Fuel%20Cell%20Electric%20Aircraft%20Energy%20Challenge%20New%20Era%20of%20Aviation - PowerPoint PPT Presentation

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Title: Fuel%20Cell%20Electric%20Aircraft%20Energy%20Challenge%20New%20Era%20of%20Aviation


1
Fuel Cell Electric Aircraft Energy
ChallengeNew Era of Aviation
  • James Dunn
  • Advanced Technology Products Worcester, MA
  • Electric Aircraft Symposium
  • San Fran May 2007

2
Fuel cells in Aviation
  • Electric UAVs Helios-NASA- Aerovironment
  • Auxiliary Power Boeing APU Madrid
  • Electric Airships HAA Lockheed Martin
  • Electric Propulsion - Manned aircraft - E-Plane

3
Aerovironment HELIOS UAVRegenerative fuel cell
system
4
High Altitude AirshipSolar PV and Fuel Cells
5
Electric Glider
Fuel Cell Powered Glider
6
Piloted Fuel Cell Aircraft2-place Electric
DynAero
7
Benefits of Electric Aircraft
  • Increased Reliability 1 moving part!
  • Improved Safety
  • QUIET - only propeller noise
  • Improved Comfort and Easy Maintenance
  • No Vibration
  • Reduced life-cycle costs
  • NO EMISSIONS !

8
Why Fuel Cells
  • High Efficiency 2.5 X Gasoline Engines
  • (60 vs. 23)
  • Zero Emissions Only Water Vapor
  • No odors or fumes
  • Hydrogen Fuel Sustainable and Renewable
  • High Energy Density 300 - 600 WH/kg
  • 2-3 X battery density

9
The Energy Challenge !
  • Airplane needs 25kW Power _at_ 100 mph
  • 300 Mi. flight requires 75 kWh of Energy
  • Energy system Weight for 75kWh
  • - Lead Acid Batteries 3000 kg
  • - NiMH Batteries 1500 kg
  • - LiIon Batteries 600 kg
  • Fuel Cell system ( 3 kg H2) 165 kg
  • (Gasoline Equivalent 100 kg !)

10
The Challenge Matching the energy density of
Gasoline and IC Engines?
Gasoline 13,200 WH/kg _at_ 20 effic. Net 2600
WH/kg Best LiIon Batts 200 WH/kg Still a
131 advantage for Gas!! (H2 30,000
WH/kg) Issues Weight, Volume, HEAT, ()
11
Hurdles Issues
  • System Weight Power Density/Effic.
  • Support Components Power Weight
  • Hydrogen Storage/Generation System
  • Heat Transfer methods HEX System
  • Safety Issues FAA Ongoing
  • Customer Acceptance
  • Costly Technology

12
Hydrogen Sources
  • H2 Gas - High Pressure Tank 5000 psi
  • Liquid Hydrogen Cryo issues
  • Reformed Gasoline CO, CO2
  • Methanol/Ethanol Direct or reformate
  • Ammonia (dissociated) high yield
  • Sodium borohydride safe, costly
  • Magnesium Hydride
  • Other ??

13
NASA Fuel Cell Study Elements
14
Selected Aircraft for Conversion
  • AGA Lafayette III
  • All Carbon Kit - 28 Wing
  • We/Wo .31
  • 80 hp. Rotax 912
  • lt 12 kW to Cruise
  • Vne of 180 kts

15
Aircraft Modeling for Hydrogen PEM Fuel Cell
Motor ConversionNASA GRC
MCR01 ULM Kit Plane Airbreathing Systems Analysis
Office (NASA GRC) Systems Analysis Branch (NASA
LaRC)
16
MCR01 ULM Fuel Cell Conversion Power Density
Technology Sensitivity PDPMAD 1.06 kW/kg
MCR01/Rotax 912 gt 800 nm Range
800
Advanced Technology Fuel Cell Stack Power
Density 2.50 kW/kg Electric Motor Power
Density 2.30 kW/kg PMAD Power Density 1.06
kW/kg Range 336 nm
2.3
Gross weight constantat 992 lb limit
2.5
2.0
2.3
1.8
2.1
1.7
1.9
PDMotor (kW/kg)
PDStack (kW/kg)
1.5
1.7
1.3
1.5
Applied State-of-the-Art Technology Fuel Cell
Stack Power Density 1.57 kW/kg Electric Motor
Power Density 1.35 kW/kg PMAD Power Density
1.06 kW/kg Range 58 nm
Further performance gains possible only if PMAD
weight is reduced!
17
MCR01 ULM Fuel Cell Conversion Power Density
Technology Sensitivity PDPMAD 2.60 kW/kg
Advanced Technology Fuel Cell Stack Power
Density 2.50 kW/kg Electric Motor Power
Density 2.30 kW/kg PMAD Power Density 2.60
kW/kg Range 644 nm
2.3
2.5
2.0
2.3
1.8
2.1
1.7
1.9
1.5
1.7
1.3
1.5
PDStack (kW/kg)
PDMotor (kW/kg)
Gross weight constantat 992 lb limit
Diminishing returns on range The heavy
compressed hydrogen tank limits further gains.
18
Program Objectives
  • Demonstrate viability of Fuel Cell powered
    electric propelled aircraft
  • Determine the optimum energy source
  • Analyze performance parameters range
  • Design/develop High efficiency H2 PEM fuel cell
  • Integrate all components into Airframe and Test
  • Provide educational vehicle for students

