SLIDE 1
2
The MC Method Ryan Harty and Steve Mathison Honda R&D Americas, - - PowerPoint PPT Presentation
The MC Method Ryan Harty and Steve Mathison Honda R&D Americas, - - PowerPoint PPT Presentation
An Advanced Fueling Algorithm The MC Method Ryan Harty and Steve Mathison Honda R&D Americas, Inc 2 Outline Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be MC Method Development Determining Tank Specific MC
SLIDE 2
SLIDE 3
3
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 4
4
Need for an advanced fueling algorithm
A fueling standard should work well for all tank systems, in all conditions, for any station configuration, in all ambient conditions, all the time. Guarantee safe fueling in all conditions Guarantee fast fueling in a wide range of conditions
Real customers using real stations need great station performance
SLIDE 5
5
Need for an advanced fueling algorithm Precooling Temperature Fill Pressure
- 40C
- 20C
0C 25MPa 35MPa 50MPa 70MPa
Some Forklift Stations Most of the Precooled Stations in US Today Some of the Future Stations in the US Tomorrow
No Cooling
Station Operating Envelope Current Fueling Standard Advanced Algorithm
Many Current Stations and Bus Stations (No Precooling)
SLIDE 6
6
Need for an advanced fueling algorithm Precooling Temperature Fill Pressure
- 40C
- 20C
0C 25MPa 35MPa 50MPa 70MPa
Some Forklift Stations
No Cooling
SAE J2601 Type A70 SAE J2601 Type A35 SAE J2601 Type B70 SAE J2601 Type B35 SAE J2601 Type C35 SAE J2601 Type D35
Station Operating Envelope Current Fueling Standard Advanced Algorithm
Most of the Precooled Stations in US Today Some of the Future Stations in the US Tomorrow Many Current Stations and Bus Stations (No Precooling)
CAFCP Rev6.1
Do the existing fill protocols always give good fueling performance to the maximum capability of the tank system?
No Standard No Standard
SLIDE 7
7
Need for an advanced fueling algorithm Precooling Temperature Fill Pressure
- 40C
- 20C
0C 25MPa 35MPa 50MPa 70MPa
SAE J2601 Type A70 SAE J2601 Type A35 SAE J2601 Type B70 SAE J2601 Type B35 SAE J2601 Type C35
Station Operating Envelope Current Fueling Standard Advanced Algorithm
Target: Safe, High Quality, Fast Fills at All Stations
No Cooling
SAE J2601 Type D35 CAFCP Rev6.1
Advanced Algorithm
Maximize the possible performance at all conditions.
SLIDE 8
8
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 9
9
An advanced fueling algorithm…
- should be based on the actual conditions of a hydrogen station
enthalpy of delivered hydrogen (any condition)
- should be applicable for all initial fill temperature, pressure
internal energy in the tank (any condition)
- should be based on the actual capabilities of a tank system
actual volume, NWP real thermodynamic characteristics hot soak, cold soak based on test results and conditions expected by the OEM and the Station
- should make use of available technology to communicate these
parameters to the station. ID-Fill? IRDA? RFID? etc
SLIDE 10
10
Knowable by the Vehicle:
- NWP
- Tank Volume
- Max Hot Soak Temp
- Max Cold Soak Temp
- Tank Thermodynamics
- Other?
Knowable by the Station:
- Ambient Temperature
- Initial Tank Pressure
- Enthalpy of Fill
- Precooler Output
- Starting Pressure
- Ending Pressure
Photo courtesy of Air Products and Chemicals Inc
An advanced fueling algorithm…
SLIDE 11
11
Knowable by the Vehicle:
- NWP
- Tank Volume
- Max Hot Soak Temp
- Max Cold Soak Temp
- Tank Thermodynamics
- Other?
Knowable by the Station:
- Ambient Temperature
- Initial Tank Pressure
- Enthalpy of Fill
- Precooler Output
- Starting Pressure
- Ending Pressure
Photo courtesy of Air Products and Chemicals Inc
Data Toss
(Static Communication – RFID, Barcode, HVAS, ID-Fill,
- etc. Not integrated to ECU)
An advanced fueling algorithm…
SLIDE 12
12
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 13
13
MC Method Development
hi=enthalpy at the inlet (at T,P,dm) m1=initial mass of hydrogen in the control volume u1=initial internal energy in the control volume m2=final mass of hydrogen in the control volume u2=final internal energy in the control volume Q=heat transferred across the control volume boundary
A control volume analysis yields several insights.
2 ) , ( ) , ( 1 1 2 ) , ( 1 1 ) , ( 2 2 ) , ( ) , ( ) , (
) ( m Q h m u m u Q u m u m h m Q u m h m
P T i i P T P T P T P T i i P T cv cv P T i i
Since internal energy, u, is a state property, if we know the density, and the pressure, for any given amount of heat transfer, Q, we can directly calculate the temperature.
Model based on Inlet Enthalpy and Internal Energy
Only source
- f energy
?
SLIDE 14
14
MC Method Development
hi=enthalpy at the inlet (at T,P,dm) m1=initial mass of hydrogen in the control volume u1=initial internal energy in the control volume m2=final mass of hydrogen in the control volume u2=final internal energy in the control volume Q=heat transferred across the control volume boundary Density=target density at end-of-fill Tadiabatic=adiabatic temperature if no heat was transferred
A control volume analysis yields several insights.
2 ) , ( ) , ( 1 1 2 ) , ( 1 1 ) , ( 2 2 ) , ( ) , ( ) , (
) ( m Q h m u m u Q u m u m h m Q u m h m
P T i i P T P T P T P T i i P T cv cv P T i i
If we study the case of Q=0, the adiabatic condition, then u2=uadiabatic, and since u is a state property, for a given density and pressure we can directly calculate the adiabatic temperature. Density, Tadiabatic
2 ) , ( 1 2 ) , ( 1 1 ) , (
) (
1 1
m i h m m u m u
P T P T P T Adiabatic
T
adiabatic depends only on station enthalpy and
initial tank conditions (Temp, Press).
Only source
- f energy
SLIDE 15
15
MC Method Development
m2=final mass of hydrogen in the control volume Q=heat transferred across the control volume boundary Density=target density at end-of-fill Tadiabatic=adiabatic temperature if no heat was transferred Tfinal=end of fill temperature Cv=specific heat capacity of hydrogen at constant volume
Now let heat transfer occur again, and let the tank hydrogen in the tank cool to some final state, Tfinal. Density is constant as the tank cools. The heat transfer can be described as:
X
) (
2 final adiabatic v
T T C m Q
Density, Tadiabatic to Tfinal
) (
2 final adiabatic v
T T C m Q
1
?
