ORGANIZACIÓN ECONÓMICA DEL ESTADO CAPÍTULO PRIMERO

Demonstration of a fuel cell range-extender application for intralogistics and installation of a solar-powered hydrogen refuelling station at a European transit node in Upper Austria

The HyLOG project demonstrates and scientifically investigates the implementation of a 2.5 kW fuel cell range extender

propulsion system to power an intralogistics application. The refuelling of this innovative transport solution is provided via a 350 bar compressed hydrogen cartridge system which is refilled at a hydrogen refuelling station installed on-site at the industrial facility. The hydrogen is generated by electrolysis utilising solar electricity from a 615 kW photovoltaic power plant installed on the rooftop of the factory. The HyLOG project will serve as a reference project for enhanced market entry of this zero-emission logistics solution.

Project management:

Fronius International GmbH

Project partner:

Bitter GmbH, Biovest Consulting GmbH, HyCentA Research GmbH, Clusterland Oberösterreich GmbH / Automobil-Cluster

The new central manufacturing and logistics facility of Fronius International is located in Sattledt, Upper Austria, adjacent to an important European transit node. The factory is a model for future energy supply on an industrial scale: solar electricity generated by a 615 kWP photovoltaic rooftop installation and heat supply via a 1.5 MW biomass

plant reduces CO2emissions by 90%. In this context the HyLOG project addresses

both, the use of renewable energy for transport applications as well as the need to develop innovative energy storage technologies.

Part of the HyLOG project was to develop and integrate a 2.5 kW fuel cell range- extender propulsion system into a tow truck used for intralogistics in the Sattledt factory. The range-extender system was designed to retrofit the lead acid traction battery used in the standard configuration of the vehicle. Compressed hydrogen provided via a 350 bar cartridge system is used for refuelling the vehicle by means of cartridge exchange. The hydrogen cartridges are refilled at the refuelling station which was installed at the production site next to the building.

The hydrogen fuel is generated on-site by electrolysis using renewable energy from a 615 kWp photovoltaic (PV) power plant installed on the rooftop of the production facility. A special research task within the HyLOG project aims to improve hydrogen generation efficiency by up to 15% through DC – direct coupling of the electrolyser and the PV generator. The potential for system standardisation and cost reduction will be investigated. Linking the installed solar-powered filling station to the European hydrogen infrastructure, presently underway will support this important initiative. The fuel cell range-extender is potentially relevant for a broad range of different transport applications, extending from the automotive sector and industrial trucks to leisure applications (e.g. boats). Market research undertaken as part of HyLOG will help to identify scenarios for early market entry.

A3-PROJECTS

A3 | A3 – Austrian Advanced Automotive Technology | A3 – 4th_{Call (2006)}

HYPERBIKE

Hybrid pedal-assisted recuperating bicycle

The HyperBike study (hybrid pedal assisted recuperating bicycle) takes up a subject The HyperBike study investigated assisting

which has been practically forgotten due to the low performance capabilities of earlier the cyclist inconspicuously using an electric

secondary battery types: assisting the cyclist by using an electric drive, without adding powertrain. Given the further development in

significant weight. The further development in both short-term electric storage electric short-term storage units, this subject

(double-layer capacitors, high-current capability lithium polymer ion secondary has become relevant again. In addition to this,

batteries) and in propulsion systems (e.g. permanent-magnet synchronous motors, the possible range is said to be increased

dual-rotor machines with axial gap, etc.) offers an opportunity to rethink the technology significantly through energy regeneration.

and/or the principle. Possible applications scenarios for this

technology in the automotive sector are being

The study looked at concepts going far beyond current technological know-how, and analysed.

applied the principle for regeneration of braking energy typical of hybrid vehicles to very small-sized energy storage units for a light two-wheeler: using these light short- term storage units means that the weight disadvantage of existing electric drive solutions can be alleviated, whilst also significantly improving range by using high- efficiency recuperation, especially in urban areas with stop & go-type operation. The specific aims of the HyperBike project were:

> Increasing comfort in stop & go traffic (acceleration without heavy pedalling) > No significant additional weight (i.e. can also be ridden without the auxiliary drive in

operation)

> Similar to a standard bicycle (no visible ballast, modern design) > Long service life, typical of bicycles, for all components Optional practical functions include:

> Integrated ABS (anti-blocking system on the drive axle) > Integrated LED daylight driving light (safety aspect)

> Safe braking without wear (no influence from wet brake blocks)

Given that both the target unit weight and the high-efficiency recuperation drive system are completely new territory, the feasibility of the concept needed to be examined. In the study, this is to be achieved in part by using a simulation of the energy flows, and in part by examining the innovative, light, electrical machine for overload capacity and cooling with regard to costs.

Looking at the flow of inner-urban transport, the conclusion is reached that there are potential savings of around 1_/

3of the total

energy used if the brake energy is regenerated in stop & go traffic. Many locally-operating fleets are operated with low maximum speeds and with frequent braking and acceleration. This includes two-wheeled vehicles (delivery vehicles), light vehicles (courier, express and parcel delivery services) and also heavy utility vehicles (waste collection and recycling vehicles), as well as rail-based transport (tram-cars).

Assessing the areas of application for the stop & go system indicated the following favourite applications:

> Inner-company transport (between buildings) > Shopping/socialising

> Assisted mobility

> Linking to public transport (Bike&Ride, public bikes) > Warehouse / indoor transport

> Vehicles for printed media and postal distribution services > Powered vehicles for room cleaning

Simulating stop & go operation using super-capacitors as energy storage has suggested a potential saving of at least 15%. The key factors are high-efficiency regeneration and low resistance when the regenerated energy has been spent. Optimising the electric drive resulted in a reduction in active mass of 25% compared to state-of-the-art machines. The market assessment indicated an initial market size of 37,500 bicycles with the stop & go system integrated. The potential has been evaluated at 450,000 units per year for Europe. Migrating of the stop & go technology into other pedal-assisted vehicle segments with a similar power demand is

Project management:

Austrian Mobility Research – FGM – AMOR gemeinnützige GmbH

Project partners:

University of Leoben – Institute for Electrical Engineering, DanklHampel Design

A3-PROJECTS

A3 | A3 – Austrian Advanced Automotive Technology | A3 – 4th_{Call (2006)}