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Research Activities of HFCV in Korea

SGS 6 - 15. 6 th HFCV-SGS Meeting. Research Activities of HFCV in Korea. May 26 ~ 29, 2009. Ministry of Land, Transport and Maritime Affairs, Korea Transportation Safety Authority (Korea Automobile Testing and Research Institute) In corporation with Hyundai Motor Company. Contents.

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Research Activities of HFCV in Korea

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  1. SGS 6 - 15 6th HFCV-SGS Meeting Research Activities of HFCV in Korea May 26 ~ 29, 2009 Ministry of Land, Transport and Maritime Affairs, Korea Transportation Safety Authority (Korea Automobile Testing and Research Institute) In corporation with Hyundai Motor Company

  2. Contents Hydrogen ? • Hydrogen Leakage Test • Driving Mode • Stop Mode • Rear Impact Test • Possibility of Hydrogen Discharge • Storage Verification Test • Summaries Hydrogen ?

  3. Air 10m/s 6M 12M 14.1M Hydrogen Leakage Test : Driving Mode • Goal : Verification of single failure conditions • Conditions • Driving speed: 36 km/h • Open space : 14.1 m x 12 m x 6 m • Leaking point: fitting area between high pressure fuel line and refilling line in the rear of vehicle • Leaking flow : 131 NL per minute • Simulation Model • Tool : STAR-CCM+ • Mesh : polyhedral mesh (1,060,000) • Turbulence model : κ-ε model • Steady-state analysis

  4. A A B H2 Vol % 0.0 4.0 % AIR 10 m/s Driving Mode Simulation Results • Results • Hydrogen was diffused by outside air flow • Hydrogen concentration level over 4 % by volume in air is localized near leaking area Vehicle underbody view Section A-A Detail of B Air flow outside vehicle Velocity profile near storages area

  5. 34 33 27 26 29 25 32 24 22 23 28 30 31 20 21 18 19 Positions of sensors 1 3 10 6 11 5 9 4 7 2 Stop Mode Test Conditions (1) • Positions of hydrogen sensor Positions of sensors (under flower) • Expected hydrogen leaking points : • High(5)/low(4) pressure lines and engine room(2)

  6. Stop Mode : Test Conditions (2) Valve Valve Regulator Storage(35MPa) leakage Valve Regulator Valve Storage Hydrogen leakage device Single failure conditions test • Conditions of hydrogen leaking flow • 10 NL per minute : low leaking mode • 40 NL per minute : max. leaking mode before activation of excess flow valve • 131 NL per minute : leaking limit in FMVSS 301

  7. Hydrogen Leakage Test Results • Driving Mode • Diffused rapidly due to wind flowing outside vehicle • Sensors did not detect leaking hydrogen except sensors near leaking area • Stop Mode • Leaking hydrogen may enter into vehicle through holes on the bottom if hydrogen leaks underneath the body • Leakinghydrogen may enter into vehicle through running HFCV system if hydrogen leaks in engine room Preventive measure needed • Hydrogen continued to leak for about 10 seconds before shutdown after 2 % hydrogen was detected  There were some area where hydrogen up to 4 % was detected before shutdown. But concentration dropped below 4 % within one minute • Conclusions • Optimization of number of sensors and their locations is needed for effective detection depending on vehicle structure 2-3 sensors out of 5 sensors may be removed in case of HFCV SUV • Interior sensors should be considered for detecting hydrogen entering from outside

  8. Goal : Verification of fuel system integrity • Test Vehicle • Mock up fuel cell vehicle • Test Conditions • KMVSS article 91(FMVSS 305) : 48 km/h rear impact test • Filled with helium 90 % of normal working pressure • During the crash, opened storage valve (severe condition) • After crash test, evaluate hydrogen discharge BIW of HFCV SUV Mounted storages Sample vehicle Rear Impact Test (Fuel System Integrity)

  9. Rear Impact Test Results : Hydrogen Discharge • After impact, no hydrogen discharge • High pressure sensor : 30 MPa • Low pressure sensor: 1 MPa

  10. Rear Impact Test Results : Verification Test of Storage • Verification Test of Storage • Storage was damaged due to deformation of suspension during impact • Verification test of damaged storage  No noticeable degradation Damaged carbon fiber layers of storage Under body rear suspension Verification test of damaged storage  Passed after 11,250 cycling tests at 103 MPa

  11. Summaries • Hydrogen Leakage Test (Single Failure Conditions) • Optimization of number of sensors and their locations is needed for effective detection depending on vehicle structure • In this particular model of HFCV SUV, some sensors are redundant • Interior sensors should be considered for detecting hydrogen entering from outside • Rear Impact Test (Fuel System Integrity) • Exterior of storage was damaged due to deformation of suspension during impact No noticeable strength degradationafter endurance test • No malfunction in other storage components • Impact absorbing structure should be devised

  12. Thank you very much for your attention ! Acknowledgement This research was supported by a grant (07-Transport System-Furture-02) from Transportation System Innovation Program funded by MLTM

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