Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE

25ICE-0061 - DESIGN AND SIMULATION OF A SOLAR HYDROGEN POWERED ELECTRIC VEHICLE – SOHYPE Gabriele Di Blasio, CNR Giacomo Silvagni, University of Bologna Michele Pipicelli, CNR – STEMS Enrico Corti, University of Bologna SAE INTERNATIONAL Agenda - Introduction and Aim - Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation - Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 2 SAE INTERNATIONAL Agenda -Introduction and Aim - Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation - Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 3 SAE INTERNATIONAL Introduction and Aim Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 4 - Decarbonization of passenger cars poses challenges and opportunities in several research areas: powertrain design, control strategies, materials, usage of energy. - In the framework of the MOST, the need for an ‘open’ demonstrator @SML in UNIBO became crucial for testing innovative solutions and the flexibility of technologies over different scenarios. SAE INTERNATIONAL Agenda - Introduction and Aim -Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation - Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 5 SAE INTERNATIONAL Vehicle Platform: Emilia4 - EMILIA 4 ST (short tail) solar vehicle version Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 6 251 Vehicle weight without batteries and driver [kg] 490Vehicle weight with driver [kg] 100Maximum speed [km/h] 2Number of EM [-] SPMSMEM type 1.3 (3)EM nominal power (max) [kW] 35 (125)EM nominal torque (max) ME [Nm] LiNiCoAlO2Battery chemistry 32Battery nominal capacity [kWh] 4x48p14sBattery configuration 3.5Photovoltaic surface [m2] 1.6Vehicle frontal area [m2] 0.20Aerodynamic drag coefficient [-] SAE INTERNATIONAL Agenda - Introduction and Aim - Vehicle Platform: Emilia4 -Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation - Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 7 SAE INTERNATIONAL Vehicle upgrade: Emilia4H -Powertrain modification Electric motors Battery PV array and MPPT Hydrogen fuel cell system Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 8 Electric motor SAE INTERNATIONAL Vehicle upgrade: Emilia4H -Powertrain modification Electric motors Battery PV array and MPPT Hydrogen fuel cell system Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 9 HP H2 Tank 2200 W FC H2 HP Regulator DCDC Buck H2 Sensor SAE INTERNATIONAL Vehicle upgrade: Emilia4H -Bodywork Hydrogen vane Rear wheel cover Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 16 Simulation of blast event SAE INTERNATIONAL Agenda - Introduction and Aim - Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H -Vehicle Safety evaluation - Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 17 SAE INTERNATIONAL Vehicle Safety evaluation -Hydrogen system risk analysis System description Risk analysis Atex classification of hazardous areas Safety procedures and system modifications Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 18 SAE INTERNATIONAL Vehicle Safety evaluation Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 19 -Hydrogen system risk analysis System description Risk analysis Atex classification of hazardous areas Safety procedures and system modifications ATEX connections and fittings (electrical and H2) Adequate storage of the car Adequate and frequent training and maintenance Effective ventilation Leak Detection SAE INTERNATIONAL Agenda - Introduction and Aim - Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation -Vehicle Performance evaluation on the WSC route - Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 20 SAE INTERNATIONAL Vehicle Performance evaluation on the WSC route Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 21 -Indipendence – Topeka route (WSC25 - Australia) Route and weather description Weight – range analysis Driving style comparison 00:00 04:48 09:36 14:24 19:12 00:00 0 200 400 600 800 1000 Global Horizontal