SLIDE 16
16
MC Method Development
20 40 60 80 100 120 140 160 600 1200 1800 2400 3000 3600 Tank Temp (C), Pressure (MPa) Time (s)
T vs Time for 35MPa Type 3 Fill at 25C
T T Adiabatic
End of Fill Time = 3min T Adiabatic T Final (3min)
) (
2 final adiabatic v
T T C m Q
Fill from 2MPa start at 25C using no precooling
T Final (30min)
The total heat transfer from the hydrogen can be described by T
adiabatic to Tfinal
Use of T
adiabatic to Calculate Q:
T
adiabatic is maximum possible temperature in the tank.
?
SLIDE 17
17
Q m2 TH2Inside TLinerWall TLinerW/CFRP TCFRPOuter TEnvironment QEnvironment
Actual Tank Model 1D or 2D Heat Transfer Temp Distribution Complex Time Domain All Time Q Environment Need to solve Heat Capacitance Each material M, C
The temperature distribution inside the liner is very complex.
Individual layer mass, specific heat capacity of liner, tank valve assy, carbon fiber, epoxy, etc
MC Method Development
SLIDE 18
18
Q m2 TH2Inside TLinerWall TLinerW/CFRP TCFRPOuter TEnvironment QEnvironment
Simplify
Actual Tank Model Model 1D or 2D Heat Transfer Lumped Heat Capacitance Temp Distribution Complex Time Domain All Time Q Environment Need to solve Heat Capacitance Each material M, C
The temperature distribution inside the liner is very complex.
Individual layer mass, specific heat capacity of liner, tank valve assy, carbon fiber, epoxy, etc
MC Method Development
SLIDE 19
19
Q m2 TH2Inside TLinerWall TLinerW/CFRP TCFRPOuter TEnvironment QEnvironment =0 Q Mcv TH2Inside T
Characteristic Volume
TEnvironment Q Environment Characteristic Volume
Simplify
Adiabatic Boundary
Actual Tank Model Model 1D or 2D Heat Transfer Lumped Heat Capacitance Temp Distribution Complex T=TH2Inside Time Domain All Time 3 min + Dt (final condition) Q Environment Need to solve Heat Capacitance Each material M, C Combined MC
The temperature distribution inside the liner is very complex. m2
=Tfinal= Combined mass and specific heat capacity = MC
Individual layer mass, specific heat capacity of liner, tank valve assy, carbon fiber, epoxy, etc
(Mathematical entity – Not actual mass or volume)
MC Method Development
SLIDE 20
20
When we make these simplifications, the heat transfer into the Characteristic Volume can be described as: And from before, the heat transfer from the hydrogen can be described as: =0 Q Mcv TH2Inside T
Characteristic Volume
TEnvironment Q Environment Characteristic Volume
MC Method Development
Adiabatic Boundary
Model Model Lumped Heat Capacitance Temp Distribution T=TH2Inside Time Domain 3 min + Dt (final condition) Q Environment Heat Capacitance Combined MC
m2
=Tfinal= Combined mass and specific heat capacity = MC
) (
initial final
T T MC Q
2
) (
2 final adiabatic v
T T C m Q
1
SLIDE 21
21
MC Method Development
These equations can be combined: And a direct analytical expression for Tfinal can be achieved: =0 Q Mcv TH2Inside T
Characteristic Volume
TEnvironment Q Environment Characteristic Volume
Adiabatic Boundary
Model Model Lumped Heat Capacitance Temp Distribution T=TH2Inside Time Domain 3 min + Dt (final condition) Q Environment Heat Capacitance Combined MC
m2
=Tfinal= Combined mass and specific heat capacity = MC
) ( ) (
2 final adiabatic v initial final
T T C m T T MC
v initial adiabatic v final
C m MC MCT T C m T
2 2
SLIDE 22
22
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 23
23
Determining Tank Specific MC from Test Data
To determine MC from test data, combine equations 1 and 2, and apply the heat transfer calculated from the test data:
) (
initial final
T T MC Q ) ( ) (
2 2 final adiabatic final adiabatic v
u u m Q T T C m Q ) ( ) (
2 initial final final adiabatic
T T u u m MC
hi=mass averaged enthalpy at the inlet uadiabatic=adiabatic internal energy in the control volume m1=initial mass of the control volume m2=final mass of hydrogen in the control volume u1=initial internal energy in the control volume ufinal=final internal energy in the control volume Q=heat transferred across the control volume boundary Tfinal=final temperature of the hydrogen (at 3 minutes) Tinitial=initial temperature of the system
2 ) , ( 1 2 ) , ( 1 1 ) , (
) ( m h m m u m u
P T i P T P T Adiabatic
Analyze test fill data to determine MC for that fill. Use a few fills to characterize the tank.
Heat transfer from the hydrogen Heat transfer to the MC Adiabatic Internal Energy (from data) Resulting MC (for the fill) Units: kJ/K
SLIDE 24
24
Determining Tank Specific MC from Test Data
20 40 60 80 100 120 140 160 180 10 20 30 40 50 60 70 80 90 600 1200 1800 2400 3000 3600 MC (kJ/K) Tank Temp (C), Pressure (MPa) Time (s)
MC vs Time for 35MPa Type 3 Fill at 25C
T P MC
) ( ) (
2 initial final final adiabatic
T T u u m MC
End of Fill Time = 3min End of Fill MC = 62 MC(t) increases with time as the tank cools
Basic Theory: For a given tank, the MC vs Time curve will be a similar shape for each fill, with the magnitude depending on conditions.
T Adiabatic = 160C
MC at end of fill, MC vs Time is characteristic for a given tank.
3min80C 10min67C 30min60C
SLIDE 25
25
Find a curve fit that represents the physics. MC varies with fill time, initial fill pressure, temperature, and precooling level Use Internal Energy and Time
Determining Tank Specific MC from Test Data
j t k init adiabatic
e g U U A C time Conditions MC
D
1 ) , (
Constant (at 3min fill target) Adjustment dependent on Fill Amount (at 3min fill target), initial conditions, and precooling temp Time adjustment of MC for >3min filling
(There are other solutions that might work better. This one is simple.)
5 Coefficients: C - Constant A - Initial Conditions g, k, j - Time Response
Coefficients of a standard equation are communicated to the station Basis of “ID Fill”
SLIDE 26
26
Determining Tank Specific MC from Test Data
25C, No Precooling 25C, -20C Precooling 2MPa 1/2 Tank 180s 300s 600s 1200s T(180) T(300) T(600) T(1200) P(180)P(300) P(600) P(1200)
For each test, Stop at 100%SOC. Take data
- f Temp and Pressure for 3600s.
Initial Fill Amount
Temperature Condition
At Powertech, we conducted a series fill tests. The goal was to determine the constants of the equation using 4 tests, and then use the equation to predict the
- utcome of a 5th test.
