the key challenges in fuel cell systems is managing the heat generated during the chemical reaction. To address this, fuel cell systems employ at least two coolant circuits or loops: the power electronics loop and the stack loop. The power electronics loop is responsible for cooling critical components such as the inverter, air compressor, and other power electronics elements. Meanwhile, the stack loop is dedicated to cooling the stack, which requires a separate circuit using deionized water to prevent ion contamination.
The power electronics controller also plays a role in recirculating excess hydrogen. In the fuel cell system, a recirculation pump is used to redirect unreacted hydrogen from the stack back to the stack's hydrogen inlet line, where it can be consumed to generate electricity. This ensures efficient use of hydrogen fuel and maximizes the system's overall efficiency.
The power electronics controller is an essential component in the overall design of electric vehicles with fuel cells. It ensures the efficient management of electrical energy, regulates critical subsystems, and maintains optimal operating temperatures. By controlling the flow of energy and recirculating excess hydrogen, the power electronics controller contributes to the smooth and efficient operation of the vehicle's fuel cell system.
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Frequently asked questions
Many companies have been working on electric car fuel cells, including General Motors (GM), Honda, Hyundai, Toyota, and Volvo.
Honda, Hyundai, and Toyota have all offered hydrogen-powered cars for sale.
Honda has produced the Honda FCX, the Honda Clarity Fuel Cell, and the Honda FCX powered by Ballard Power Systems.
The best-selling hydrogen-powered car in the US is the Toyota Mirai.
Honda was the first company to establish a fuel cell vehicle dealer network in 2008.