19
Basic Schematic of Components

20
Students at Oshkosh
21
Energy Distribution
22
Battery Fuel Cell System Rqmts.
  • Max Power - Batteries Fuel Cell 75 kw
  • Bus voltage 270 DC
  • Net Stack power - cont. 17 kw
  • No. of Cells 180
  • Efficiency 60
  • Fuel Cell sys. Wt. (w/sgl.H2 tank) 80 kg
  • Battery Master Power Xtrol Wt. 50 kg
  • Total Energy System Weight 130 kg

23
Fuel Cell System target weight
  • Stack (10-18kW) 25 kg
  • Blower (Compressor) duct 5 kg
  • Misc. BOP, plumbing, sensors 4 kg
  • HEX System w/Radiators 9 kg
  • DC-DC Up-convertor 7 kg
  • Fuel Cell Controller/mon. 5 kg
  • Dynatech Tank/Reg. 18 kg
  • Mounting Misc. 5 kg
  • TOTAL fuel Cell System Weight 78 kg

24
New Lynntech Stack Design
  • Ultrahigh Efficiency
  • (60)
  • LightWeight Metal (No
  • Graphite) Bipolar Plates
  • Ambient Air Ops
  • No Compressor
  • No Hydrators

25

10 kW Fuel Cell Stack
  • DESIGN SPECIFICATIONS
  • 180 cells
  • 300 cm2 active area
  • Generation 3 endplates
  • 10.25 kW _at_ 16 psia
  • 137 V
  • 75 A
  • 50 C
  • 25 kg (hydrated)
  • 400 W/kg (_at_ 250 mA/cm2)
  • 720 W/kg (_at_500 mA/cm2) 18KW

26
Specific Energy Equivalent Total Fuel Cell System
  • Sgl. Tank - 78 kg System - 1 kg H2 24 kWH
  • Net Energy Density 24/78 307 WH/kg
  • Dbl. Tank 96 kg system 2 kg H2 48 kWH
  • Net Energy Density 48/96 500 WH/kg

27
Boeing Fuel Cell Glider Activities System
Integration
  • System Lay out Design
  • Motor and Drive
  • Fuel Cell Systems
  • Compressor
  • Heat exchanger
  • Pumps
  • Controller
  • Battery
  • Controllers and Converters
  • H2 System

28
Boeing Activities Electrical Subsystem
  • Electrical Subsystem Configuration
  • Power Balance
  • Power Demand
  • Motor Drive
  • Controllers
  • Converters
  • Power Generation
  • Fuel Cells
  • Battery
  • Ground Auxiliary Power

29
Safety and Flight Testing
  • Major concern on all new Aircraft
  • Pilot and Airframe issues

30
Safety and Flight Testing(Whoops wrong button
!)
31
Energy System Challenges
  • Energy Density
  • Thermal Management
  • Recharge or Refuel
  • Integration of Solar PV
  • Cost
  • Life
  • Reliability

32
Technology Evolution
  • Area Today Future (2020)
  • Motor/Xtrol 2kw/kg 8-10 kw/kg
  • Fuel Cell Sys. 2kw/kg 5-6 kw/kg
  • Fuel/H2 Storage 7 H2 Wt. 12-15
  • Energy Storage 200 WH/kg 5-800 WH/kg
  • Energy Produced 150 kWH 1000 kWH
  • Range 100 Mi 1000 mi.

33
Emerging Energy Solutions
  • Advanced Batteries Lithium Ion
  • High Density UltraCaps EEStor Other
  • NanoStructured Electrodes 500-2000 WH/kg
  • High Temp Fuel Cells Higher power density
  • Advanced H2 Storage New matls tanks
  • New Energy Gen. Sources - Many

34
Future Technology Options
  • Airframe Weight reduction
  • Improved Airframe/Propulsion Efficiency
  • Energy/Fuel Storage options
  • Higher Energy Density Storage Techs
  • New Designs with integrated storage
  • Improved Solar PV Design - Integration

35
Future Electric PAV ?
36
CarterCopter Hi-Speed Electric GyroCopter

37
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