Modular Fuel Cell Range Extender for Electric Vehicles
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Solution Overview
Problem
Current fuel cell-based range extenders for electric vehicles are complex and expensive to adapt to different boundary conditions, requiring intricate compressor adjustments and costly electrical interconnections.
Innovation Solution
A modular range extender system comprising fuel cell basic modules that can be connected in series and parallel to provide varying outputs and voltages, with a media supply device for hydrogen and air, allowing for scalable and cost-effective configuration of range extenders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fuel cell based range extenders are adapted to different boundary conditions, then versatility is improved, but device complexity and cost increase due to complex compressor adjustments and electrical interconnections
Solution Approach 1:
The fuel cell system is divided into modular basic modules that can be independently configured. Each module contains standardized components (fuel cells, interfaces, media supply connections), allowing the system to be segmented into reusable building blocks that simplify adaptation to different applications while reducing overall complexity.
Solution Approach 2:
The basic fuel cell modules are designed with universal interfaces and standardized media supply connections that can serve multiple functions across different vehicle types and boundary conditions. The same modular module can be used in various configurations (series, parallel) to meet different power and voltage requirements without requiring custom compressor adjustments or specialized electrical interconnections.
2Adaptability or versatility
If fuel cell based range extenders are adapted to different boundary conditions, then versatility is improved, but manufacturing cost increases due to expensive electrical interconnections
Solution Approach 1:
The electrical system is segmented into standardized modules with pre-defined voltage outputs. By connecting basic modules in series or parallel, different voltage levels are achieved through simple modular assembly rather than custom electrical interconnections, significantly reducing manufacturing costs while maintaining versatility.
Solution Approach 2:
The system achieves different voltage and power outputs by changing the configuration parameters (series/parallel connections) of identical basic modules rather than manufacturing different electrical interconnection systems. This parameter-based approach to variability reduces manufacturing complexity and cost.
3Adaptability or versatility
If standardized fuel cell modules are configured in series and parallel circuits, then versatility and cost-effectiveness are improved, but system configuration complexity increases
Solution Approach 1:
The system uses clearly defined basic modules with standardized interfaces and connection points. Each module is segmented with explicit electrical terminals and media supply interfaces, making the configuration process more manageable despite the modular nature. The segmentation provides structure that reduces rather than increases complexity.
Solution Approach 2:
The system configuration is made dynamic and adaptable through standardized interfaces that allow flexible series and parallel connections. The modular design enables the system to dynamically adjust its electrical and media supply configuration based on required output parameters, with pre-defined connection standards that simplify the dynamic reconfiguration process.
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
Enables simple adaptation to different vehicle types and boundary conditions, reducing production costs and extending service life by allowing standardized fuel cell modules to be configured into various variants, eliminating the need for expensive DC-DC converters.
Implementation Method 1
range extenders, which have a large number of fuel cells. One advantage of these range extenders is that they are virtually emission-free, since hydrogen and oxygen usually react to form water
Implementation Method 2
Typically, such fuel cell based range extenders require one or more compressors to deliver compressed air to the fuel cells
Data Source
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AI summary
The invention relates to a modular range extender system (20) for an electrically driven motor vehicle (52), comprising: a plurality of fuel cell basic modules (10), which each have a plurality of fuel cells connected in series and interfaces for supplying hydrogen and air as well as for discharging water and residual gas; and a media supply device, which is designed to supply air and hydrogen to the fuel cell basic modules (10) via the interfaces and to discharge water and residual gas from the fuel cell basic modules (10) via the interfaces, wherein, in order to provide different outputs and/or voltages, different numbers of the fuel cell basic modules (10) are electrically connectable to one another in different series and/or parallel circuits and are configurable with the media supply device to form different variants of a range extender (22). The invention also relates to a circuit arrangement (40) for a vehicle electrical system of an electrically driven motor vehicle (52) and to an electrically driven motor vehicle having a circuit arrangement (40) of this kind.