Tanks tested: 35MPa Type 3, 70MPa Type 4, and 70MPa Type 4 tank filled to 50MPa. Test Matrix
SLIDE 27
27
Conduct a few test fills at different conditions to find the constants of the equation
Determining Tank Specific MC from Test Data
y = 0.3361x + 53.844 R² = 0.8996 54 56 58 60 62 64 10 20 30 MC (kJ/K) Uadiabatic/Uinit
MC vs Uadiabatic/Uinit
Result of 4 tests to characterize the tanks can determine all of the coefficients
MC MC e g U U A C t U MC
j t k init adiabatic
D
D
1 ) , (
A C
3 minute fill >3minute fill 20 40 60 80 100 1000 2000 3000 4000 Data Model
g * (1- exp-kt)j g = 6.33E+04 k = 3.66E-09 j = 5.83E-01
MC vs (t-180s) DMC (kJ/K) t-180s 2 Fills at 50% SOC 2 Fills at 0% SOC
SLIDE 28
28
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 29
29
Applying MC Method Knowable by the Vehicle:
- NWP
- Tank Volume
- Max Hot Soak Temp
- Max Cold Soak Temp
- Tank MC Characteristics
- Other?
Knowable by the Station:
- Ambient Temperature
- Initial Tank Pressure
- Enthalpy of Fill
- Precooler Output
- Starting Pressure
- Ending Pressure
Photo courtesy of Air Products and Chemicals Inc
Data Toss
(Static Communication – RFID, Barcode, HVAS, ID-Fill,
- etc. Not integrated to ECU)
Step 0) Toss the vehicle information to the station
SLIDE 30
30
) ( 1 ) , , ( ) , ( ) , (
) , ( v cv Initial Adiabatic v cv Final j t k init adiabatic adiabatic adiabatic target adiabatic cv average add initial initial adiabatic add P T e add average initial initial initial initial initial cv add target cv initial initial initial init hot ambient init
C m MC MCT T C m T e g U U A C MC u P T T m h m u m u m h m h P T u u m m m V m P T V m t T T T D D
D
Applying MC Method
Step 1) Set the fill time based on Hot Soak Tinit=Tambient+DTHot Soak
Tfinal >85C
Yes No
Dt=Dt+10
Step 2) Optimizes Fill Time for Hot Soak Optimizes T Final Close to 85C Set target SOC=100% Estimate average enthalpy to be delivered Calculate adiabatic internal energy and temperature Set hot soak temp Calculate initial mass Calculate additional mass Calculate initial internal energy Calculate MC
Vehicle Station
(Similar to SAEJ2601)
SLIDE 31
31
Applying MC Method
t s P P CPRR SOC T P P C m MC MCT T C m T e g U U A C MC u P T T m h m u m u m h m h P T u u m m m P T V m T T T
init et T target Final target Target v cv Initial Adiabatic v cv Final j t k init adiabatic adiabatic adiabatic target adiabatic cv average add initial initial adiabatic add P T e add average initial initial initial initial initial cv add initial initial initial init cold ambient init
D D
D
180 % 100 and ) , ( ) ( 1 ) , , ( ) , ( ) , (
arg ) , (
Step 2) Set the Pressure Target based on Tinit=Cold Soak Calculate Tfinal Estimate average enthalpy to be delivered Calculate adiabatic internal energy and temperature Set cold soak temp Calculate cold initial mass Calculate additional mass Calculate initial internal energy Calculate MC Calculate Pressure Target Resulting Pressure Ramp Rate (Similar to SAEJ2601)
Vehicle Station
SLIDE 32
32
Applying MC Method to J2601
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling50 1.8 75.8 75.4 74.8 74.4 74.0 73.4 73.0 72.7 72.6 72.4
no fueling45 2.5 75.0 74.6 74.1 73.7 73.4 72.9 72.7 72.6 72.5 72.3
no fueling40 3.4 74.5 74.1 73.7 73.3 73.1 72.7 72.6 72.6 72.4 72.3
no fueling35 4.4 74.2 73.8 73.4 73.1 72.9 72.7 72.6 72.5 72.4 72.3
no fueling30 5.5 73.6 73.3 72.8 72.5 72.2 71.9 71.7 71.5 71.2
no fueling no fueling25 6.7 73.2 72.8 72.2 71.8 71.5 71.1 70.8 70.4 70.0
no fueling no fueling20 7.9 72.7 72.3 71.7 71.3 70.9 70.3 69.8 69.3 68.8
no fueling no fueling10 10.7 72.0 71.5 70.8 70.2 69.6 68.7 67.8 67.0 66.3
no fueling no fueling13.6 71.4 70.8 69.8 69.0 68.3 67.0 65.8 64.6 63.6
no fueling no fueling- 10
13.6 70.1 69.4 68.4 67.4 66.5 65.0 63.6 62.2
61.1 no fueling no fueling- 20
13.6 68.9 68.1 66.8 65.8 64.7 62.9 61.2 59.5
no fueling no fueling no fueling- 30
13.6 67.7 66.7 65.3 64.1 62.8 60.7 58.6 56.8
no fueling no fueling no fueling- 40
13.6 67.3 66.4 65.0 63.8 62.6 60.6 58.7 56.8
no fueling no fueling no fueling< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fuelingB-70 1-7kg
Average Pressure Ramp Rate, APRR (MPa/min)
Ambient Temperature, Tamb (°C)
Lookup Table: 70MPa, -20°C, 1-7kg
Fueling Target Pressure, Ptarget (MPa)
Initial Tank Pressure, P0 (MPa)
Step 1 Information
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 65
- 17.5
1.6 1.8 54.0 48.6 3.3 3.7 45 60
- 17.5
2.3 2.5 38.5 34.6 4.8 5.3 40 55
- 17.5
3.1 3.4 28.6 25.7 6.5 7.2 35 50
- 17.5
4.0 4.4 22.1 19.9 8.5 9.4 30 45
- 17.5
4.9 5.5 17.7 15.9 10.6 11.8 25 40
- 17.5
6.0 6.7 14.6 13.1 12.9 14.4 20 35
- 17.5
7.2 7.9 12.2 11.0 15.4 17.1 10 25
- 17.5
9.6 10.7 9.1 8.2 20.6 22.8 15
- 17.5
