Modular Fuel Cell Chassis Layout for Refuse Vehicle Range
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Solution Overview
Problem
Existing refuse vehicles face inefficiencies in power systems, particularly in terms of fuel efficiency and maintenance accessibility, which affect their operational range and downtime.
Innovation Solution
Integration of a modular hydrogen power system with hydrogen fuel cells and pods positioned in various locations on the vehicle, allowing for easy maintenance and refueling, and the ability to supplement power with hydrogen fuel cells and pods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If fuel cells are integrated into the refuse vehicle power system, then power availability and operational range are improved, but device complexity increases
Solution Approach 1:
The fuel cell system is divided into modular components including fuel cell stacks, hydrogen storage tanks, power control units, and exhaust systems that can be independently installed, maintained, and replaced. This segmentation allows the complex fuel cell system to be integrated into the existing vehicle without requiring complete system redesign.
Solution Approach 2:
The fuel cell power system is designed to serve multiple functions: primary propulsion power source, auxiliary power for body systems, and range extension capability. The system can operate in conjunction with existing diesel or electric powertrains, providing versatile power availability across different operating conditions.
2Ease of repair
If modular hydrogen fuel cell components are used, then ease of maintenance and refueling is improved, but device complexity increases
Solution Approach 1:
Hydrogen storage tanks are designed as separate, removable modules with standardized mounting interfaces. Fuel cell stacks are housed in independent compartments with access panels. This segmentation enables maintenance personnel to quickly replace individual components without disassembling the entire power system, significantly improving maintenance accessibility.
Solution Approach 2:
The system incorporates quick-connect interfaces and standardized mechanical/electrical connections that change the coupling parameters between components. This allows fuel cell modules and hydrogen tanks to be rapidly attached and detached using simple coupling mechanisms rather than permanent fastening systems.
3Power
If multiple fuel cell modules are positioned along the chassis, then power availability is improved, but volume of the vehicle increases
Solution Approach 1:
Fuel cell modules and hydrogen storage tanks are arranged in a three-dimensional configuration utilizing vertical space above the chassis and lateral spaces between frame rails. This dimensional arrangement distributes power components throughout the vehicle volume rather than concentrating them in a single location, providing adequate power availability without excessive overall vehicle volume increase.
Solution Approach 2:
Hydrogen storage tanks are positioned within existing chassis frame spaces and underbody cavities. Fuel cell modules are mounted in compartments that utilize unused volume between the chassis frame and body panels. This nesting approach integrates power system components into existing vehicle architecture, minimizing additional volume requirements.
4Adaptability or versatility
If hydrogen fuel pods are selectively coupled to attachment points, then adaptability is improved, but device complexity increases
Solution Approach 1:
The coupling system uses standardized mechanical interfaces and electrical connectors that are consistent across all fuel pod attachment points. This universal interface design allows the same coupling mechanism to serve multiple functions: mechanical attachment, electrical connection for fuel delivery, and communication linkage, thereby improving adaptability without proportionally increasing 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
Enhances power availability, reduces downtime, and increases operational range by providing flexible and efficient power solutions with modular components that can be easily swapped or upgraded.
Implementation Method 1
a plurality of fuel cells longitudinally disposed along the chassis, positioned between the right frame member and the left frame member
Data Source
AI summary
A refuse vehicle includes a chassis. The chassis includes a right frame member and a left frame member spaced apart in a lateral direction and extending lengthwise in a longitudinal direction, the right frame member being separate from the left frame member. The refuse vehicle further includes a body supported by the right frame member and the left frame member, the body defining a refuse compartment, and a hydrogen power system including a plurality of fuel cells longitudinally disposed along the chassis, positioned between the right frame member and the left frame member. The hydrogen power system may also include plurality of fuel pods for providing hydrogen to the fuel cells. The hydrogen power system can be packaged in modular pods on various locations of the refuse vehicle. The hydrogen power system can work in conjunction with other power sources or fuels (e.g., electric batteries, ultra-capacitors, diesel ICE, CNG, etc.).