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Intelligent hydrogen fuel cell range extender for pure electric vehicles

Wu Dongxiao

Road transport is considered to have a negative impact on the environment. The policy focuses on replacing the internal combustion engine (ICE) with less polluting technologies, including battery electric and fuel cell electric powertrains. However, progress has been slow and both battery and fuel cell electric vehicles face significant challenges to commercialization. To understand these challenges, we review current battery and fuel cell electric technologies. Based on this review, this paper proposes a battery electric vehicle (BEV) whose components are sized to take into account the needs of most users, with the remainder met by a trailer-based detachable smart fuel cell range extender. The proposed design can extend the range of small BEVs by more than 50% and that of large BEVs by more than 25% (vehicles with a range of more than 250 miles), thereby reducing the cost of BEVs and improving their efficiency. It enables pure electric vehicle manufacturers to design vehicle batteries suitable for the most common journeys, reduce charging time, and provide convenience and flexibility to drivers. The use of a rent-and-drop business model reduces the demand for raw materials, fills the gap in the number of charging (refueling) stations, and extends the service life of the battery pack. Environmental and legislative requirements related to greenhouse gas (GHG) reduction are encouraging the automotive industry to move from internal combustion engine (ICE) propulsion to zero tailpipe emission (ZTE) systems. Battery electric and hydrogen fuel cell (FC) technologies are considered to have the most potential for automotive ZTE systems. Remaining challenges hindering wider commercial adoption of battery electric vehicles (BEVs) include insufficient range, reliance on charging infrastructure, overall vehicle efficiency, limited raw materials, and recycling. In addition, challenges facing fuel cell electric vehicles (FCEVs) include hydrogen fueling infrastructure, vehicle costs, and vehicle design to reduce accident-related risks.