12.2 13.6 7.2 6.5 25.9 28.8
- 10
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 20
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 30
15
- 17.5
12.2 13.6 7.2 6.4 26.0 28.8
- 40
15
- 17.5
12.2 13.6 7.1 6.4 26.0 28.9 < -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Lookup 174l 7kg
Peak Flow (g/s)
157l 6.3kg
Simulation Results
Hot Soak
Ramp Rate (MPa/min)
Simulation Input
Ramp Rate (min/87.5MPa)
10% slower
Ambient Temperature, Tamb (°C)
Temperature (°C)
Cold Fill 10% slower
B-70 1-7kg
Lookup
Step 2 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 25
- 22.5
1.6 54.0 50 41.0 39.1 36.0 33.0 30.0 24.1 18.3 12.6 7.0 1.3
no fueling
45 25
- 22.5
2.3 38.5 45 28.9 27.5 25.3 23.2 21.1 17.0 12.9 8.9 4.9 0.9
no fueling
40 25
- 22.5
3.1 28.6 40 21.3 20.3 18.7 17.2 15.6 12.6 9.6 6.6 3.7 0.7
no fueling
35 25
- 22.5
4.0 22.1 35 16.4 15.7 14.4 13.2 12.0 9.7 7.4 5.1 2.8 0.5
no fueling
30 20
- 22.5
4.9 17.7 30 13.0 12.4 11.4 10.5 9.5 7.6 5.8 3.9 2.0
no fueling no fueling
25 15
- 22.5
6.0 14.6 25 10.7 10.1 9.3 8.5 7.7 6.2 4.6 3.1 1.5
no fueling no fueling
20 10
- 22.5
7.2 12.2 20 8.9 8.5 7.8 7.1 6.4 5.1 3.8 2.4 1.1
no fueling no fueling
10
- 22.5
9.6 9.1 10 6.6 6.2 5.7 5.2 4.6 3.6 2.6 1.6 0.6
no fueling no fueling
- 10
- 22.5
12.2 7.2 5.1 4.8 4.4 4.0 3.6 2.7 1.9 1.1 0.3
no fueling no fueling
- 10
- 20
- 22.5
12.2 7.2
- 10
5.0 4.7 4.3 3.9 3.4 2.6 1.7 0.9 0.1
no fueling no fueling
- 20
- 30
- 22.5
12.2 7.2
- 20
4.9 4.6 4.2 3.7 3.3 2.4 1.6 0.7
no fueling no fueling no fueling
- 30
- 40
- 30.0
12.2 7.2
- 30
4.8 4.5 4.1 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
- 40
- 40
- 40.0
12.2 7.1
- 40
4.8 4.5 4.0 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Cold Soak
Temperature (°C) Ambient Temperature, Tamb (°C)
(MPa/ min)
Ramp Rate Ambient Temperature, Tamb (°C)
B-70 1-7kg
(min/ 87.5MPa)
B-70 1-7kg
Actual Fueling Duration (min)
Add intermediate leak check times: up to 10 sec after every 25MPa increase in fueling pressure
Initial Tank Pressure, P0 (MPa) Cold Fill
Step 3 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 91% 91% 90% 90% 90% 90% 90% 90% 90% 91%
no fueling
45 90% 90% 90% 89% 89% 89% 90% 90% 91% 92%
no fueling
40 90% 90% 89% 89% 89% 90% 90% 91% 92% 93%
no fueling
35 90% 89% 89% 89% 90% 90% 91% 92% 93% 94%
no fueling
30 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
25 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
20 88% 88% 88% 89% 89% 90% 90% 92% 93%
no fueling no fueling
10 88% 88% 88% 88% 88% 89% 90% 91% 93%
no fueling no fueling
87% 87% 87% 88% 88% 89% 90% 91% 93%
no fueling no fueling
- 10
86% 86% 86% 86% 87% 87% 88% 89% 91%
no fueling no fueling
- 20
85% 85% 85% 85% 85% 85% 86% 87%
no fueling no fueling no fueling
- 30
84% 84% 83% 83% 83% 84% 84% 85%
no fueling no fueling no fueling
- 40
84% 83% 83% 83% 83% 83% 84% 85%
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Initial Tank Pressure, P0 (MPa)
Ambient Temperature, Tamb (°C) Hot Case Final State of Charge, SOC
(Hot Soak - No History)
B-70 1-7kg
Look-up tables from J2601
SLIDE 33
33
Applying MC Method to J2601
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling50 1.8 75.8 75.4 74.8 74.4 74.0 73.4 73.0 72.7 72.6 72.4
no fueling45 2.5 75.0 74.6 74.1 73.7 73.4 72.9 72.7 72.6 72.5 72.3
no fueling40 3.4 74.5 74.1 73.7 73.3 73.1 72.7 72.6 72.6 72.4 72.3
no fueling35 4.4 74.2 73.8 73.4 73.1 72.9 72.7 72.6 72.5 72.4 72.3
no fueling30 5.5 73.6 73.3 72.8 72.5 72.2 71.9 71.7 71.5 71.2
no fueling no fueling25 6.7 73.2 72.8 72.2 71.8 71.5 71.1 70.8 70.4 70.0
no fueling no fueling20 7.9 72.7 72.3 71.7 71.3 70.9 70.3 69.8 69.3 68.8
no fueling no fueling10 10.7 72.0 71.5 70.8 70.2 69.6 68.7 67.8 67.0 66.3
no fueling no fueling13.6 71.4 70.8 69.8 69.0 68.3 67.0 65.8 64.6 63.6
no fueling no fueling- 10
13.6 70.1 69.4 68.4 67.4 66.5 65.0 63.6 62.2
61.1 no fueling no fueling- 20
13.6 68.9 68.1 66.8 65.8 64.7 62.9 61.2 59.5
no fueling no fueling no fueling- 30
13.6 67.7 66.7 65.3 64.1 62.8 60.7 58.6 56.8
no fueling no fueling no fueling- 40
13.6 67.3 66.4 65.0 63.8 62.6 60.6 58.7 56.8
no fueling no fueling no fueling< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fuelingB-70 1-7kg
Average Pressure Ramp Rate, APRR (MPa/min)
Ambient Temperature, Tamb (°C)
Lookup Table: 70MPa, -20°C, 1-7kg
Fueling Target Pressure, Ptarget (MPa)
Initial Tank Pressure, P0 (MPa)
Step 1 Information
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 65
- 17.5
1.6 1.8 54.0 48.6 3.3 3.7 45 60
- 17.5
2.3 2.5 38.5 34.6 4.8 5.3 40 55
- 17.5
3.1 3.4 28.6 25.7 6.5 7.2 35 50
- 17.5
4.0 4.4 22.1 19.9 8.5 9.4 30 45
- 17.5
4.9 5.5 17.7 15.9 10.6 11.8 25 40
- 17.5
6.0 6.7 14.6 13.1 12.9 14.4 20 35
- 17.5
7.2 7.9 12.2 11.0 15.4 17.1 10 25
