1. Extended Range Fuel Cell Utility Vehicle: Design, Build, and Demonstration Clay Hearn April 27, 2011

2. Introduction Program Goals Team Members Model Based Design Vehicle Build

3. Program Goals Program sponsored through Defense Logistics Agency (DLA) and Crane to provide extended range hydrogen fuel cell vehicles for use at Warner Robbins AFB in Georgia Hydrogen refueling infrastructure on base Currently using hydrogen fuel cell fork lifts Numerous all-electric utility vehicles and NEVs Maximize on-board hydrogen storage without sacrificing vehicle performance Build and deliver units in 8 months to Warner Robbins AFB for 12 month evaluation

4. Project Team Members Center for Transportation and the Environment Project management Vehicle Modeling (PSAT) Vehicle Design Final Integration Vehicle Support and Analysis Fuel cell system and integration support Gas Technology Institute Hydrogen storage development Base vehicle supplier and support

5. Energy Storage Options

6. Vehicle Configurations Li-Ion batteries double range of vehicle over stock lead-acid batteries Range of hydrogen vehicle driven by onboard stored hydrogen ~ 10X higher specific energy storage with 350 bar hydrogen fuel cell over advanced Li-ion batteries Analysis to right assumes 2 kg on-board hydrogen storage Plug-in options increase range by 25% – 50% over fuel cell alone, but also increase vehicle mass up to 250 kg Fuel cell dominant hybrids increase range 25% – 27% over fuel cell alone

7. Hydrogen Storage Options Gravimetric capacity Affects overall vehicle mass Limits additional cargo bed capacity Reduces vehicle economy Volumetric capacity Limits storage volume Poses integration issues

8. Evaluating Hydrogen Storage Increasing on-board H2 Increasing on-board H2

9. Vehicle Integration 8-month build schedule to retrofit two vehicles Supervisory control and data recording NI CompactRIO Labview software CAN communication between fuel cell and boost converter “Rolling Benchtop” testing

10. Final Integration and Testing Completed October 2010 Vehicle Range Testing 309 mile range demonstrated 87.8 mi/kg average 5 days to complete! Vehicles include 120V 1.5 kW inverter for on-site power 12 month demonstration at DDWG began November 2010

11. Questions?