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Large sport utility vehicles have relatively low fuel economy, and thus a large potential for improvement. One way to improve the vehicle efficiency is by converting the drivetrain to hydrogen fuel cell power. Virginia Tech has designed a fuel cell hybrid electric vehicle based on converting a Chevrolet Suburban into an environmentally friendly truck. The truck has two AC induction drive motors, regenerative braking to capture kinetic energy, a compressed hydrogen fuel storage system, and a lead acid battery pack for storing energy. The fuel cell hybrid electric vehicle emits only water from the vehicle. The fuel cell stacks have been sized to make the 24 mpg (gasoline equivalent) vehicle charge sustaining, while maintaining the performance of the stock vehicle. The design and integration challenges of implementing these systems in the vehicle are described.

The Hybrid Electric Vehicle Team (HEVT) of Virginia Tech has designed a fuel cell hybrid electric vehicle to compete in the 2002 FutureTruck Challenge. This year the competition is focused on reducing tailpipe emissions and increasing vehicle efficiency without compromising vehicle performance. The team has converted a Ford Explorer into an environmentally friendly truck. Our truck has an AC induction drive motor, regenerative braking to capture kinetic energy, compressed hydrogen fuel storage system, and a lead acid battery pack. The Virginia Tech FutureTruck emits only water from the vehicle. The fuel cell stacks have been sized to make the 35.8 mpg (combined adjusted gasoline equivalent) vehicle charge sustaining.

The Virginia Tech Hybrid Electric Vehicle Team (HEVT) has integrated a proton exchange membrane (PEM) fuel cell as the auxiliary power unit (APU) of a series hybrid design to produce a highly efficient zero-emission vehicle (ZEV). This design is implemented in a 1997 Chevrolet Lumina sedan, renamed ANIMUL H2, using an efficient AC induction drivetrain, regenerative braking, compressed hydrogen fuel storage, and an advance lead-acid battery pack for peak power load leveling. The fuel cell is sized to supply the average power demand and to sustain the battery pack state-of-charge (SOC) within a 40-80% window. To optimize system efficiency, the fuel cell is driven with a load-following control strategy. The vehicle is predicted to achieve a combined city/highway fuel economy of 4.3 L/100 km or 51 mpgge (miles per gallon gasoline equivalent).

This paper describes the design and construction of a fuel cell hybrid electric vehicle based on the conversion of a five passenger production sedan. The vehicle uses a relatively small fuel cell stack to provide average power demands, and a battery pack to provide peak power demands for varied driving conditions. A model of this vehicle was developed using ADVISOR, an Advanced Vehicle Simulator that tracks energy flow and fuel usage within the vehicle drivetrain and energy conversion components. The Virginia Tech Fuel Cell Hybrid Electric Vehicle was tested on the EPA City and Highway driving cycles to provide data for validation of the model. Vehicle data and model results show good correlation at all levels and show that ADVISOR has the capability to model fuel cell hybrid electric vehicles.

The Hybrid Electric Vehicle Team of Virginia Tech (HEVT) has integrated a proton exchange membrane fuel cell as the auxiliary power unit of a series hybrid design to produce a highly efficient zero-emission vehicle. A 1997 Chevrolet Lumina sedan, renamed ANIMUL H2, carries this advanced powertrain, using an efficient AC induction drivetrain, regenerative braking, compressed hydrogen fuel storage, and an advance lead-acid battery pack for peak power load leveling. The fuel cell supplies the average power demand and to sustain the battery pack state-of-charge within a 40-80% window. To optimize system efficiency, a load-following strategy controls the fuel cell power level. The vehicle weighed 2000kg (4400lb) and achieved a combined city/highway fuel economy of 9L/100 km or 26 mpgge (miles per gallon gasoline equivalent).

The Hybrid Electric Vehicle Team of Virginia Tech is one of 15 schools across the United States and Canada currently competing in EcoCAR 2: Plugging In to the Future. EcoCAR 2 is a three year competition that mimics GM's Vehicle Development Process (VDP): design, build, then refine. The first step in the design process is the selection of a powertrain architecture. In the architecture selection process, HEVT considered three options: a Battery Electric Vehicle (BEV), a Series Plug-in Hybrid Electric Vehicle (PHEV), and a Series-Parallel PHEV. The team chose the Series-Parallel PHEV based on powertrain modeling and simulation and CAD packaging analysis. Next, the team looked at a variety of component combinations and selected the one that offered the best capacity to meet competition and team goals. These components are then packaged in the CAD model to plan for component integration. As this integration was happening, a control system was also being developed.