- 17.5
9.6 10.7 9.1 8.2 20.6 22.8 15
- 17.5
12.2 13.6 7.2 6.5 25.9 28.8
- 10
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 20
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 30
15
- 17.5
12.2 13.6 7.2 6.4 26.0 28.8
- 40
15
- 17.5
12.2 13.6 7.1 6.4 26.0 28.9 < -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Lookup 174l 7kg
Peak Flow (g/s)
157l 6.3kg
Simulation Results
Hot Soak
Ramp Rate (MPa/min)
Simulation Input
Ramp Rate (min/87.5MPa)
10% slower
Ambient Temperature, Tamb (°C)
Temperature (°C)
Cold Fill 10% slower
B-70 1-7kg
Lookup
Step 2 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 25
- 22.5
1.6 54.0 50 41.0 39.1 36.0 33.0 30.0 24.1 18.3 12.6 7.0 1.3
no fueling
45 25
- 22.5
2.3 38.5 45 28.9 27.5 25.3 23.2 21.1 17.0 12.9 8.9 4.9 0.9
no fueling
40 25
- 22.5
3.1 28.6 40 21.3 20.3 18.7 17.2 15.6 12.6 9.6 6.6 3.7 0.7
no fueling
35 25
- 22.5
4.0 22.1 35 16.4 15.7 14.4 13.2 12.0 9.7 7.4 5.1 2.8 0.5
no fueling
30 20
- 22.5
4.9 17.7 30 13.0 12.4 11.4 10.5 9.5 7.6 5.8 3.9 2.0
no fueling no fueling
25 15
- 22.5
6.0 14.6 25 10.7 10.1 9.3 8.5 7.7 6.2 4.6 3.1 1.5
no fueling no fueling
20 10
- 22.5
7.2 12.2 20 8.9 8.5 7.8 7.1 6.4 5.1 3.8 2.4 1.1
no fueling no fueling
10
- 22.5
9.6 9.1 10 6.6 6.2 5.7 5.2 4.6 3.6 2.6 1.6 0.6
no fueling no fueling
- 10
- 22.5
12.2 7.2 5.1 4.8 4.4 4.0 3.6 2.7 1.9 1.1 0.3
no fueling no fueling
- 10
- 20
- 22.5
12.2 7.2
- 10
5.0 4.7 4.3 3.9 3.4 2.6 1.7 0.9 0.1
no fueling no fueling
- 20
- 30
- 22.5
12.2 7.2
- 20
4.9 4.6 4.2 3.7 3.3 2.4 1.6 0.7
no fueling no fueling no fueling
- 30
- 40
- 30.0
12.2 7.2
- 30
4.8 4.5 4.1 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
- 40
- 40
- 40.0
12.2 7.1
- 40
4.8 4.5 4.0 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Cold Soak
Temperature (°C) Ambient Temperature, Tamb (°C)
(MPa/ min)
Ramp Rate Ambient Temperature, Tamb (°C)
B-70 1-7kg
(min/ 87.5MPa)
B-70 1-7kg
Actual Fueling Duration (min)
Add intermediate leak check times: up to 10 sec after every 25MPa increase in fueling pressure
Initial Tank Pressure, P0 (MPa) Cold Fill
Step 3 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 91% 91% 90% 90% 90% 90% 90% 90% 90% 91%
no fueling
45 90% 90% 90% 89% 89% 89% 90% 90% 91% 92%
no fueling
40 90% 90% 89% 89% 89% 90% 90% 91% 92% 93%
no fueling
35 90% 89% 89% 89% 90% 90% 91% 92% 93% 94%
no fueling
30 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
25 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
20 88% 88% 88% 89% 89% 90% 90% 92% 93%
no fueling no fueling
10 88% 88% 88% 88% 88% 89% 90% 91% 93%
no fueling no fueling
87% 87% 87% 88% 88% 89% 90% 91% 93%
no fueling no fueling
- 10
86% 86% 86% 86% 87% 87% 88% 89% 91%
no fueling no fueling
- 20
85% 85% 85% 85% 85% 85% 86% 87%
no fueling no fueling no fueling
- 30
84% 84% 83% 83% 83% 84% 84% 85%
no fueling no fueling no fueling
- 40
84% 83% 83% 83% 83% 83% 84% 85%
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Initial Tank Pressure, P0 (MPa)
Ambient Temperature, Tamb (°C) Hot Case Final State of Charge, SOC
(Hot Soak - No History)
B-70 1-7kg
10 20 30 40 50 60 70 80 90 100 5 10 15 20 25 30 35 40 MC Fill Time (minutes) 2.1 5.1 10.1 15.1 20.1 30.1 40.1 50.1 MCCalc
MC vs Fill Time, SAE J2601 Type B Station
Look-up tables from J2601 can be fully described by an equation with default coefficients using the MC Method.
) 1 (
v cv Initial Adiabatic v cv Final
C MC m T T C MC m T
j t k init adiabatic
e g U U b C MC
D
1
MC Method can also be used to set the target for a communications fueling.
SLIDE 34
34
Applying MC Method to J2601
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling50 1.8 75.8 75.4 74.8 74.4 74.0 73.4 73.0 72.7 72.6 72.4
no fueling45 2.5 75.0 74.6 74.1 73.7 73.4 72.9 72.7 72.6 72.5 72.3
no fueling40 3.4 74.5 74.1 73.7 73.3 73.1 72.7 72.6 72.6 72.4 72.3
no fueling35 4.4 74.2 73.8 73.4 73.1 72.9 72.7 72.6 72.5 72.4 72.3
no fueling30 5.5 73.6 73.3 72.8 72.5 72.2 71.9 71.7 71.5 71.2
no fueling no fueling25 6.7 73.2 72.8 72.2 71.8 71.5 71.1 70.8 70.4 70.0
no fueling no fueling20 7.9 72.7 72.3 71.7 71.3 70.9 70.3 69.8 69.3 68.8
no fueling no fueling10 10.7 72.0 71.5 70.8 70.2 69.6 68.7 67.8 67.0 66.3
no fueling no fueling13.6 71.4 70.8 69.8 69.0 68.3 67.0 65.8 64.6 63.6
no fueling no fueling- 10
13.6 70.1 69.4 68.4 67.4 66.5 65.0 63.6 62.2
61.1 no fueling no fueling- 20
13.6 68.9 68.1 66.8 65.8 64.7 62.9 61.2 59.5
no fueling no fueling no fueling- 30
13.6 67.7 66.7 65.3 64.1 62.8 60.7 58.6 56.8
no fueling no fueling no fueling- 40
13.6 67.3 66.4 65.0 63.8 62.6 60.6 58.7 56.8
no fueling no fueling no fueling< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fuelingB-70 1-7kg
Average Pressure Ramp Rate, APRR (MPa/min)
Ambient Temperature, Tamb (°C)
