Fuel Cell Drive Train

The Fuel Cell Drive Train is a modular platform designed to simulate and study the complete powertrain of a hydrogen fuel cell hybrid electric vehicle (FCEV). It provides a real-world learning experience on how hydrogen fuel is converted into electric propulsion, integrating advanced control electronics, power conversion units, and electromechanical systems. This lab-scale setup includes a PEM Fuel Cell, bidirectional power converters, battery bank, ultracapacitor module, and a complete motor drive system comprising a Permanent Magnet Synchronous Motor (PMSM) acting as the traction motor, coupled to a loading PMDC motor and a resistive load bank for rad condition simulation.

Key Features

Modifiable Control Algorithms
Comes with open-source application software and an FPGA-based controller, allowing users to modify inverter control algorithms and simulate drive cycles with full customization.
Real PEM Fuel Cell Stack : Operates with dry hydrogen at 0.55–0.75 bar
DC Power Conditioning:
- Boost Converter for fuel cell output stabilization.
- Bidirectional Converter connects ultracapacitor and battery bank to the DC link.
Energy Storage:
- 48V, 75Ah Li-ion Battery Bank
- 165F Ultracapacitor Module for handling power transients.
Electric Motor Drive System:
- PMSM Motor as traction motor.
- Loading PMSM coupled to a resistive load bank for road condition simulation.
- Controlled by a 3-phase inverter and motor controller.
Sensor Boards for individual monitoring of fuel cell, battery, ultracapacitor, and 3-phase motor outputs.
Control & Interface:
- FPGA controller / microcontroller with analog/digital I/O, real-time feedback control.
- Integrated with NI LabVIEW software for live visualization and user control.
Safety & Accuracy: Embedded protections for over-current, voltage ripple control, temperature derating, and noise reduction (<70 dBa).

Learning Module

Fuel Cell Systems & Energy Management

Operate PMSM motor using a 3-phase inverter and controller.
Simulate traction dynamics under variable load and speed.
Characterize motor performance: voltage, current, torque vs. RPM, efficiency.
Conduct drive cycle simulations (IDC, NEDC) for real-world validation.

EV Drivetrain & Motor Control

Operate PMSM motor using a 3-phase inverter and controller.
Simulate traction dynamics under variable load and speed.
Characterize motor performance: voltage, current, torque vs. RPM, efficiency.
Conduct drive cycle simulations (IDC, NEDC) for real-world validation.

Embedded Control & System Integration

Develop real-time control algorithms on STM32 microcontroller.
Monitor energy flows and system behavior using LabVIEW.
Evaluate system performance under dynamic conditions.

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