Fuel Cell Range Extender for Utility Vehicle Energy Supply
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Solution Overview
Problem
Utility vehicles, such as trucks, face challenges with long charging times and reduced energy availability when equipped with electrical energy storage devices, especially when a body or trailer is added, leading to impaired propulsion and downtime due to the need for mechanical power take-off or separate energy supply units.
Innovation Solution
Integration of a fuel cell device that serves as a range extender and multifunctional power take-off, providing electrical energy and waste heat to consumers, such as trailers or bodies, while allowing operation during downtime and charging the traction battery, thus eliminating the need for mechanical power take-off and separate energy supply units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If battery-powered utility vehicles use only electrical energy storage devices, then the vehicle structure is simple, but charging times are long and operational duration is limited
Solution Approach 1:
The energy supply system is segmented into multiple independent components: traction batteries for propulsion, fuel cell device for range extension, and separate energy supply units for body consumers. This segmentation allows each component to operate independently and simultaneously, resolving the contradiction between simple structure and extended operational duration.
Solution Approach 2:
The fuel cell device is designed with multi-functionality, serving both as a range extender for the drivetrain and as an energy source for body consumers. This universal application eliminates the need for separate energy supply units, maintaining structural simplicity while extending operational duration through continuous fuel cell operation.
2Adaptability or versatility
If a body or trailer with electrical consumers is added to the utility vehicle, then the vehicle functionality is improved, but the energy available for propulsion is significantly reduced
Solution Approach 1:
The electrical energy supply is segmented into separate circuits: one for the drivetrain with traction batteries and range extender, and another for body consumers with dedicated energy supply units. This segmentation ensures that energy consumption by body consumers does not deplete propulsion energy, resolving the contradiction between enhanced functionality and maintained propulsion energy availability.
Solution Approach 2:
The fuel cell device serves dual purposes: extending the drivetrain range and supplying energy to body consumers. This multi-functionality allows the vehicle to maintain full propulsion energy availability while supporting additional body consumers, thereby resolving the energy allocation contradiction.
3Power
If a mechanical power take-off is used to supply additional energy to the body or trailer, then the energy supply is sufficient, but the drivetrain complexity increases
Solution Approach 1:
The energy supply function for body consumers is extracted from the drivetrain system by implementing separate energy supply units powered by the fuel cell device. This extraction eliminates the need for mechanical power take-off mechanisms, maintaining drivetrain simplicity while ensuring sufficient energy supply capacity for body consumers.
4Power
If separate energy supply units are installed on the body or trailer, then the energy demand is met, but the overall vehicle complexity and cost increase
Solution Approach 1:
The fuel cell device is designed as a universal energy source that simultaneously serves the drivetrain range extension and body consumer energy supply needs. This multi-functionality eliminates the requirement for separate independent energy supply systems, reducing overall vehicle system complexity and cost while meeting all energy demands.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the electric range of utility vehicles by providing continuous energy supply to both the vehicle and attached bodies or trailers, reducing downtime and energy consumption, and eliminating the need for separate energy supply units, thereby improving operational efficiency and reducing costs.
Implementation Method 1
The fuel cell device (12) is designed to generate electrical energy from a fuel, for example hydrogen or methanol
Implementation Method 2
During operation, the fuel cell device (12) also produces waste heat
Implementation Method 3
A cooling circuit is provided for removing the waste heat from the fuel cell device (12), in particular from the stack (12A)
Implementation Method 4
at least one heat exchanger (30) for transferring thermal energy from the cooling circuit to at least one consumer (20)
Data Source
AI summary
The invention relates to a utility vehicle (IO), preferably a truck, comprising a structure (22) or trailer (46) having a consumer (20) and a fuel cell device (12). The fuel cell device (12) is designed to be connectable as a range extender of the utility vehicle (IO) and to supply the consumer (20) with electrical power and/or waste heat.