Lookup Table: 70MPa, -20°C, 1-7kg
Fueling Target Pressure, Ptarget (MPa)
Initial Tank Pressure, P0 (MPa)
Step 1 Information
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 65
- 17.5
1.6 1.8 54.0 48.6 3.3 3.7 45 60
- 17.5
2.3 2.5 38.5 34.6 4.8 5.3 40 55
- 17.5
3.1 3.4 28.6 25.7 6.5 7.2 35 50
- 17.5
4.0 4.4 22.1 19.9 8.5 9.4 30 45
- 17.5
4.9 5.5 17.7 15.9 10.6 11.8 25 40
- 17.5
6.0 6.7 14.6 13.1 12.9 14.4 20 35
- 17.5
7.2 7.9 12.2 11.0 15.4 17.1 10 25
- 17.5
9.6 10.7 9.1 8.2 20.6 22.8 15
- 17.5
12.2 13.6 7.2 6.5 25.9 28.8
- 10
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 20
15
- 17.5
12.2 13.6 7.2 6.4 25.9 28.8
- 30
15
- 17.5
12.2 13.6 7.2 6.4 26.0 28.8
- 40
15
- 17.5
12.2 13.6 7.1 6.4 26.0 28.9 < -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Lookup 174l 7kg
Peak Flow (g/s)
157l 6.3kg
Simulation Results
Hot Soak
Ramp Rate (MPa/min)
Simulation Input
Ramp Rate (min/87.5MPa)
10% slower
Ambient Temperature, Tamb (°C)
Temperature (°C)
Cold Fill 10% slower
B-70 1-7kg
Lookup
Step 2 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling
> 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 25
- 22.5
1.6 54.0 50 41.0 39.1 36.0 33.0 30.0 24.1 18.3 12.6 7.0 1.3
no fueling
45 25
- 22.5
2.3 38.5 45 28.9 27.5 25.3 23.2 21.1 17.0 12.9 8.9 4.9 0.9
no fueling
40 25
- 22.5
3.1 28.6 40 21.3 20.3 18.7 17.2 15.6 12.6 9.6 6.6 3.7 0.7
no fueling
35 25
- 22.5
4.0 22.1 35 16.4 15.7 14.4 13.2 12.0 9.7 7.4 5.1 2.8 0.5
no fueling
30 20
- 22.5
4.9 17.7 30 13.0 12.4 11.4 10.5 9.5 7.6 5.8 3.9 2.0
no fueling no fueling
25 15
- 22.5
6.0 14.6 25 10.7 10.1 9.3 8.5 7.7 6.2 4.6 3.1 1.5
no fueling no fueling
20 10
- 22.5
7.2 12.2 20 8.9 8.5 7.8 7.1 6.4 5.1 3.8 2.4 1.1
no fueling no fueling
10
- 22.5
9.6 9.1 10 6.6 6.2 5.7 5.2 4.6 3.6 2.6 1.6 0.6
no fueling no fueling
- 10
- 22.5
12.2 7.2 5.1 4.8 4.4 4.0 3.6 2.7 1.9 1.1 0.3
no fueling no fueling
- 10
- 20
- 22.5
12.2 7.2
- 10
5.0 4.7 4.3 3.9 3.4 2.6 1.7 0.9 0.1
no fueling no fueling
- 20
- 30
- 22.5
12.2 7.2
- 20
4.9 4.6 4.2 3.7 3.3 2.4 1.6 0.7
no fueling no fueling no fueling
- 30
- 40
- 30.0
12.2 7.2
- 30
4.8 4.5 4.1 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
- 40
- 40
- 40.0
12.2 7.1
- 40
4.8 4.5 4.0 3.6 3.1 2.3 1.4 0.5
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Cold Soak
Temperature (°C) Ambient Temperature, Tamb (°C)
(MPa/ min)
Ramp Rate Ambient Temperature, Tamb (°C)
B-70 1-7kg
(min/ 87.5MPa)
B-70 1-7kg
Actual Fueling Duration (min)
Add intermediate leak check times: up to 10 sec after every 25MPa increase in fueling pressure
Initial Tank Pressure, P0 (MPa) Cold Fill
Step 3 Information
2 5 10 15 20 30 40 50 60 70 > 70 > 50
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
50 91% 91% 90% 90% 90% 90% 90% 90% 90% 91%
no fueling
45 90% 90% 90% 89% 89% 89% 90% 90% 91% 92%
no fueling
40 90% 90% 89% 89% 89% 90% 90% 91% 92% 93%
no fueling
35 90% 89% 89% 89% 90% 90% 91% 92% 93% 94%
no fueling
30 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
25 89% 89% 89% 89% 89% 90% 91% 92% 93%
no fueling no fueling
20 88% 88% 88% 89% 89% 90% 90% 92% 93%
no fueling no fueling
10 88% 88% 88% 88% 88% 89% 90% 91% 93%
no fueling no fueling
87% 87% 87% 88% 88% 89% 90% 91% 93%
no fueling no fueling
- 10
86% 86% 86% 86% 87% 87% 88% 89% 91%
no fueling no fueling
- 20
85% 85% 85% 85% 85% 85% 86% 87%
no fueling no fueling no fueling
- 30
84% 84% 83% 83% 83% 84% 84% 85%
no fueling no fueling no fueling
- 40
84% 83% 83% 83% 83% 83% 84% 85%
no fueling no fueling no fueling
< -40
no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling no fueling
Initial Tank Pressure, P0 (MPa)
Ambient Temperature, Tamb (°C) Hot Case Final State of Charge, SOC
(Hot Soak - No History)
B-70 1-7kg
10 20 30 40 50 60 70 80 90 100 5 10 15 20 25 30 35 40 MC Fill Time (minutes) 2.1 5.1 10.1 15.1 20.1 30.1 40.1 50.1 MCCalc
MC vs Fill Time, SAE J2601 Type B Station
Look-up tables from J2601 can be fully described by an equation with default coefficients using the MC Method.
) 1 (
v cv Initial Adiabatic v cv Final
C MC m T T C MC m T
j t k init adiabatic
e g U U b C MC
D
1
Benefits of MC Method for SAE J2601
- No need for Station Types
- Allows refueling at any level of precooling
- To meet local climate needs
- Best efficiency operation for location
- Best station cost for application
- Allows fueling for “out-of-tolerance” situations
- With ID-Fill, fuels to the maximum capability of the tank system
- Highest SOC
- Fastest fill time given conditions
- No need to redevelop the tables if a new pressure standard, tank type,
- r station type is developed.
- Sets the bounds for communications fueling, so the vehicle T signal
does not need to control the station (just a check).
