Development of a Fuel Cell Electric Vehicle Powertrain for Airport Applications

Hybrid propulsion systems using fuel cells can be an effective alternative, in any field of use, to replacing conventional ones using thermal engines, which have low efficiencies and emit high amounts of local and global emissions. The conversion to this type of powertrain is analysed to be developed for an airport vehicle called "Follow me", for assistance in runways and for aircraft guiding, whose operating cycles are characterised by the inefficient use of thermal engines, contributing to the environmental problems that involve airport decarbonisation and electrification policies. The automotive research centre INSIA in Madrid carries out a project to adapt to a real FCEV prototype this particular airport vehicle, whose initial phases of activity are described in this thesis. Specifically, these parts are the data analysis of the powertrain and the driving mission data, the sizing and design of the powertrain components and the creation and development of control algorithms for a tailor-made energy management strategy. To define which elements and characteristics must be present in the new FCEV powertrain, the original combustion vehicle data and its real driving missions have been collected and analysed, achieving a series of conventional cycles and energy, power and performance requirements. These have been translated into a series of values for defining the characteristics of the vehicle and its elements, including fuel cell, tank, battery, electric motor and control electronics. Through market analysis, the actual components that will be installed in the new prototype powertrain have been selected and modelled within longitudinal dynamics software. These models have been iteratively developed together with the energy management strategy for the propulsion control of the new hybrid vehicle. By means of these simulation and control software, it was possible to replicate the performance of the original "Follow me" vehicle with the new hybrid propulsion system, in order to achieve a functioning that if converted into the actual creation and use of such a vehicle on the runways, it would give satisfactory and consistent operating results. With the results shown in this activity, the aim is to generate knowledge, for every sector and entity involved, related to the topic of hydrogen as power source, fuel cell vehicles and viability, convenience and effectiveness of this solution.