Hybrid Powertrain Energy Control for Variable Cargo Loads
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Solution Overview
Problem
Hybrid fuel cell powertrains for commercial vehicles face challenges in achieving parity with diesel powertrains due to limitations in energy storage system durability, power efficiency, and total cost of ownership, primarily due to the immaturity of powertrain sub-systems and the need for compromises in design that affect cargo load, acceleration, and peak velocity.
Innovation Solution
The SEMAS controller and related control system implement a holistic, adaptive simulation-based energy management system that optimizes powertrain operations by actively measuring cargo properties and adjusting energy flows to balance fuel usage, power generation, and parasitic loads, ensuring efficient energy use and extending the life of fuel cell and energy storage systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hybrid fuel cell powertrains are used in commercial vehicles, then zero-emission operation is achieved, but total cost of ownership increases due to immature powertrain sub-systems
Solution Approach 1:
The control system dynamically adjusts powertrain operations based on real-time cargo load measurements, adapting energy management strategies to actual vehicle conditions. This dynamic optimization improves fuel efficiency and reduces operational costs, directly addressing the high TCO issue while maintaining zero-emission operation.
Solution Approach 2:
The system implements feedback control by actively measuring cargo properties and using this information to optimize powertrain performance. This closed-loop control ensures the vehicle operates at optimal efficiency points, reducing fuel consumption and operational expenses, thereby lowering total cost of ownership.
2Force
If energy storage system capacity is increased to handle heavy cargo loads, then cargo load capability is improved, but system weight and cost increase
Solution Approach 1:
The control system dynamically optimizes powertrain operations based on actual cargo load, allowing the vehicle to handle heavy loads when necessary while operating at optimal efficiency points during normal conditions. This eliminates the need for oversized energy storage systems, reducing both weight and cost.
Solution Approach 2:
The system changes operational parameters based on cargo load measurements, adjusting energy management strategies to match actual vehicle needs. This allows the powertrain to operate efficiently across a range of loads without requiring excessive energy storage capacity, thereby reducing system weight and cost.
3Use of energy by moving object
If powertrain subsystems are optimized for maximum efficiency, then fuel consumption is reduced, but acceleration and peak velocity performance deteriorate
Solution Approach 1:
The control system dynamically adjusts powertrain operations based on cargo load and driving conditions. During acceleration and peak velocity events, the system temporarily increases power output beyond optimal efficiency points, while maintaining fuel-efficient operation during steady-state conditions. This dynamic approach preserves performance while reducing overall fuel consumption.
Solution Approach 2:
The system employs periodic optimization cycles, operating at maximum efficiency during steady-state conditions and temporarily deviating to provide peak performance when needed. This periodic switching between efficiency-optimized and performance-optimized modes reduces overall fuel consumption while maintaining required acceleration and velocity capabilities.
4Device complexity
If cargo load variations are not accounted for in powertrain control, then control system complexity is reduced, but energy efficiency and fuel consumption worsen
Solution Approach 1:
The control system performs preliminary measurements of cargo load and uses this information to pre-optimize powertrain operations. By knowing the actual cargo load before operation begins, the system can establish optimal control parameters in advance, improving energy efficiency without requiring complex real-time adjustments.
Solution Approach 2:
The system implements feedback control by measuring cargo load and using this information to continuously optimize powertrain performance. This feedback mechanism ensures the vehicle operates at optimal efficiency points for the actual cargo load, significantly improving energy efficiency while adding only moderate control system complexity.
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 approach reduces the total cost of ownership by optimizing energy efficiency, increasing durability, and minimizing fuel consumption, thereby achieving comparable ranges or cargo loads without compromising acceleration and peak velocity, while extending the life of powertrain components.
Implementation Method 1
In a fuel cell, electric energy is generated from the electrochemical reaction of hydrogen and oxygen
Implementation Method 2
a fuel cell stack is operated with reactant gas and cooling management systems, coupled with energy storage devices, such as batteries and/or supercapacitors
Implementation Method 3
In addition, for commercial vehicles, the refueling infrastructure can be provided co-terminus with the existing petroleum fuel infrastructure including locations and overground installations. Therefore, fuel cell electric vehicle technology is an attractive option for commercial vehicles and HGVs that operate on fixed routes. Hybrid fuel cell electric vehicle powertrains, fueled by hydrogen fuel, offer many advantages over more conventional powertrain systems which release hydrocarbons, nitrogen oxides, carbon monoxide and other chemicals.
Data Source
AI summary
There is provided a control system for a vehicle comprising a powertrain comprising a plurality of energy sources and for transporting cargo, the control system being configured to optimise the control of the powertrain by accounting for variations in one or more properties of the cargo. More specifically a controller and related control system for the energy balancing of the vehicle taking into consideration such factors as fuel usage, power management between the various power generating and storage sub-systems, regenerative braking, terrain topology, weather and other environmental conditions, operation of vehicle peripherals and parasitic power demands in addition to cargo management and environmental needs and driver comfort and safety, as well as vehicle fleet management.