SLIDE 35
35
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
Outline
SLIDE 36
36
Using the test fills that we conducted, we generated the constants for the equation below, and applied the algorithm. Testing MC Method at Powertech
y = 0.3361x + 53.844 R² = 0.8996 54 56 58 60 62 64 10 20 30 MC (kJ/K) Uadiabatic/Uinit
MC vs Uadiabatic/Uinit
) ( ) ( 1 ) , ( t MC U MC e g U U A C t U MC
j t k init adiabatic
D D
D
A C
3 minute fill >3minute fill 20 40 60 80 100 1000 2000 3000 4000 Data Model
g * (1- exp-kx)j g = 6.33E+04 k = 3.66E-09 j = 5.83E-01
MC vs (t-180s) DMC (kJ/K) t-180s 2 Fills at 50% SOC 2 Fills at 0% SOC
Result of 4 tests to characterize the tanks can determine all of the coefficients
SLIDE 37
37
Testing MC Method at Powertech
10 20 30 40 50 60 70 80 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
35MPa Type 3, 5MPa Start, 35C Ambient, 4.8C Nozzle
196 Temp Model
Vehicle Data Toss Station Data Read
Result of 35MPa Fill 5 5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
Hot Soak Bound – 74.3C Cold Soak Bound – 62.3C 196s 41.3MPa 35MPa Type 3 – 5MPa Start, 35C Ambient, 4.8C Nozzle Target – 69.2C
99.7% SOC Note: This test confirmed how difficult it is for a station to control the nozzle temperature in the real world. J2601 tolerance is unrealistic.
35MPa Type 3 Tank Result
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions)
SLIDE 38
38
Testing MC Method at Powertech
10 20 30 40 50 60 70 80 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
35MPa Type 3, 5MPa Start, 35C Ambient, 4.8C Nozzle
196 Temp Model
10 20 30 40 50 60 70 80
Tank Temp Tank Pressure Temp Model
Vehicle Data Toss Station Data Read
Result of 35MPa Fill 5 5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
Hot Soak Bound – 74.3C Cold Soak Bound – 62.3C 196s 41.3MPa 35MPa Type 3 – 5MPa Start, 35C Ambient, 4.8C Nozzle Target – 69.2C
99.7% SOC Note: This test confirmed how difficult it is for a station to control the nozzle temperature in the real world. J2601 tolerance is unrealistic.
35MPa Type 3 Tank Result
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions)
SLIDE 39
39
Testing MC Method at Powertech
Vehicle Data Toss Station Data Read
Result 5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
10 20 30 40 50 60 70 80 90 100 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
50MPa Type 4, 2MPa Start, 30C Ambient, -14.8C Nozzle
T Model Hot Soak Bound – 89C Cold Soak Bound – 83C 183s 61.4MPa 50MPa Type 4 – 2MPa Start, 30C Ambient, -14.8C Nozzle Target – 86.7C
99.6% SOC
70MPa Type 4 Tank Result Filled to 50MPa
Note: Target was based on -20C Precooling. Station actually delivered -14.8C gas. So the targets shown here are adjusted to show -15C gas target.
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions)
SLIDE 40
40
Testing MC Method at Powertech
Vehicle Data Toss Station Data Read
Result 5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
10 20 30 40 50 60 70 80 90 100 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
50MPa Type 4, 2MPa Start, 30C Ambient, -14.8C Nozzle
T Model
10 20 30 40 50 60 70 80 90 100
Tank Temp Tank Pressure T Model Hot Soak Bound – 89C Cold Soak Bound – 83C 183s 61.4MPa 50MPa Type 4 – 2MPa Start, 30C Ambient, -14.8C Nozzle Target – 86.7C
Note: Original targets were based on expected -20C nozzle temp with 2.5C
- tolerance. “Targets” shown here are
adjusted to see what they would have been based on actual hydrogen nozzle temp of -14.8C.
99.6% SOC
70MPa Type 4 Tank Result Filled to 50MPa
Note: This test confirmed how difficult it is for a station to control the nozzle temperature in the real world. J2601 tolerance is unrealistic.
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions)
SLIDE 41
41
Testing MC Method at Powertech
Vehicle Data Toss Station Data Read
5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
10 20 30 40 50 60 70 80 90 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
70MPa Test 4 - 17MPa Start, 25C Ambient, -7.5C Nozzle T Model
Hot Soak Bound – 81C Cold Soak Bound – 70C 185s 76.7MPa 70MPa Type 4 – 17MPa Start, 25C Ambient, -7.5C Nozzle Target – 76.6C
95.6% SOC
70MPa Type 4 Tank Result
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions) Result of 70MPa Fill 5
SLIDE 42
42
Testing MC Method at Powertech
Vehicle Data Toss Station Data Read
Result of 70MPa Fill 5 5 MC Parameters (From Testing) Tank Volume NWP Max Hot Soak DT=7.5C Cold Soak DT =-10C Ambient Temperature Initial Tank Pressure Expected Average Nozzle Temperature Nozzle Pressure
1) Calculate Hot Soak Fill Time (Based on 85C) 2) Calculate Cold Soak Pressure Target (100% Density or MAWP) 3) Calculate Expected Result
10 20 30 40 50 60 70 80 90 50 100 150 200 250 300 Temperature (C), Pressure (MPa) Fill Time (s)
70MPa Test 4 - 17MPa Start, 25C Ambient, -7.5C Nozzle T Model
10 20 30 40 50 60 70 80 90
T Model Tank Temp Tank Pressure Hot Soak Bound – 81C Cold Soak Bound – 70C 185s 76.7MPa 70MPa Type 4 – 17MPa Start, 25C Ambient, -7.5C Nozzle Target – 76.6C
95.6% SOC
70MPa Type 4 Tank Result
(Using results of 4 fills to predict fill 5. Fill 5 at different conditions)
SLIDE 43
43
Using the test fills that we conducted, we generated the constants for the equation below, and applied the algorithm. Testing MC Method at Powertech
y = 0.3361x + 53.844 R² = 0.8996 54 56 58 60 62 64 10 20 30 MC (kJ/K) Uadiabatic/Uinit
MC vs Uadiabatic/Uinit
) ( ) ( 1 ) , ( t MC U MC e g U U A C t U MC
j t k init adiabatic
D D
D
A C
3 minute fill >3minute fill 20 40 60 80 100 1000 2000 3000 4000 Data Model
g * (1- exp-kx)j g = 6.33E+04 k = 3.66E-09 j = 5.83E-01
MC vs (t-180s) DMC (kJ/K) t-180s 2 Fills at 50% SOC 2 Fills at 0% SOC
Result of 4 tests to characterize the tanks can determine all of the coefficients
SLIDE 44
44
Additional data from verification at other conditions closely follows tank characterization data the model works.
20 40 60 80 100 1200 2400 3600 Data Model
y = 0.3361x + 53.844 R² = 0.8996 54 56 58 60 62 64 10 20 30 MC (kJ/K) Uadiabatic/Uinit
MC vs Uadiabatic/Uinit
Testing MC Method at Powertech
) ( ) ( 1 ) , ( t MC U MC e g U U A C t U MC
j t k init adiabatic
D D
D
A C
3 minute fill >3minute fill
g * (1- exp-kx)j g = 6.33E+04 k = 3.66E-09 j = 5.83E-01
MC vs (t-180s) DMC (kJ/K) t-180s 2 Fills at 50% SOC 2 Fills at 0% SOC
The model describes data outside of the conditions used to generate the model!