Irradiance (W/m 2 ) Time (UTC) Independence - July 2023 Topeka - July 2023 0 20 40 60 80 100 120 140 160 0 25 50 75 100 125 Speed limit [km/h] Distance [km] Elevation Speed Limits 250 300 350 400 Elevation [m] SAE INTERNATIONAL Vehicle Performance evaluation on the WSC route Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 22 -Indipendence – Topeka route (WSC25 - Australia) Route and weather description Weight – range analysis Driving style comparison 0.00 kg 0.12 kg 0.22 kg 0.29 kg 0.48 kg 250 300 350 400 450 0 5 10 15 20 25 30 35 40 Electrical energy stored [kWh] Vehicle weight w/o Driver [kg] 1 battery module 2 battery modules 3 battery modules 4 battery modules 1 redesigned battery module H 2 storage ~30 kg EMILIA 4ST EMILIA 4H config 1 WSC 2025 Cruiser limit EMILIA 4H config 2 (WSC 2025 compliant) DIFFERENCE EMILIA 4H #2 DIFFERENCE EMILIA 4H #1 EMILIA 4ST -6.2 W/km (-23.5%) 20.2 -0.8 W/km (-3.0%) 25.626.4 Energy consumption @ 50 km/h [W/km] -6.4 W/km (-22.3%) 22.3 -0.9 W/km (-3.1%) 27.828.7 Energy consumption @ 55 km/h [W/km] -6.9 W/km (-21.9%) 24.6 -0.9 W/km (-2.9%) 30.631.5 Energy consumption @ 60 km/h [W/km] SAE INTERNATIONAL Vehicle Performance evaluation on the WSC route Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 23 -Indipendence – Topeka route (WSC25 - Australia) Route and weather description Weight – range analysis Driving style comparison 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 Driving style 1 (V avg = 60 km/h) Driving style 2 (V avg = 70 km/h) Driving style 2 (V avg = 80 km/h) Vehicle speed [km/h] Distance [km] H2HHV (LHV) efficiency [%] H2HHV (LHV) energy [kWh] BP delivered energy [kWh] PV delivered energy [kWh] H2used [g] FC Power [kW] Driving style Vehicle n/an/a 5.170.95 n/an/a #1 EMILIA 4ST 6.800.77#2 8.360.65#3 26.4 (31.3)3.01 (2.54)4.18 0.95 76.30.3 #1 EMILIA 4H #1 26.1 (30.8)4.07 (3.44)3.91103.20.4 25.8 (30.5)5.13 (4.34)3.65130.30.5 23.4 (27.7)7.92 (6.69)2.99200.90.7 24.3 (28.8)10.90 (9.21)2.33276.71.0 26.4 (31.2)2.55 (2.15)5.94 0.77 64.70.3 #2 26.0 (30.8)3.44 (2.91)5.7287.40.4 25.7 (30.4)4.35 (3.68)5.49110.50.5 23.4 (27.6)6.71 (5.67)4.93170.30.7 24.2 (28.7)9.24 (7.81)4.37234.51.0 26.4 (31.2)2.24 (1.89)7.61 0.65 56.80.3 #3 25.9 (30.7)3.04 (2.57)7.1477.10.4 25.6 (30.3)3.85 (3.25)7.2297.60.5 23.5 (27.8)5.87 (4.97) 6.73149.10.7 24.5 (29.0)8.05 (6.80)6.24204.21.0 26.4 (31.3)3.01 (2.54)3.59 0.95 76.30.3 #1 EMILIA 4H #2 26.0 (30.8)4.07 (3.44)3.33103.30.4 25.7 (30.4)5.15 (4.36)3.07130.80.5 25.2 (29.8)7.37 (6.23)2.54187.10.7 24.4 (28.9)10.84 (9.16)1.75275.11.0 26.5 (31.3)2.54 (2.14)5.34 0.77 64.40.3 #2 26.0 (30.8)3.44 (2.91)5.1287.30.4 25.7 (30.4)4.35 (3.68)4.89110.50.5 25.2 (29.8)6.23 (5.26)4.45158.10.7 24.5 (28.9)9.16 (7.74)3.78232.41.0 26.6 (31.5)2.22 (1.88)7.12 0.65 56.40.3 #3 26.2 (31.0)3.01 (2.54)6.9276.40.4 25.8 (30.6)3.81 (3.22)6.7396.80.5 25.3 (29.9)5.45 (4.61)6.34138.40.7 24.6 (29.1)8.02 (6.78)5.75203.51.0 SAE INTERNATIONAL Agenda - Introduction and Aim - Vehicle Platform: Emilia4 - Vehicle upgrade: Emilia4 Emilia4H - Vehicle Safety evaluation - Performance evaluation on the Indipendence-Topeka route -Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 24 SAE INTERNATIONAL Conclusions Paper 25ICE-0061, Design and Simulation of a SOlar HYdrogen Powered Electric Vehicle – SOHYPE 25 - The project SOHYPE allowed to realize an innovative zero-emission vehicle prototype, focusing on the integration of the powertrain components, designing new chassis components for research and future challenges. - The “open-vehicle” platform created will guarantee full access to the powertrain and vehicle management while running and it can be used for improving the vehicle performance. - The ATEX analysis and the vehicle performance evaluation pointed out useful insight on the on-board application of H2 and the usage of the energy during realistic route based on the mission profile, respectively. - Future challenges are under evaluation to test the Emilia4H capabilities.