Data of Additional Verification Fills Data of Additional Verification Fills
SLIDE 45
45
- 10
- 8
- 6
- 4
- 2
2 4 6 8 10
35MPa Fill 1 2MPa 25C 35MPa Fill 2 17MPa 25C 35MPa Fill 3 2MPa -20C 35MPa Fill 4 17MPa -20C 35MPa Fill 1R 2MPa 25C 35MPa Fill 2R 17MPa 25C 35MPa Fill 3R 2MPa -20C 35MPa Fill 4R 17MPa -20C 35MPa Fill 5 5MPa 0C 70MPa Fill 2 17MPa 25C 70MPa Fill 4 17MPa -20C 70MPa Fill 2R 17MPa 25C 70MPa Fill 3R 2MPa -20C 70MPa Fill 4R 17MPa -20C 70MPa Fill 5 22MPa -20C 50MPa Fill 1 2MPa 25C 50MPa Fill 2 17MPa 25C 50MPa Fill 3 2MPa -20C 50MPa Fill 4 17MPa -20C 50MPa Fill 1R 2MPa 25C 50MPa Fill 2R 17MPa 25C 50MPa Fill 3R 2MPa -20C 50MPa Fill 6 2MPa -20C
T Final Error (K)
Error in Calculated Temp Using MC Method
Definition MC Method Model
Error in MC Method Use
Temp Measured
final final
T Error T
Overestimate Tfinal = conservative temp but slight overshoot target density Underestimate Tfinal = slightly
- ver target temp but undershoot target density.
Thermocouple Standard Error Thermocouple Placement and Time Lag Error Max Error in modeling of SAE J2601 development
3K error in Tfinal 1% error in Density
MC Method yields accurate results for Type 3 and Type 4 tanks at any fill pressure
Type 3 Tank Type 4 Tank
SLIDE 46
46
Sensitivity Analysis of MC Method
- 10.0
- 8.0
- 6.0
- 4.0
- 2.0
0.0 2.0 4.0 6.0 8.0 10.0
55 57 59 61 63 65
Tfinal Error (K) MC (kJ/K)
Tfinal Error vs MC for Various Input Errors for Type 3 Tank
+10% Error in MC
- 10% Error in MC
+10K Error in TH2 Station
- 10K Error in TH2 Station
+10K Error in Tinit
- 10K Error in Tinit
- 10.0
- 8.0
- 6.0
- 4.0
- 2.0
0.0 2.0 4.0 6.0 8.0 10.0
14 15 16 17 18
Tfinal Error (K) MC (kJ/K)
Tfinal Error vs MC for Various Input Errors for Type 4 Tank
+10% Error in MC
- 10% Error in MC
+10K Error in TH2 Station
- 10K Error in TH2 Station
+10K Error in Tinit
- 10K Error in Tinit
Type 3 most sensitive to: Initial Temperature Error (large heat mass)
10K error in initial temp 6K error in final temp
Type 4 most sensitive to: Inlet Temperature Error (poor heat transfer)
10K error in station nozzle temp 8K error in final temp
Robust Result T Final is not sensitive to errors in MC, or Input Error
SLIDE 47
47
Outline
Need for Advanced Fueling Algorithm What An Advanced Algorithm Should Be… MC Method Development Determining Tank Specific MC From Test Data Applying MC Method Testing MC Method at Powertech Summary and Conclusions
SLIDE 48
48
Summary – An advanced fueling algorithm… + Fast, High SOC, Safe Fills
- should be based on the actual conditions of a hydrogen station
enthalpy of delivered hydrogen (any condition)
- should be applicable for all initial fill temperature, pressure
internal energy in the tank (any condition)
- should be based on the actual capabilities of a tank system
actual volume, NWP real thermodynamic characteristics hot soak, cold soak based on test results and conditions expected by the OEM and the Station
- should make use of available technology to communicate these
parameters to the station. ID-Fill? IRDA? RFID? etc
SLIDE 49
49
Conclusions
MC Method shows excellent promise to enhance SAEJ2601, through the use
- f additional information to improve vehicle fueling (fast fill, high SOC).
MC Method enables the use of thermodynamic parameters of the vehicle tank, plus actual station conditions, to allow the best possible fill for a given vehicle (shortest fill time and highest SOC). MC Method allows fueling at conditions that operate outside of current J2601 tables, such as new stations with -10C precooling, or already existing stations, and works at any fill pressure, for any tank system. The equation with coefficients derived from J2601 tables can replace the look-up table-based approach of SAE J2601.
MC Method provides for station design flexibility and fill
- ptimization for each vehicle.
SLIDE 50
Thank you for your attention!
Questions? Please contact us: Ryan Harty – rharty@hra.com Steve Mathison – smathison@hra.com
(Meet us at the Honda Booth at 5:35pm!)
SLIDE 51
51
Fueling Methods (@ 70MPa) using
- 20C max pre-cooling
Type 3 Fill Time Type 3 SOC Type 4 Fill Time Type 4 SOC Station Cost Station Reliability Station Design Flexibility
Non-CommJ2601 Type B (-20C) Non-Commusing MC Method (-20C max but variable) Full-CommJ2601 Type B (-20C) Full-Commusing MC Method (-20C max but variable) ID Fill with MC Method (-20C max but variable)
X X X X X X
*
* Majority of tank systems ** Station throughput improves since customer can still fuel if pre-cooling capability falls outside the tolerance allowed in
- J2601. Cost also improves since pre-cooling system can be downsized and operated at optimal temperature.
* ** ** * **
X= No Good
= Ok (acceptable) = Good = Excellent
Summary – An advanced fueling algorithm…
J2601 fill using MC adjustment for fill temp Station Design Flexibility! MC Method fill gives Full Comm SOC and Fill Time, without active temperature and pressure monitoring, at lower cost stations.
Default
SLIDE 52
52
Characteristics of MC
MC is not directly a physical constant such as the mass and the specific heat capacity of the liner material. Rather it is a composite of many things. All of the intricacies of the temperature distribution of the wall of the tank get washed out by using a parameter such as MC, especially over a time scale such as a hydrogen tank refueling.
MC model cannot be used for phenomena that occur over very short time
Systems with slow heat transfer characteristics (convection or conduction) will result in small values of MC (such as Type 4 tanks), because they absorb small quantities of heat in the 3 minute time domain. Systems with faster heat transfer characteristics (convection or conduction) will result in high values of MC (such as Type 3 tanks), because they absorb small quantities of heat in the 3 minute time domain. MC is a function of many things; MC=MC(time, fill conditions, tank materials, etc). But for a given tank, fill time, and conditions, MC will always be the same.
The trend of MC with time is predictable. The trend of MC with fill conditions is predictable.